U.S. patent application number 14/559127 was filed with the patent office on 2015-06-04 for waterproof shoe with size and shape-adjustable bootie.
The applicant listed for this patent is TBL Licensing LLC. Invention is credited to Peter Dillon, John Healy, Michael P. Kirk.
Application Number | 20150150335 14/559127 |
Document ID | / |
Family ID | 53264002 |
Filed Date | 2015-06-04 |
United States Patent
Application |
20150150335 |
Kind Code |
A1 |
Healy; John ; et
al. |
June 4, 2015 |
WATERPROOF SHOE WITH SIZE AND SHAPE-ADJUSTABLE BOOTIE
Abstract
A footwear system is disclosed for protecting a user's foot from
water or other liquid substances. In one embodiment, the footwear
comprises a shoe having an upper, a seamless sock-shaped bootie, an
inner lining, and a sole engaged to the upper. The seamless bootie
may be composed of waterproof material and include at least one
ribbed portion adapted to expand to allow the bootie to conform to
the size of the inner lining. The bootie may be arranged between
the upper and inner lining. Methods of manufacturing the
aforementioned footwear system are also disclosed.
Inventors: |
Healy; John; (Madbury,
NH) ; Dillon; Peter; (Topsfield, MA) ; Kirk;
Michael P.; (Beverly, MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
TBL Licensing LLC |
Wilmington |
DE |
US |
|
|
Family ID: |
53264002 |
Appl. No.: |
14/559127 |
Filed: |
December 3, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61911696 |
Dec 4, 2013 |
|
|
|
Current U.S.
Class: |
36/87 ; 12/142R;
36/8.1 |
Current CPC
Class: |
A43B 7/12 20130101; A43B
23/07 20130101; A43B 23/0235 20130101; A43B 3/26 20130101 |
International
Class: |
A43B 7/12 20060101
A43B007/12; A43B 1/14 20060101 A43B001/14 |
Claims
1. A shoe comprising: an upper having an exterior surface and an
interior surface; a sole having an exterior surface for contacting
the ground and an interior surface, the sole being secured to the
upper, wherein the interior surface of the upper and the interior
surface of the sole define a cavity for receiving a wearer's foot;
an inner lining arranged within the cavity; and a seamless bootie
formed of waterproof material in a sock shape, the seamless bootie
overlying the inner lining within the cavity and including one or
more ribbed portions adapted to expand to allow the bootie to
conform to the size of the inner lining, the seamless bootie being
configured to shield a wearer's foot from contact with water or
another liquid.
2. The shoe according to claim 1, wherein the seamless bootie
entirely covers the inner lining.
3. The shoe according to claim 1, wherein the inner lining is
composed of pieces of fabric that are stitched together.
4. The shoe according to claim 1, wherein the waterproof material
of the seamless bootie is selected from the group consisting of
latex, polyurethane, rubber, Ethyl Vinyl Acetate, or any
combination of thereof.
5. The shoe according to claim 1, wherein the bootie includes
multiple ribbed portions configured to expand so that the bootie
conforms to the size of the inner lining, at least some of the
ribbed portions being arranged transverse to a longitudinal axis of
the bootie.
6. The shoe according to claim 1, wherein the bootie includes a toe
region with a perimeter, and the one or more ribbed portions extend
along a portion of the perimeter of the toe region.
7. A method of manufacturing a shoe, the method comprising:
providing an upper, an inner lining, and a foot-shaped mold having
an outer surface, the foot-shaped mold including at least one
ribbed portion on its outer surface; applying a waterproof material
to the outer surface of the foot-shaped mold, thereby creating a
seamless functional layer with at least one ribbed portion
corresponding to the at least one ribbed portion on the outer
surface of the foot-shaped mold, the seamless functional layer
being in the form a seamless, sock-shaped bootie; placing the
seamless functional layer over the inner lining, such that the at
least one rib expands to conform the seamless bootie to the size of
the inner lining; placing the upper over the seamless functional
layer; and affixing a sole to the upper.
8. The method according to claim 7, wherein the upper is stitched
to a foot bed that is interposed between the sole and the
upper.
9. The method according to claim 7, wherein the foot-shaped mold
includes multiple ribbed portions on its outer surface, at least
some of the ribbed portions being arranged transverse to a
longitudinal axis of the mold.
10. The method according to claim 9, wherein the foot-shaped mold
includes a toe region with a perimeter, and at least one of the
ribbed portions extends along a portion of the perimeter of the toe
region.
12. The method according to claim 7, further comprising the step of
immersing the foot-shaped mold in a body of waterproof material to
cover a substantial amount of the mold's outer surface with the
waterproof material.
13. The method according to claim 12, further comprising the steps
of removing the foot-shaped mold from the body of waterproof
material, and heating the foot-shaped mold and waterproof material
to cure the waterproof material.
14. The method according to claim 7, wherein foot-shaped mold
includes one or more ribs at a heel portion of the mold.
15. An article for waterproofing footwear comprising a seamless,
sock-shaped bootie formed of waterproof material, the seamless
bootie having at least one rib extending transversely from a
surface of the bootie and being configured for insertion over an
inner lining of a shoe, wherein the bootie is adapted to conform to
the size of the inner lining via the at least one rib.
16. The article according to claim 15, wherein the seamless bootie
includes multiple ribs.
17. The article according to claim 16, wherein the seamless bootie
includes a toe region with a perimeter, and at least one of the
ribs extends along a portion of the perimeter of the toe
region.
18. The article according to claim 15, wherein at least one rib is
placed vertically along an instep area of the bootie.
19. The article according to claim 18, wherein at least one rib is
placed transverse in relation to the vertical rib on the
bootie.
20. The article according to claim 15, wherein the waterproof
material of the seamless bootie is selected from the group
consisting of latex, polyurethane, rubber, Ethyl Vinyl Acetate, or
any combination of thereof.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of the filing date of
U.S. Provisional Patent Application No. 61/911,696, filed Dec. 4,
2013, the disclosure of which is hereby incorporated herein by
reference.
BACKGROUND OF THE INVENTION
[0002] Aspects of the present invention relate, in general, to
waterproof footwear, and specifically to an adjustable waterproof
bootie for use in footwear of different sizes and/or shapes.
[0003] Footwear developed to withstand water or other liquids must
be constructed to keep a user's feet dry upon contact with such
water or other liquids. To that end, it is known to utilize a
waterproof layer of material within certain shoe constructions to
prevent water or another liquid from permeating through the shoe.
For instance, some waterproof shoe constructions involve the use of
a waterproof liner that is positioned under an upper of the shoe.
The liner prevents water from permeating all the way through the
shoe and to the user's foot.
[0004] In such constructions, however, shoes of different sizes
generally utilize an individually-sized liner that is dedicated
exclusively to the specific shoe size. While this type of
construction may be effective, it nonetheless requires a number of
specifically-sized components to produce the waterproof liner, and
the liner is not usable with shoes of different sizes and/or
shapes. Unfortunately, this can increase the time and expense
needed to mass-manufacture the aforementioned waterproof shoes.
Other deficiencies of such shoe constructions not noted here also
exist.
BRIEF SUMMARY OF THE INVENTION
[0005] Aspects of the present invention provide a seamless
waterproof bootie that can be adjusted to fit shoes of different
sizes and/or shapes.
[0006] A first embodiment of the present invention includes a shoe
having an upper with exterior and interior surfaces, a sole having
an exterior surface for contacting the ground and an interior
surface, the sole being secured to the upper, wherein the interior
surface of the upper and the interior surface of the sole define a
cavity for receiving a wearer's foot, an inner lining being
arranged within the cavity, and a seamless bootie formed of
waterproof material in a sock shape, the seamless bootie overlying
the inner lining within the cavity and including one or more ribbed
portions adapted to expand to allow the bootie to conform to the
size of the inner lining, the seamless bootie being configured to
shield a wearer's foot from contact with water or another liquid.
In certain aspects of the first embodiment, the seamless bootie is
made from a waterproof material that is selected from the group
consisting of latex, polyurethane, rubber, or other materials that
can be extruded or molded into a seamless, thin material layer.
[0007] A second embodiment of the invention includes a method of
constructing footwear comprising the steps of: (1) providing an
upper, an inner lining, and a foot-shaped mold having an outer
surface, the foot-shaped mold including at least one ribbed portion
on its outer surface; (2) applying a waterproof material to the
outer surface of the foot-shaped mold, thereby creating a seamless
functional layer with at least one ribbed portion corresponding to
the at least one ribbed portion on the outer surface of the
foot-shaped mold, the seamless functional layer being in the form a
seamless, sock-shaped bootie; (3) placing the seamless functional
layer over the inner lining, such that the at least one rib expands
to conform the seamless bootie to the size of the inner lining; (4)
placing the upper over the seamless functional layer; and (5)
affixing a sole to the upper. Additionally, in other aspects of the
second embodiment, the foot-shaped mold includes multiple ribbed
portions, at least some of the ribbed portions being arranged
transverse to a longitudinal axis of the foot-shaped mold.
[0008] A third embodiment of the invention includes an article for
waterproofing footwear comprising a seamless, sock-shaped bootie
formed of waterproof material having at least one rib extending
transversely from a surface of the bootie, the seamless bootie
being configured for insertion over an inner lining of a shoe, and
being adapted to conform to the size of the inner lining via the at
least one rib. In some instances, at least one rib is placed
vertically along an instep area of the bootie, and at least one rib
is arranged transverse to the vertical rib.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1A is an exploded view of a shoe, according to one
embodiment of the present invention.
[0010] FIG. 1B is a perspective view of a waterproof bootie formed
from the foot-shaped mold of FIGS. 3A-B, while FIG. 1C is a bottom
perspective view of the bootie.
[0011] FIG. 2 is a perspective, partial cutaway view of the shoe of
FIG. 1A in assembled form.
[0012] FIG. 3A is a perspective view of a foot-shaped mold utilized
to form a seamless waterproof bootie, which is incorporated, for
example, within the shoe of FIG. 2.
[0013] FIG. 3B is a bottom perspective view of the foot-shaped mold
of FIG. 3A.
DETAILED DESCRIPTION
[0014] In describing certain features of the present invention,
specific terminology will be used for the sake of clarity. However,
the invention is not intended to be limited to any specific terms
used herein, and it is to be understood that each specific term
includes all technical equivalents, which operate in a similar
manner to accomplish a similar purpose.
[0015] FIG. 1A depicts a shoe 10 having an upper 20, a seamless
sock-shaped bootie 30, an inner lining 50, and a sole 60. FIG. 1B
further depicts the seamless bootie 30, while FIGS. 3A-B depict a
foot-shaped mold 70 used to create the seamless bootie 30.
[0016] As shown in FIG. 1A, shoe upper 20, which comprises an
exterior layer 26 and an interior layer 27, may be constructed of
different fabrics that are sewn together. Upper 20 may include
identifiable holes 22 to allow for shoelaces to be placed therein,
as in traditional shoe constructions. In addition, upper 20 and
sole 60 define an inner cavity 24, which is dimensioned to allow
for insertion of the seamless bootie 30 and the inner lining 50
therein. Thus, seamless bootie 30 and inner lining 50 may be
disposed under upper 20.
[0017] Upper 20 further includes a top perimeter portion 21. In one
embodiment, the seamless bootie 30 and the inner lining are
stitched or otherwise secured to the upper 20 at perimeter portion
21 (e.g., during construction of shoe 10). As such, traditional
hung lining techniques may be used during construction of shoe 10,
thereby connecting upper 20, seamless bootie 30, and inner lining
50 via stitching along perimeter portion 21 of upper 20.
[0018] The seamless bootie 30 is, in one embodiment, made from a
waterproof material(s) that is selected from the group consisting
of latex, polyurethane, rubber, Ethyl Vinyl Acetate, or other
materials that can be extruded into a seamless, thin material layer
(or any combination of the foregoing). As shown, the seamless
bootie 30 includes one or more functional ribs 31-on its surface
that have hollow insides open to an inner cavity 35 of the bootie
30. In a particular construction of seamless booties 30, as
illustrated in FIGS. 1B-C, one or more vertical ribs 31 may be
formed along an instep area of the bootie 30, one or more ribs 32
may be placed transverse in relation to the vertical rib 31, one or
more ribs 34 may be placed horizontally along a toe region 37 of
the bootie 20, the rib(s) 34 spanning the ends of the toe region 37
of the bootie 30, and one or more ribs 33 may extend along a
perimeter of toe region 37. In one example, the rib(s) 33 may
connect or be adjacent to a rib 34. Also, in certain embodiments,
any of ribs 31, 32, 34 may completely or partially encircle bootie
30, such that a section of the applicable ribs 31, 32, 34 extends
along a bottom surface of bootie 30 (e.g., each rib 31, 32, 34 may
form a continuous rib along the bottom surface of bootie 30 or be
spaced apart by a particular distance at the bottom surface of
bootie 30, thereby forming multiple, discontinuous rib segments 31,
32, 34). Continuous ribs are shown in FIG. 1C, while discontinuous
ribs are not shown in the figures, but are nonetheless
contemplated. In other cases, ribs 31, 32, 34 may not be formed on
the bottom surface of bootie 30. While a particular configuration
of ribs 31-34 is described herein, alternate configurations are
contemplated, of course, and one or more ribs 31-34 may be removed
from bootie 30, or alternatively other ribs (not shown) may be
added to improve the functionality of bootie 30. As discussed
herein, ribs 31-34 are configured to enable expansion of the bootie
30 to adjust to different shoe sizes as well as different shoe
shapes.
[0019] Returning to FIG. 1A, an inner lining 50 may comprise
various pieces of fabric that are sewn together to form a
sock-shaped lining 50. As shown, in one embodiment the fabric
pieces of inner lining 50 are stitched together to form a sock
shape, such that a user's foot may be accommodated within lining
50. Alternatively, other inner linings as known in the art may be
utilized with shoe 10. In addition, while not depicted in the
figures, a foot bed may be provided with shoe 10 (e.g., for
placement between outsole 60 and inner lining 50 of shoe 10). In
some cases, the foot bed may be stitched, cemented, or otherwise
adhered to the upper 20 of shoe 10.
[0020] FIGS. 3A-B depict a foot-shaped form or mold 70, which may
be utilized to manufacture seamless bootie 30. Foot-shaped mold 70
includes ribbed portions 71-74 that roughly, or in some cases
exactly, mirror ribs 31-34 of seamless bootie 30. As shown,
foot-shaped mold 70 includes a toe region 75 and a mid-foot region
76 and a longitudinal axis extending from mid-foot region 76 to toe
region 75. As with bootie 30, one or more vertical ribs 71 are
created along mid-foot region 76 of the foot-shaped mold 70, one or
more ribs 72 are placed transverse in relation to the at least one
vertical rib 71, one or more ribs 74 are arranged transverse to the
longitudinal axis of foot-shaped mold 70 along toe region 75, and
one or more ribs 75 are situated along a perimeter of toe region
75. In some case, as shown in FIG. 3B, ribs 71, 72, 74 can extend
along a bottom surface of foot-shaped mold 70, such that a
continuous rib is formed. Alternatively, although not shown, any of
ribs 71, 72, 74 may be spaced apart along the bottom surface of
mold 70 so that a discontinuous rib is formed. These ribbed
portions 71-74 may be imparted onto the bootie 30 according to the
method discussed below.
[0021] To construct seamless bootie 30 from foot-shaped form or
mold 70, as depicted in FIGS. 3A-B, one may first provide a body of
material(s) that is impermeable to water or other liquids, such as
a body of latex, polyurethane, rubber, Ethyl Vinyl Acetate, or
other water proof materials that can be extruded/molded into a
seamless, thin material layer (or a combination of any of the
aforementioned materials). The mold may then be dipped into the
body of latex or other such material(s) using, for example, an
automated process. After coating an outer surface of the
foot-shaped mold 70 with the latex or other material(s), mold 70
may be removed from the vat of material(s), the material(s) may be
allowed to cure, and then the material(s) may be removed from mold
70 to form seamless bootie 30. Bootie 30 then includes ribs 31-34
that substantially or exactly mirror ribs 71-74 formed on
foot-shaped mold 70. In an alternate embodiment, prior to removing
the waterproof material(s) from mold 70, mold 70 may be dipped into
the body of material(s) one or more additional times to further
coat foot-shaped mold's 70 outer surface with the latex or other
material(s). The material(s) may then be allowed to cure, at which
point it can be removed from mold 70 to form a multi-layered
seamless bootie 30. In some instances, during this process
foot-shaped mold 70 may be immersed in the same material(s)
multiple times, or mold 70 may be dipped into a first material(s)
one or more times, and then into a second material(s) one or more
times. Mold 70 may also be dipped into the vat of latex or other
material(s) at an angle sufficient to keep air bubbles from being
trapped between the mold 70 and the cured latex/material(s) so as
to keep the cured latex/material(s) free of air bubbles once
solidified.
[0022] During the curing of the material(s), it is also
contemplated that a stimulus of some form may be used, such as heat
provided by a heat source (not shown), to assist with curing of the
material(s) applied to foot-shaped mold 70. Other stimuli besides
heat, such as a combination of heat and forced air, might also be
used to assist with curing of the waterproof material(s).
Particular releasing agents and/or a coagulant may also be used
with mold 70 to more easily allow the material(s) to be removed
from mold 70 after it cures. A coagulant coating on the mold 70
may, for instance, help the latex or other material(s) to form a
skin on the mold 70 allowing for easier release.
[0023] After construction of seamless bootie 30 according to the
foregoing method, it may be incorporated into shoe 10, as follows.
Inner lining 50 (FIG. 1A) may first be inserted into inner cavity
35 of seamless bootie 30, which is dimensioned to receive lining
50. Thus, seamless bootie may overlie substantially all or a
portion of inner lining 50. Once situated thereon, one or both of
seamless bootie 30 and inner lining 50 may be stitched to upper 20
of shoe 10 at its top perimeter portion 21. Alternatively, the
bootie 30 and/or lining 50 may be cemented or otherwise adhered to
upper 20 (e.g., along perimeter portion 21 or at other sections of
upper 20). For instance, once bootie 30 is placed over inner lining
50, it may be glued, cemented, or otherwise adhered to portions or
all of interior layer 27 of upper 20. If bootie 30 and lining 50
are stitched to upper 20 at its top perimeter portion 21, the
resulting punctures through bootie 30 due to the stitching may
remain unsealed, or alternatively may be sealed using, for example,
a waterproof tape or other such device. Lastly, an inner surface of
outsole 60 may be engaged to the bottom of seamless bootie 30 (as
arranged over inner lining 50) to complete shoe 10.
[0024] During construction of shoe 10, it is advantageous that ribs
31-34 of seamless bootie 30 may act to accommodate, for example,
various differently-sized and/or shaped inner linings 50. For
instance, a particular seamless bootie 30, by virtue of any of ribs
31-34, may be usable with an inner lining that is designed to
accommodate a user's foot of anywhere between U.S. men's or women's
size 8-12. Alternatively (or in addition), such a bootie 30 may
also be usable with footwear having differently-shaped inner
linings 50, such as a general purpose running shoe as compared to a
hiking boot. Bootie 30 may adapt to the aforementioned situations
via expansion of at least a portion of one or more of its ribs
31-34 longitudinally, laterally, or in any alternate direction. In
other words, a particular rib, for example rib 34, may stretch or
expand longitudinally by virtue of its position horizontally across
toe region 37 of bootie 30, while another rib, for example rib 32,
may permit expansion of bootie 30 in its instep area in both a
vertical and longitudinal direction (the vertical direction
extending top-to-bottom in FIGS. 1A-B, and the longitudinal
direction extending left-to-right). Likewise, if the inner lining
50 includes, as an example, an enlarged toe region (which might be
the case in certain hiking boots), rib 33 extending along the
perimeter of toe region 37 of bootie 30 may act to expand and
accommodate such an enlarged toe region of inner lining 50. Ribs 34
may also, in some cases, expand to assist in accommodating an
enlarged toe region of the inner lining 50, if needed.
[0025] Bootie 30 including one or more of ribs 31-34, as described
herein, therefore reduces the capital required to produce various
waterproof shoes 10 (e.g., having different sizes and/or shapes).
For instance, as ribs 31-34 may expand to accommodate different
shoe sizes and/or shapes, a manufacturer need not produce a
specifically-sized mold 70 for use in the method described herein,
and may utilize a single or only a few differently-sized molds 70
for the production of a seamless bootie 30 that is usable with
shoes of varying sizes/shapes. Thus, manufacturing costs are
decreased. In addition, time and labor are also decreased as it is
not necessary to, for instance, change the particular foot-shaped
mold 70 being used in an automated process for manufacturing
seamless booties 30. Indeed, a single or only a few molds 70 may be
utilized in the creation of many seamless booties 30 without having
to constantly substitute one specifically-sized mold 70 for
another.
[0026] A completely-constructed shoe 10, shown in partial cutaway,
is depicted in FIG. 2. As can be appreciated, seamless bootie 30
incorporated between the shoe's upper 20 and its inner lining 50
(shown at the cutaway section) can provide waterproofing
characteristics for a user in undertaking various activities. The
user's foot is therefore adequately protected from contact with
water or other liquids during use. While a general purpose shoe is
shown, seamless bootie 30 may be utilized in any different type of
shoe such as, for example, a hiking boot, a running shoe, etc.
[0027] In the devices depicted in the figures, particular
structures are shown that are adapted for use in a waterproof shoe
10, and/or in methods of constructing the same. The use of
alternative structures for such purposes, including structures
having different lengths, shapes, and configurations is also
contemplated. As an example, ribbed portions may be placed along
different locations of seamless bootie 30, other than those
described above. For instance, one or more ribs may be placed
vertically or horizontally along a heel portion of the bootie 30.
Alternatively, or in addition, ribbed portions may also be placed
longitudinally along the bottom surface of the bootie 30. The
ribbed portions, although rounded and semi-circular in shape, may
also be created in a wave, trapezoidal, triangular, or other shaped
patterns so long as such ribs enable the bootie 30 to adjust to
shoes of different shapes and sizes. Also, any of the ribbed
portions may be formed as a discontinuous rib so that the
particular rib(s) is broken into sections that are individually
spaced apart from one another and, in combination, form a
substantially continuous rib(s). As an example, while rib 33 is
shown as being continuous, it is equally contemplated that rib 33
could be formed into discrete sections so that a discontinuous rib
33 is formed that extends along a perimeter of toe region 37. The
same is true of the other ribs 31, 32, 34 and, by extension, any of
ribs 71-74 of mold 70.
[0028] While shoe 10 is also discussed as incorporating an inner
lining 50, it is contemplated that inner lining 50 may be omitted
and that solely bootie 30 may be situated along inner surface 27 of
upper 20 to shield a user's foot from contact with water. In some
cases, bootie 30 may include one or more layers that act to
substitute for inner lining 50, such as textile layers that are
coated with a layer(s) of waterproof material(s) (e.g., latex or
the other materials mentioned above).
[0029] Although aspects of the invention herein have been described
with reference to particular embodiments, it is to be understood
that these embodiments are merely illustrative of aspects of the
present invention. It is therefore to be understood that numerous
modifications may be made to the illustrative embodiments and that
other arrangements may be devised without departing from the spirit
and scope of the present invention as set forth in the appended
claims.
[0030] It will also be appreciated that the various dependent
claims and the features set forth therein can be combined in
different ways than presented in the initial claims. It will also
be appreciated that the features described in connection with
individual embodiments may be shared with others of the described
embodiments.
* * * * *