U.S. patent application number 14/514531 was filed with the patent office on 2015-01-29 for running shoes, hiking shoes and boots, snowboard boots, alpine boots, hiking boots, and the like, having waterproof/breathable moisture transfer characteristics.
The applicant listed for this patent is Solid Water Holdings. Invention is credited to Baychar.
Application Number | 20150031258 14/514531 |
Document ID | / |
Family ID | 46301877 |
Filed Date | 2015-01-29 |
United States Patent
Application |
20150031258 |
Kind Code |
A1 |
Baychar; |
January 29, 2015 |
RUNNING SHOES, HIKING SHOES AND BOOTS, SNOWBOARD BOOTS, ALPINE
BOOTS, HIKING BOOTS, AND THE LIKE, HAVING WATERPROOF/BREATHABLE
MOISTURE TRANSFER CHARACTERISTICS
Abstract
The waterproof/breathable moisture transfer liner for a running
and hiking shoe includes an inner liner selected from technically
advanced fabrics which are carefully selected. A series of layers
are provided outside the inner liner including foam material
layers, breathable membranes, a supportive mesh or a moldable foam,
and an outer shell fabric. The applicability of the liner to
alpine, snowboard boots, cross country, hiking boots, protective
gear and helmets, along with appropriate variations for each
application.
Inventors: |
Baychar;; (Eastport,
ME) |
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Applicant: |
Name |
City |
State |
Country |
Type |
Solid Water Holdings |
Eastport |
ME |
US |
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|
Family ID: |
46301877 |
Appl. No.: |
14/514531 |
Filed: |
October 15, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13684671 |
Nov 26, 2012 |
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14514531 |
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13047449 |
Mar 14, 2011 |
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13684671 |
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12684588 |
Jan 8, 2010 |
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13047449 |
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10786416 |
Feb 26, 2004 |
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12684588 |
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09500535 |
Feb 9, 2000 |
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10786416 |
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08910116 |
Aug 13, 1997 |
6048810 |
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09500535 |
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08832800 |
Apr 4, 1997 |
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08910116 |
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08747340 |
Nov 12, 1996 |
5738937 |
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08832800 |
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Current U.S.
Class: |
442/118 |
Current CPC
Class: |
Y10T 442/637 20150401;
B32B 5/022 20130101; A43B 7/12 20130101; Y10T 428/24273 20150115;
B32B 5/024 20130101; A43B 23/07 20130101; A43B 23/026 20130101;
B32B 2307/304 20130101; Y10T 442/2484 20150401; B32B 5/245
20130101; B32B 2307/724 20130101; Y10T 442/2008 20150401; B32B
2262/0253 20130101; Y10T 442/696 20150401; A43B 7/125 20130101;
D04H 13/00 20130101; A43B 23/0235 20130101; Y10T 442/20 20150401;
B32B 2266/06 20130101; Y10T 442/655 20150401; B32B 2307/728
20130101; Y10T 442/612 20150401; B32B 2437/02 20130101; B32B 5/026
20130101 |
Class at
Publication: |
442/118 |
International
Class: |
A43B 23/07 20060101
A43B023/07; D04H 13/00 20060101 D04H013/00 |
Claims
1. A thermal nonwoven material comprised of synthetic fibers
topically treated to have phase change reversible enhanced thermal
properties.
Description
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is a continuation application of U.S. Ser.
No. 13/684,671, filed Nov. 26, 2012 which is a continuation of U.S.
Ser. No. 13/047,449, filed Mar. 14, 2011 (now abandoned), which is
a continuation U.S. Ser. No. 12/684,588, filed Jan. 8, 2010 (now
abandoned), which is a continuation application of U.S. Ser. No.
10/786,416, filed Feb. 26, 2004 (now abandoned), which is a
continuation-in-part application of U.S. Ser. No. 09/500,535, filed
Feb. 9, 2000 (now abandoned), which is a continuation application
of U.S. Ser. No. 08/910,116, filed Aug. 13, 1997 (now U.S. Pat. No.
6,048,810), which is a continuation-in-part application of U.S.
Ser. No. 08/832,800, filed Apr. 4, 1997 (now abandoned), which is a
continuation-in-part application of U.S. Ser. No. 08/747,340, filed
Nov. 12, 1996 (now U.S. Pat. No. 5,738,937), and claims priority to
U.S. Provisional Applications 60/449,580 and 60/449,584, both filed
on Feb. 26, 2003. The entire disclosures of all of these
applications are hereby incorporated by reference. In addition, the
entire disclosures of abandoned applications U.S. Ser. No.
10/600,711, filed Jun. 23, 2003 and U.S. Ser. No. 10/757,454, filed
Jan. 15, 2004, are also hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a variety of shoes and
boots used in a variety of applications. For example, the present
invention may be employed in a variety of applications including
running shoes, lite hiking shoes and hiking boots, snowboard boots,
alpine boots, and the like. The shoes and boots are breathable and
waterproof to increase comfort for the runner, hiker or rider, etc.
These shoes and boots include liner that transfer moisture in a way
never before accomplished in the prior art.
BACKGROUND OF THE INVENTION
[0003] Various types of liners are known from the prior art.
However, these liners do not provide the advantages realized by the
present invention. The present inventor has recognized the problems
faced by runners, snowboarders, skiers and hikers and developed
shoes, boots and liners to overcome such problems.
[0004] There is an on-going need for comfort, breathability, and
support for running shoes, snowboard boots and alpine boots and
linings therefor. In prior designs, a rigid, non-breathable outer
material, such as vinyl, foam, and nylon is often used. The inner
liners have been leather, synthetic leather, nylon, or polyester
blends which extremely limit the ability to breathe or wick
moisture away from a runner or rider's body. These materials have
prevented the foot from breathing adequately.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 illustrates a first portion of the liner according to
a first embodiment of the present invention.
[0006] FIG. 2 illustrates a second portion of the liner according
to a first embodiment of the present invention.
[0007] FIG. 3 illustrates an example of the liner according to the
first embodiment of the present invention.
[0008] FIG. 4 illustrates the liner shown in FIG. 3 which will form
a part of a running shoe, snowboard boot or alpine boot liner.
[0009] FIGS. 5(a) and 5(b) illustrate a sole portion of a liner
constructed according to a preferred embodiment of the present
invention.
[0010] FIGS. 6 and 7 illustrate a tongue portion of a shoe or
snowboard boot constructed according to the first embodiment of the
present invention.
[0011] FIG. 8 illustrates a more detailed view of the liner portion
used for the tongue of FIGS. 6 and 7.
[0012] FIG. 9 illustrates a portion of the liner used in the upper
cuff area.
[0013] FIG. 10 illustrates the travel of moisture through a
reticulated foam, then a flexible mesh, into and through a
breathable membrane according to the first embodiment of the
present invention.
[0014] FIG. 11 illustrates the toe portion of a shoe, snowboard
boot or alpine boot according to a preferred embodiment of the
present invention.
[0015] FIG. 12 illustrates an overall drawing of a snowboard boot,
soft alpine, alpine or hiking boot which will incorporate the liner
of the present invention.
[0016] FIG. 13 illustrates an overall drawing of a running
shoe.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] 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. 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 in these materials. For example, while the
preferred embodiments are illustratively presented below as a
specific sequence of layers, it should be understood that one or
more of these layers may be omitted depending upon the specific
needs of any application. In other words, it is not strictly
necessary to have a certain number of foam layers just as that
disclosed in the currently preferred embodiment. This also applies
for the other elements that are described. For the sake of
conciseness, every possible combination contemplated by the
inventor is not specifically enumerated. With this in mind, the
preferred embodiments currently envisioned are set forth below.
[0018] FIG. 1 illustrates a portion of the liner, or lining system,
according to a first embodiment of the present invention. This
embodiment is directed to a liner for a running shoe which is
generally non-removable or for a snowboard or alpine boot which is
generally removable. The liner may be non-removable in some
embodiments. The various layers of materials discussed below can be
attached to one another in a number of ways, particularly by
lamination, mechanical bonding (or stitch bonding such as that done
by Tietex, Inc. or XYMED GROUP by DuPont.RTM.) or Foss
Manufacturing, or the like, or a combination of lamination and
mechanical bonding. Mechanical bonding can be performed using
nylon, spandex or LYCRA.RTM. thread, or the like. As shown in FIG.
1, a first foam material (20) is provided between an inner liner
(10) and a nonwoven attached to a second foam material (30). The
inner liner (10) can be attached to the first foam material (20) by
lamination or the like. The second foam material (30) is a
germicidal, reticulated and/or open cell foam and has a thickness
of approximately 1/20 to 1/4 inch. All of the foam materials used
in the present invention are assumed to be breathable and their
thickness can be varied depending upon specific needs.
Alternatively, some of the foam materials can be replaced with a
germicidal, hydrophilic open-cell foam. For example, a foam called
AQUAZONE or VPF (made by FOAMEX) may be used. Preferably, the
AQUAZONE or VPF is attached to a non-woven top sheet made of wool,
wood pulp, polyester, cotton, rayon, polypropylene, LYCRA.RTM.,
spandex, lyocel, acetate or a combination of these, etc.
[0019] The inner liner (10) is preferably constructed using
specific fabrics possessing certain desired characteristics. A list
of fabrics which can be employed depending upon the individual
needs of their application as well as the individual needs of each
runner or rider is provided below. These fabrics may either be used
individually or in combination and can be double sided with one
fiber on one side and another on the other side. Variations for use
in a running or hiking shoe, snowboard or soft alpine or shell boot
or liner are specifically recited.
[0020] The first fabric is an anti-microbial, anti-fungal
polypropylene (also referred to as polyolefin) LYCRA.RTM. blend
(2%) with INNOVA fiber, or the like. INNOVA is a continuous
filament fiber (manufactured by Deercreek Fabrics, Inc. or Coville,
Inc.).
[0021] The second fabric is an anti-microbial, anti-fungal
polypropylene having a polyester or cotton backing, or the like
(such as that manufactured by Coville, Inc.). For uses such as
winter hiking, alpine boots, the polyester or cotton backing can be
replaced with wool, silk, acetate, lyocel or the like.
[0022] The third fabric is an anti-microbial, anti-fungal
polypropylene/cotton blend with ALPHA fiber (such as that
manufactured by Intex Fabrics, Inc.).
[0023] The fourth fabric is a field sensor polyester with waffle
weave construction (such as that manufactured by Toray and
distributed by Yagi & Co., Inc.). Alternatively, a polyester
material known as AQUA-DRY, manufactured by Teijin Shojin can be
employed.
[0024] The fifth fabric is a hydrophilic anti-microbial DRI-LEX
BABY KID or perforated material (such as that manufactured by
Faytex Corp.).
[0025] The sixth fabric is a polyester looped terry (such as that
manufactured by Kronfli Spundale Mills, Inc.).
[0026] The seventh fabric is a sueded/sanded polyester microfiber
material (distributed by Yagi & Co., Inc. and Teijin Shojin,
Inc.).
[0027] The eighth fabric is POLAR TEC Series 2000, which is a
wickable, moisture transfer fiber, containing LYCRA.RTM. and
polypropylene. This fabric is also anti-microbial.
[0028] The ninth fabric is a moisture transfer fabric by Tietex,
Inc.
[0029] The tenth fabric is a wool blend with a cotton, polyester,
or the like backing. Double faced knitted fabric
[0030] The eleventh fabric is nylon or nylon polyester blend
treated with or without transfer dry fiber technology manufactured
by Guilford Mills.
[0031] The twelve fabric is a spacer fabrics constructed of nylon,
polyester, polyester or polypropylene blends manufactured by Malden
Mills or Deercreek Fabrics or the like.
[0032] The thirteenth fabric is a polypropylene, polyester or
acrylic blends. Chemically ionized synthetic fabrics by Sterling
Fiber. (CYSTAR AF ECT.)
[0033] The fourteenth fabric is acrillan or DURASPUN acrylics
fabrics by Monsanto.
[0034] Fifteen fabric is an acetate blend.
[0035] Other fabrics recommended are DRILINE by Milliken & Co.
DRYWICK by Adidas, DRI F.I.T. by Nike, DRYLINER by Insport, DRY-LEX
by Faytex, HYDROMOVE by Reebok International, HYDRASUEDE by
Insport, M.C.S. by Burlington Mills, NATUREXX POLARTEC 100 series
bi polar by Malden Mills, QUICK WICK Collection by Summit
Knitting.
[0036] All synthetic fibers and fabrics may be treated with
transfer dry fiber technologies.
[0037] Finally, spacer fabrics, polyester or polyester blends
manufactured by Malden Mills and others can be used. These are
composite fabrics having layers of fibers.
[0038] All of these fabrics have good moisture transfer
characteristics which prevent damage to a runner or rider's foot by
preventing excessive moisture build-up.
[0039] The moisture transfer characteristics of the inner liner
(10) causes moisture vapors to pass from a runner or rider'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 or second foam material (30).
[0040] The first foam material (20) may be a cellular elastomeric
composite (as described in U.S. Pat. No. 6,074,966 the disclosure
of which hereby incorporated by reference), or the like. The
cellular elastomeric composite is formed in one process and is
developed by Foxrun Technology. Layer 20 is a 1/20'' to 1/8''
germicidal, reticulated foam (or germicidal, hydrophilic flexible
polyester, open-cell foam such as AQUAZONE or VPF, Or the like)
backed with a non-woven top sheet comprised of wool, wood pulp,
rayon, cotton, polypropylene, lyocel, polyester, LYCRA.RTM.,
spandex, or a combination there of or the like. The elastomeric
composite natural synthetic or blend fibers and foam are
hydroentangled or fused together with water pressure.
[0041] 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, stitched, or ultrasonically
bonded. The non-woven top sheet (when used) abuts the next layer of
1/20'' to 1/4'' reticulated/hydrophilic flexible polyester, open
cell foam, or second foam material 30. The second foam material 30
may also be a germicidal, hydrophilic, open cell 1/20'' to 1/4''
foam, such as AQUAZONE or VPF or the like. 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 and can be a flexible polyester open
cell foam. In fact the running shoe, hiking shoe, snowboard boot,
soft alpine boot and shell boot or liner may utilize the composites
to transfer moisture vapor. The composite system combines multiple
layers of foams and nonwovens in numerous locations to absorb, move
and transfer moisture. This foam composite creates a one-way system
that allows moisture to travel only in an outward direction. Also,
many of the foam materials are interchangeable depending upon
specific needs. Alternatively, the foam materials can be flame
laminated to a non-woven apertured top sheet of wool, cotton,
lyocel, polypropylene or polyester, or a blend thereof, for
example. The apertured top sheet may also be coated with a foam or
may have a polymer dot matrix applied that is a polymer with phase
change material (which have reversible enhanced thermal
properties).
[0042] For example, the first foam layer 20 may also be substituted
with a germicidal, hydrophilic open-cell, 1/16'' to 1/8'' foam,
such as AQUAZONE or VPF. The foam can also be backed by non-woven
top sheet. Also, a temperature regulating membrane called Outlast,
by Gateway Technologies can be inserted between inner layer 10 and
the first foam material 20, or applied to the fibers of layer
10.
[0043] Alternatively, Frisby Technologies can be embedded in the
first open cell flexible polyester, hydrophilic foam layer 20 or
placed in the second foam material 30. The hydrophilic foam is
preferably AQUAZONE or VPF, but may be a Frisby product called
COMFORTEMP, or the like.
[0044] The outlast membrane or coating can be placed on the other
side of the foam, outside the non-woven top sheet, if present. In
fact, phase change technology by Outlast, Frisby, Freudenberg,
Schoeller or Invista, or the like may be combined with any foam,
nonwoven or insulative layer and can be on either side.
[0045] A number of patents have been issued to Triangle Research
& Development Corp. disclosing 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. 5,415,22;
5,290,904; and 5,244,356. These patents are also hereby
incorporated by reference.
[0046] 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.
[0047] The nonwoven may as well by treated with a thermal enhancing
technology by Wisconsin Global Technologies or nanotechnology.
Nanotechnology may be used in any portion of this invention.
[0048] As shown in FIG. 2, a third foam material 50, which provides
support and has similar characteristics to the second foam material
30, allows the moisture vapors to continue their movement toward
the outside. This third foam material 50 may be a foam, a nonwoven
or spacer fabric, or combination thereof, is formed in certain
areas to take necessary shapes such as the shape of an ankle, heel
cup and foot bones, and is positioned so as to allow the moisture
to pass through into subsequent elements, such as a
waterproof/breathable membrane 70 and the outer layer 80 of the
overall lining system. The outer layer 80 is preferably
waterproofed by encapsulation or by using a waterproof/breathable
finish or film. The third foam material 50 may alternatively be a
spacer fabric by Muller or Malden or the like. The easily molded
spacer fabric or the third reticulated/open cell foam material 50
can be designed to provide a well defined heel lift, and heel
pocket. This invention develops the components necessary to
increase technical performance with the increases support around
the heel, toe, and ankle. For snowboard boots or alpine boots, the
toe box is from top to bottom, wider and more flexible than in
previous snowboard or alpine boots. The laminated or mechanically
bonded foams and nonwovens under the heel support the runner and
rider's lower back and allows for a comfortable stride. With this
added comfort, the aggressive or recreational runner, hiker, rider
or skier can achieve a higher level of continued performance.
Spacer fabrics can be combined for improved performance.
[0049] 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 or the like, that adds structural integrity to the
lining system. A spacer fabric, moldable foam, or the like, may
also be used in place of this flex guard or mesh. Also, neither may
be used in some circumstances. The moldable foam, if not very
breathable, can be made breathable by puncturing. Alternatively,
the moldable foam can be a reticulated or hydrophilic, open-cell
structure, or the like. A non-woven top-sheet (with or without
apertures) can be attached to the moldable foam. If a spacer fabric
or moldable foam is used, then the second foam material may be
omitted. Also, the moldable foam can be AQUAZONE or VPF.
Preferably, for extreme sports applications the moldable foam or
spacer fabrics are used instead of the flexible mesh as layer
40.
[0050] As mentioned earlier, the material 50 is preferably similar
in construction to the second foam material, namely being either
germicidal, reticulated and approximately 1/20'' to 1/4 inch thick,
or being germicidal, hydrophilic open-cell (for example AQUAZONE or
VPF). This material is preferably laminated to a non-woven top
sheet (which may or may not be apertured) comprised of wood pulp,
lyocel, acetate, rayon, or cotton. The top sheet abuts the
waterproof/breathable membrane 70 or an encapsulated or coated
outer fabric.
[0051] For snowboard, alpine and hiking boots, due to the cold
weather conditions, a combination of THERMOLITE (or THERMALOFT) or
the like and foam mechanically bonded or laminated together, or a
foam and nonwoven, or SSOFTHERM inclusive of an open cell foam, or
THERMOLITE with a spacer fabric or THERMOLITE by itself is
preferably used for the third foam material 50. THERMOLITE,
manufactured by DuPont.RTM., is a thin insulation having a hollow
polyester fiber laid in random layers with an acrylic binder (loose
felted) needle punched through the cross section to attach layers
and tie them down. Various types of THERMOLITE can be used, such as
THERMOLITE EXTREME, THERMOLOFT, MICROLOFT, TFI 2000 G/M2 or TFI
4000 G/M2, etc.
[0052] Alternatively, a thermal nonwoven composite (by Foss
Manufacturing) created with synthetic fibers having a open cell
foam needle-punched into its internal structural layers can form
layer 50, and abut layer 60, an elastomeric composite, a open cell
foam, another nonwoven, a spacer fabric, another thermal product
such as THERMOLITE, Foss thermal, or layer 70 a breathable membrane
or layer 80 the exterior fabric or synthetic leather. Also, the
foam can be combined with the fibers of the nonwoven or the
nonwoven can be combined into the foam depending upon the
application and whether there is a need for cooling or warming. The
Foss composite may be next to outlast membrane or have the Frisby
Technology embedded in the needled open cell foam applied.
COMFORTEMP by Frisby Technology may also be needled into the
existing Foss to thermal composite layer.
[0053] If encapsulation is used in outer layer 80 as discussed
herein, then it is important to use THERMOLITE, THERMOLITE with
foam or the Foss composite contracted of SSOFTHERM and acetate,
polyester, acrylic or the like with open cell foam needled into the
base as layer 50 and 60 in all alpine liners and hiking
applications. The Foss composite may be bi-polar in nature and may
contain wood pulp or lyocel fibers. Again, the Outlast membrane or
Frisby can be used in combination with the third material 50, 60,
especially in condition with THERMOLITE or the like.
[0054] The moisture vapor continues from the second foam material
30 through the mesh or spacer material 40 and on through the third
exterior foam or THERMOLITE material 50 or combinations if applied
in layer 60. The moisture vapors are then passed through
waterproof/breathable membrane layer 70 if applied. The moisture
vapors are absorbed into waterproof/breathable membrane passed
through to an outer layer of fabric 80, as shown in FIG. 4. The
waterproof/breathable membrane 70 can be selected from a variety
presently available on the market. Those under the tradenames VAPEX
2000/Plus/Standard/1300, SECO-TEC, THINTECH, LAY-TEK and WITCOFLEX
SUPER DRY FILM by Baxanden Chemicals (a hydrophilic membrane), and
breathable membranes by Harrison Technologies are currently being
considered. However, the membranes currently considered to be the
preferred ones are called TX-1540 (application by Shawmut Mills).
TX-1540 is intended to be an ultra-thin, skin friendly, moisture
barrier that allows moisture vapors to escape while preventing
outside water from penetrating. The Outlast membrane or the Frisby
Technologies can be used in combination with other membranes with
encapsulation techniques, or with structurally knitted fabrics and
can adjust to temperature changes. Of the various encapsulation
techniques, the one practiced by Nextec is particularly
advantageous.
[0055] Also shown in FIG. 4 is an optional protective rim or cuff
90, preferably made of a slow recovery foam (by FOAMEX, for
example) a spacer product by Muller Textil or neoprene covered by
LYCRA.RTM.. Cuff 90 could also be made of a reticulated foam. The
cuff is optional in all alpine and hiking boots. A pull tab 100,
preferably made of nylon, is connected to the protective rim 90. In
adventure sports applications an abrasive protective material 110
is provided adjacent to a tongue 300. Another abrasive protective
material 120 is provided around the heed portion of the shoe.
Abrasive protective material 120 is supplied by Schoeller,
Dupont.RTM., or the like. the protective material is optional in
all alpine liners.
[0056] The outer layer of fabric 80 of the lining system has 200 to
6000 denier strength and is made waterproof by a membrane, a
coating, encapsulation technology or by using structurally knitted,
water repelling fabrics. Encapsulation technology is being utilized
by a company called Nextec, Inc. or Toray, Inc. (a Japanese company
or the like). Nextec Technology can be combined with the Outlast
membrane or Frisby Technology. The Outlast membrane may be coated
or laminated to the outer fabric. If the outer fabric is
encapsulated then the outlast technology must be applied to the
fiber or fabric prior to encapsulation. The Frisby temperature
regulating molecules can be incorporated into the spaces between
the encapsulated fibers and may be inserted at the time of
encapsulation. The breathable membranes preserve the outer layer of
fabric 80 and perform as a waterproof barrier for the runner
orrider's liners. If the encapsulation technology is applied to the
outer layer of fabric 80, then the breathable laminate membranes
need not be used.
[0057] The outer layer 80 may be any of the following materials,
either individually or in combination. These materials include
synthetic leathers, synthetic breathable fabrics, or the like, by
Daewoo, Kevlar, and Cordura fabrics, by Schoeller, travis or the
like, Kevlar, and technical fabrics by DuPont.RTM. and Toray,
Cordura treated by encapsulation by Nectex, Toray, DuPont.RTM.,
Travis, and the like, 4-ply Supplex, Cordura waterproofed by the
breathable membrane, F.L. fabric by Malden Mills, DERMIZAX by
Toray, ENTRANT-GIL and WAXEY by Toray, GYMSTAR PLUS and TUFLEX-HR
both by Unitika. The Corduras can be those made by others as well.
Nylon or polyester spacer meshes waterproofed by coating,
encapsulation or film. There are primarily three ways of protecting
outer layer 80, encapsulation, using a membrane, structurally
knitting the fabric to repel water or coating the fabrics with a
waterproof film. Preferably, the outer layer 80 is a combination of
one of the above-mentioned materials with one of the following: the
Outlast or Frisby Technologies and encapsulation by Nextec or the
like, or the Outlast membrane or Frisby Technologies and the
waterproof/breathable fabrics such as ENTRANT-GIL, DERMIZAX,
TUFLEX, GYMSTAR or the like. The Outlast membrane is laminated or
coated to the outer fabric or woven into the fabric or fibers, or
the Frisby Technology embedded in the encapsulated outer fabric and
then laminated to the waterproof/breathable membrane, the Frisby or
Outlast Technologies in combination with structurally knitted or
woven waterproofed fabrics, or finally the Frisby or Outlast
Technologies in combination with ENTRANT-GIL, DERMIZAX, TUFLEX, or
GYMSTAR, nylon supplex or cordura, polyester, Kelvar or synthetic
blends or the like. The outer fabrics in several performance
categories may not apply either Frisby or Outlast Technologies. The
Frisby technology may also be in combination with an elastomeric
technology preferable by Foxrun Technologies or abutting the outer
fabric layer 80 in any of the open cell foams or a membrane by
Outlast technologies may be laminated to the elastomeric composite
abutting the outer fabric layer 80. In fact phase change technology
by Frisby, Outlast or Wisconsin Global Technologies may be applied
to any layer of elastomeric, foam or nonwoven where specified.
[0058] Elastomeric composite technology may be substituted in any
area where there is a foam abutting nonwoven composite
combination.
[0059] Selecting the proper materials depends upon the needs of
each individual runner or hiker or rider or skier's needs. The
non-abrasive fabrics used in the moisture transfer inner liner of
the present invention greatly reduces the possibility of trapped
moisture, thereby protecting the foot from fungus growth and any
damage. The anti-fungal, anti-microbial polypropylene (polyolefin)
fabrics quickly remove moisture away from the foot. Skin damage is
minimized because the polypropylene fabric has a smooth, continuous
surface or soft fleeced texture. This fabric also prevents
bacterial build-up which can cause foot odor and fungus. Chemical
ionization may be applied to polyolefin
[0060] The polyester looped terry blend is an excellent wicking
fabric and can remove moisture rapidly when treated with a wetting
agent or chemical ionization.
[0061] The anti-fungal, anti-microbial, DRI-LEX nylon fabrics, like
the polypropylene, is sanded and soft. The material is extremely
comfortable and cool to the tough. Chemical ionization can be
applied to nylon and nylon blends.
[0062] The polyester field sensor fabric works well with those
individuals who prefer high performance. The liner absorbs moisture
immediately.
[0063] A polyester microfiber fabric is smooth to touch and
wickable. A wetting agent may be added to assist in moisture
transfer. Chemical ionization can be applied to nylon and nylon
blends
[0064] Finally, a wool, cotton or polyester blend backed with
polyester, acrylic or cotton or the like. Structurally knitted
double faced and ionized fabrics.
[0065] As a result of using this lining system, the runner, rider
or hiker continues to have a cooler, drier foot. The lightweight
Kevlar, STARLITE, Cordura, DERMIZAX or the like outer liner
materials are twice as durable as the former heavyweight leathers,
synthetic leathers and materials often used on the outer shell,
functions as a flexible, high abrasive, breathable outer surface
and aid in the moisture transfer and may be in combination with
synthetic leathers and nylon or polyester spacer meshes
products.
[0066] FIGS. 5(a) and 5(b) illustrate a sole portion 200 of a
footbed insert. This removable footbed is constructed to remove
moisture downward and out away from the runner or rider's foot. The
inner lining material abuts an open cell foam laminated to a
nonwoven abutting a moldable spacer product preferably by Muller
Textil. In some cases the nonwoven may be removed. In extreme
temperatures the Foss thermal composite constructed with Ssoftherm
and a combination of one or more synthetic fibers is preferable.
The synthetic fibers that may be blended with the Ssofttherm
include a combination of polyester, acrylic, lyocel blends needled
together with and open foam may take the place of the nonwoven and
open cell foam combination or may abut the open cell on one side
and the spacer product on the other side or the outer fabric.
THERMOLITE or the like may be an option to the Foss thermal
composite and may be needled together with an open cell foam. The
footbed may be covered with CAMBRELLE DRI-LEX nylon, the Toray
field sensor products or one of the selected inner lining materials
or a nonwoven. The inserted hydrophilic open cell and spacer fabric
composite adds support and transfers moisture downward. The bottom
portion of the foam is preferably provided with a non-woven top
sheet as described earlier. The heel pocked foam or spacer fabric
protects the back of the heel. This cushion protector allows
circulation in the heel. ComforMaxSport by DuPont.RTM., an
anti-microbial CAMBRELLE DRI-LEX nylon, Toray field sensor or one
of the selected moisture transfer fabrics, or the like, covers a
spacer fabric material, a slow recovery foam or molded hydrophilic
foam 220 that supports the arch and insures additional comfort for
a runner in some applications. This footbed insert is removable and
when inserted abuts a nonwoven thermal inside the liner. BA FIGS.
6, 7, and 8 illustrate the tongue 300 of the shoe 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 liner materials mentioned above,
especially the field sensor by Toray, polypropylene, LYCRA.RTM.
blend with INNOVA fiber, the polyester microfiber, the polyester
looped terry or the fabrics by Malden Mills, looped terry
polypropylene blends or, polyester by Kronfli, Miliken or the like.
This inner liner fabric 310 is preferably laminated to a structural
support foam 320 and nonwoven. The nonwoven abuts a moldable spacer
fabric followed by the nonwoven foot bed fabric. The foot bed is
preferably molded and removable. Preferably, the foam is an 1/8
inch or 1/4 inch and is germicidal, reticulated flexible polyester
and open cell foam. The inner lining fabric may also be abutting an
elastomeric composite or may be directly abutting a moldable spacer
fabric and exterior materials. A hydrophilic open cell or
perforated foam 330 (also could be a reticulated foam, or the like)
abuts a structural support foam or spacer product 320. The
hydrophilic perforated foam or spacer fabric 330 can take the shape
of the foot bones and protect the upper foot from damage. The
structural support 320 can also be shaped to accommodate the foot
and protect the ankle bones. Optionally, a moldable spacer fabric
by Muller, or the like, may also be used as portion 330. A moisture
transfer material 340 lies over the hydrophilic open cell or
perforated foam 330. This moisture transfer material 340 is
preferably made from material known as aero-spacer DRI-LEX, which
is manufactured by Faytex Corp, BIRDEYE nylon by Gilford Mills
treated with or without transport technology, an aero-spacer fabric
manufactured by Apex Mills, or a waterproof nylon or polyester
blend or the like. The abutting exterior fabrics may be either a
nylon or polyester blend spacer mesh material or one of the
selected exterior fabrics mentioned and can be coated with a
waterproof coating. In one embodiment, the aero-spacer, exterior
spacer meshes products or outer fabrics are in combinations with
synthetic leathers. It should be understood that non-woven
synthetic materials can always be substituted for the aero-spacer
DRI-LEX, spacer mesh products even if not specifically mentioned in
other parts of this disclosure. The spacer mesh products 340, in
some hiking applications, is wrapped around the outer edge of the
tongue to allow moisture vapors traveling from the upper foot area
to escape through moisture transfer material 340 to the outer
surface of the tongue 300. Material 340 also aids in providing a
softer edged tongue. Finally, an outer layer 350 may be added in
some hiking applications over a central portion of the material
340. Another hydrophilic, molded foam (not shown), or slow recovery
form, moldable spacer fabric or hydrophilic foam, is shaped to fit
between the outer layer 350 and material 340. In extreme adventure
sport applications the added protection may be required.
[0067] As shown in FIG. 6, outer layer 350, which can be a
breathable synthetic leather (by Daewoo Corp. for example) or a
Kevlar, or the like is surrounded by aero-spacer DRI-LEX 340, a
substitute as mentioned above or a combination thereof. At the top
of the tongue 300 an abrasive reflective grip fabric may be added
for running and hiking applications (such as that manufactured by
Schoeller and identified by the number 6500, or the like), also
shown in FIG. 4. Stitching is identified by numeral 370. FIG. 7
illustrates a top portion of the tongue 300, and shows stitching
370 and the liner fabric 310.
[0068] The liners are preferably provided with a pull tab 100 as
illustrated in FIGS. 4, 9, and 10 on the back of cuff 90
constructed of a slow recovery foam (by Rogers, or the like),
moldable spacer fabric or neoprene covered by LYCRA.RTM..
Optionally, cuff 90 can be omitted altogether. FIG. 9 shows an
opened up version of the liner looking from the back of the liner
or hiking boot. Located just beneath the LYCRA.RTM. covered
neoprene cuff or spacer fabric 90 is an abrasive grip fabric
material 410, such as manufactured by Schoeller, Inc., and referred
to by the number 6500. Below material 410 is a reflective grip
composite material 420. An option in the hiking application is a
highly abrasive fabric 110 as shown in FIG. 4. Fabric 110 is
preferable a Kevlar or STARLITE, or a Cordura, or the like.
Finally, outer shell fabric 80 is the same as that shown in FIG. 4,
and can be any of the fabrics listed previously in connection with
outer shell fabric 80. The nylon pull tab 100 allows the rider's
easily entree into the liner.
[0069] FIG. 10 shows the other side of the liner of FIG. 9. In FIG.
10, 510 can be a 1/4 inch moldable foam which has been punctured or
a moldable spacer fabric or the like. 520 represents the
combination of the flexible mesh and foam (in case the moldable
foam is not used as depicted), the outer shell fabric. As in all of
the figures, the arrows depict the flow of moisture. FIG. 11
illustrates the toe portion 400 of the liner. Preferably, the toe
portion 400 is constructed with an inner liner 10, followed by a
foam nonwoven composite abutting a thermal composite material 30,
followed by a breathable membrane if used 60 and finally followed
by the outer fabric 70. Foam material 30 can either be a single
foam, two foams, a foam, nonwoven, foam composite, a THERMOLITE, a
THERMOLITE and foam combination, Foss thermal composite with
SSOFTHERM and synthetic fiber blends or any of these in combination
with a non-woven top sheet (or a cellular elastomeric composite).
Abrasive grip fabric is also shown. The breathable membrane is
optional the shoe.
[0070] The 6500 high abrasive fabrics manufactured by Schoeller,
Inc. or the like are optionally located on the back of the cuff and
the top of the toe box and heel. The Kevlar and Cordura, STARLITE
and Cordura fabrics provide comfort and durability to the liners
and are extremely strong and resistant to abrasion and allow for
breathability and performance.
[0071] FIG. 12 illustrates a snowboard boot liner incorporating the
lining system discussed above. The following elements of the
snowboard boot are shown: numeral 610 represents a waterproof
breathable synthetic leather, a Kevlar fabric (made by Schoeller,
or a similar material), Schoeller, DuPont.RTM. & Toray or the
like, Cordura 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, 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 molded breathable foam or spacer fabric; 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 the removable liner insert if desired.
[0072] The sock 675 is made up of three layers. The first layer can
be any of the inner liner materials discussed above. The second
layer is a layer of foam or THERMOLITE, THERMOLITE with foam or the
Foss thermal composite with a foam needled in or a combination
thereof. The third layer is a fabric such as moisture transfer
polyester blend manufactured by Deercreek fabrics, Menra Mills, or
the like. Encapsulation technology can also be applied to the third
layer. Sock 675 can be used for additional warmth and is removable,
unlike the shoe liner and can be inserted into the all weather
synthetic rubber or leather boot or a combination of leather and
synthetic rubber boot, a snowboard boot, soft alpine boot or alpine
shell liner. The insert is preferable used in a boot where the
inner liner is not removable. The three layers can be attached to
one another by lamination, although mechanical bonding, or
stitching, or ultrasonic bonding, can also be used.
[0073] FIG. 13 illustrates a running shoe 700 that is formed by the
various combination of layers discussed above. The top portion of
the shoe 700 emphasizes the various layers that make up the shoe
and should be interpreted in the context of the discussion above
regarding the various options.
[0074] The microfiber technology disclosed above is rapidly
developing and changing and has greatly increased the potential for
improved performance of such products such as running shoes and
alpine boots, 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 fabric, foam, nonwovens, moldable spacer materials
and THERMOLITE or SSOFTHERM blended layers with or without open
cell foam needled into the layers, with or without breathable
membranes. Breathable membranes are optional in the running or
hiking shoe. Other options include structurally woven or knitted
waterproof fabrics, coated fabrics, or encapsulated outer fabrics
in such combinations that increase the performance of the products
in which they are used as well as increasing breathability. The
breathable membrane is optional in all alpine, snowboard boot,
hiking applications and removable insert sock liners rubber boots
or the like. While the discussion above has focused upon running
and hiking shoes and snowboard and alpine boot liners, similar
applications can be made with cross country boots, or in-line
skates, protective gear, helmets, gloves, accessories and apparel
with slight modifications. For example, in the case of a cross
country ski boot, the liner would preferably have a waterproofed
outer fabric, attached to a synthetic rubber base. Encapsulation
technology and membranes such as TX1540, WILCOFLEX DRY combined
with the Outlast technology from Gateway Technologies can be
employed. It is preferable to use Outlast or Frisby close to the
individual's foot in alpine, snowboard, or alpine cross country
boots. Outlast or Frisby Technologies may also be added to any of
the inner lining material listed. Otherwise, the liner could be
very similar, although the use of the supportive mesh could be
limited to certain areas. Adjustments in the breathable membrane
would be made to accommodate winter conditions and cosmetic changes
could be applied to the surface areas.
[0075] The following is a brief discussion of the variations that
are preferably employed for a running and hiking shoes and
snowboard or alpine liners and the like. Similar names correspond
to similar products discussed above and are not described in
further detail.
[0076] Alpine Boots
[0077] First, a liner for alpine boots is similar to in-line skate
boots with moldable spacer products and plastic mesh by Naltex used
for high-performance boots. This liner would have the following
layers of materials (additional drawings for these applications are
omitted in order to be concise). The liner will be described in a
sequence of layers beginning with the innermost layer. The first
layer is selected from a group including field sensor technology by
Toray, anti-microbial, anti-fungal, polypropylene INNOVA or ALPHA;
DRI-LEX CAMBRELLE, or DRILEX DOE SKIN manufactured by Faytex Corp.,
looped poly terry by Kronfli, DRI-LEX/polyterry by Faytex,
polypropylene or wool blends backed by another fiber for example
cotton or wool or the like by Coville, Cordura, polyester sueded or
fleeced, moisture transfer materials, or Malden Mills polyester and
blends thereof, or the like. A combination of these materials may
also be employed depending upon the needs of an individual skier.
All fabrics may be chemical ionization.
[0078] Just in the case of the snowboard boot, 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 AQUAZONE OR VPF, FOAMEX or COMFORTEMP by Frisby or the
like. Alternatively, these layers can be a cellular elastomeric
composite which is one of the above-mentioned foams backed by a
non-woven apertured top sheet composed of wood pulp, polyester,
rayon, cotton, or polypropylene, in a single process. A foam
nonwoven, foam, nonwoven composite may also be used followed by a
thermal composite if applicable.
[0079] The fourth layer is a hydrophilic, open cell (AQUAZONE or
VPF), slow recovery foam or flex-guard or a polyester spacer
material (by Muller) or the like for support. In this case,
AQUAZONE or VPF is laminated to a flat non-woven top sheet composed
of wood pulp, rayon, cotton, polyester, lyocel, polypropylene which
abuts a waterproof/breathable membrane (fifth layer). If the
flex-guard is used, it is followed by another layer of AQUAZONE or
VPF with a top sheet abutting the waterproof/breathable membrane or
the encapsulated outer fabrics. If the spacer material is used, it
may or may not be molded to accommodate the foot. The non-woven top
sheet may be eliminated. The spacer material will be followed by
either a waterproof membrane, an encapsulated or coated fabric. The
spacer material may alternatively be used in a number of the boot
layers in combination with a thermal composite, foam or a foam,
nonwoven composite.
[0080] The fifth layer is a waterproof/breathable membrane which
may be any one of the following: Outlast membrane by Gateway
Technologies in combination with SECO-TEX, No. TX1540 (laminated by
Shawmut Mills), THINTECH, VAPEX 2000/1300 standard, Laytex and
ENTRANT-GIL by Toray or the like. The Outlast membrane by Gateway
Technologies is in conjunction with one of the suggested breathable
membranes or the like. The laminated or coated outlast membrane may
also be combined with some encapsulated fibers and fabrics. The
Frisby Technology may be embedded in the preceding foam or
THERMOLITE or MICROLOFT by DuPont.RTM., but is not in combination
with a breathable membrane. Frisby Technology can be used in
conjunction with structurally knitted waterproof fabrics, or with
the encapsulation technology by Nectex, Toray or the like.
Encapsulation by Nextec combined with the Outlast Technologies is
preferred. If encapsulation is employed, then the fourth layer
preferably includes THERMOLITE or a thermal foam composite
inclusive of SSOFTHERM, a product by Foss Manufacturing, needled
together with foam. If a non-removable liner is employed instead of
a removable liner, a waterproof-breathable thin film can be used
instead of encapsulation or a waterproof/breathable membrane.
[0081] The sixth and final layer in this removable shell liner may
be Cordura, STARLITE, Tudor 3/4 ply Supplex, Kevlar fabrics,
DERMIZAX or encapsulated fabric or any combination of them. Also, a
waterproof breathable thin film coated fabric could be used.
[0082] Alpine Cross Country Boots
[0083] A liner for the alpine cross country boots is similar to the
snowboard boot liner except the cross country boot does not have a
sock liner, and the foams (or THERMOLITE and foam) are thinner.
This liner would include the following. A first layer selected from
a group including polypropylene, LYCRA.RTM. or wool backed by
cotton, wool, or a rayon blend or an anti-microbial, anti-fungal
INNOVA or ALPHA; sueded polyester; polyester field sensor; looped
polyester terry; DRI-LEX DOESKIN or BABY KID by Faytex Corp.;
polyester DRI-LEX Terry by Faytex; polyester spacer fabric by
Malden; and polypropylene backed by cotton by Coville.
[0084] The second layer is a germicidal open cell hydrophilic foam.
It may be COMFORTEMP by Frisby or AQUAZONE or VPF with Frisby
Technologies. This foam can be provided with or without a non-woven
top sheet. The non-woven top sheet can be selected from any of the
materials previously specified.
[0085] The third layer is a structural support foam or a moldable
spacer material by Muller Textil. The foam may be a moldable
hydrophilic AQUAZONE OR VPF. The heel and arch may also have a slow
recovery foam or spacer product added for comfort. The thickness of
the layer of foam or spacer fabric and THERMOLITE may vary for
performance.
[0086] The fourth layer is a thin layer of THERMOLITE, the Foss
foam thermal composite or AQUAZONE OR VPF or the like with a
non-woven top sheet made of wood pulp, rayon, cotton, polyester, or
polypropylene. The fourth layer may be optional in some performance
categories.
[0087] The fifth layer is optionally, a waterproof/breathable
membrane which may be any one of the following: SECO at Shawmut
Mills, THINTECH, VAPEX 2000/1300 standard, Laytex, breathable
membranes by Harrison Technologies, or ENTRANT-GIL by Toray. The
outlast membrane by Gateway Technologies is employed for this
layer. The outlast membrane can be used by itself, with another
membrane or with encapsulation technology on the outer fabric, such
as Nextec, Toray or the like. Frisby Technology may also be applied
in the open cell foam, or encapsulated outer fabrics. COMFORTEMP by
Frisby Technology may be used in some applications. Alternatively,
instead of the membrane, just encapsulation of the sixth layer can
be performed to achieve similar results. A combination of Outlast
or Frisby and encapsulation fibers or fabrics by Nextec or the like
is preferred. If encapsulation is employed, then the fourth layer
preferably includes THERMOLITE or the Foss Manufacturing thermal
foam composite.
[0088] 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.RTM. blends; STARLITE
by Faytex Corp.; Kevlar fabric by Schoeller (14705, 6500, 13207,
13632, 65563, etc.); DuPont.RTM. and Toray or the like, Cordura
2000 by DuPont.RTM., DERMIZAX and ENTRANT-GIL by Toray, 3 or 4 ply
Supplex; Mojave and Tudor nylon and polyester blends by Travis; 6
ply Maxus nylon blends or the like; and synthetic leathers by
Daewoo, Inc. or the like. These fabrics may be used individually or
in combination.
[0089] The seventh layer is a LYCRA.RTM. covered neoprene, moldable
spacer fabric or slow recovery foam or reticulated open cell foam
ankle cuff.
[0090] 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 AQUAZONE OR VPF
molded foams with a 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 Aero-spacer,
polyester field sensor by Toray, polyester spacer by Malden,
polypropylene, polar fleece, INNOVA or ALPHA or DRI-LEX DOESKIN,
polyester sueded or fleeced or the like. The outer tongue fabrics
are high abrasive fabrics Kevlar, STARLITE, or Schollar's Corduras,
6500, DRI-LEX Aero-Spacer (or other Aero-spacer materials by
Faytex, or the like, and breathable synthetic leathers by Daewoo,
or the like.
[0091] Hiking Boots
[0092] 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 by Faytex, DOE SKIN, BABY KID,
CAMBRELLE by Faytex, anti-fungal, anti-microbial polypropylene
fabrics, INNOVA or ALPHA, sueded polyester blends, COOL MAX or
nylon blends, or the like. Any combination of these moisture
transfer fabrics can also be used.
[0093] The second layer is a cellular elastomeric composite or
hydrophilic open cell AQUAZONE OR VPF foam or COMFORTEMP by Frisby.
The Outlast membrane is optional in this layer. If a foam is used,
a non-woven top sheet selected from previously mentioned materials
can be attached as a backing.
[0094] The third layer is a molded hydrophilic AQUAZONE OR VPF
backed by an aperture top sheet composed of cotton, polyester,
polypropylene, lyocel, rayon, or wood pulp 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 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.
[0095] The fourth layer may utilize 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, VAPEX 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 membrane, encapsulation of the fifth
layer can be performed to achieve similar results. If encapsulation
is employed, then the third layer is preferably AQUAZONE OR VPF or
a moldable spacer fabric, or THERMOLITE or the thermal Foss
composite. The Outlast technology can be used in combination outer
fabrics with or without encapsulation, such as by Nextec, or the
like.
[0096] The fifth and last layer is a combination of one or more of
the following: Corduras; Supplex Nylon; STARLITE; Tudor; Kevlar;
polyester nylon blends; and breathable synthetic leathers.
Preferably, this layer is waterproofed by using encapsulation,
waterproof films or coatings, or breathable membranes, with or
without the Outlast or Frisby Technologies.
[0097] Elastomeric composite technology may be substituted in any
area where there is a foam abutting nonwoven combination.
[0098] Furthermore, the breathable liner according to the present
invention could also be added to clothing such as shirts, pants,
gloves, helmets, 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 composite or a 1/16-1/8''
AQUAZONE OR VPF open cell foam which may be embedded with or
without Frisby Technologies. A non-woven may or may not be
laminated to the foam. A breathable membrane abuts the foam or
non-woven and is laminated to the outer fabric. The outer fabric
may be encapsulated, laminated to a breathable waterproof membrane,
coated with a waterproof film, or structurally woven or knitted to
repel water. Indeed, the amount of foam used can be reduced due to
cost consideration, etc. Presently, this liner system is using
THERMOLITE or the thermal Ssoftherm product mechanically bonded to
a needle punched composite inclusive of open cell foam and is may
use a polyester spun bonded filter products by Tangerding
Vlitesstoffe, Vitafiber, or the like to be used as an alternative
to hydrophilic foam layers.
[0099] 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.
* * * * *