Waterproof Garment and Method of Manufacture

Abstract

A waterproof garment, such as a shoe, is formed from a first seamless circular knitted liner, which is coated with resin and cured to form a waterproof layer. The first liner is fitted within a second seamless circular knitted liner. In the case of a shoe, a sole can be attached and a reliably waterproof shoe is thereby provided which can be efficiently manufactured. In another embodiment, the combined liners are used as a waterproof lining for a shoe upper.

Claims

1. A method of constructing a waterproof garment comprising: providing a seamless first liner; coating the first liner with a resin; curing the resin to thereby waterproof the first liner; and covering the resin with a second liner.

2. A method according to claim 1, wherein the first liner, and typically also the second liner, is seamless.

3. A method according to claim 21, wherein the first and second liners are circular knitted liners in the form of closed tubes.

4. A method according to claim 1, which is a method of making a waterproof shoe.

5. A method according to claim 4, further comprising the step of fitting the first and second liners into an upper such that the first and second liners thereby form a waterproof lining for the shoe.

6. A method according to claim 4, wherein the first and second liners together form an upper for the shoe.

7. A method according to claim 4, wherein the outermost of the first and second liners forms at least 50% of the outside upper surface of the shoe, and typically wherein the innermost of the first and second liners defines the foot-receiving interior of the shoe.

8. A method according to claim 4, wherein the that the first liner is coated with resin, which is then cured, thereby waterproofing the first liner at least where it extends around a wearer's foot in use.

9. A method according to claim 4, further comprising testing the coated first liner after the resin has cured to determine the waterproofness of the first liner.

10. A method according to claim 4, wherein the first and second liners are formed from water permeable textiles.

11. A method of constructing a waterproof shoe according to claim 4, wherein the first and second liners are shaped to enclose a wearer's foot, the method further comprising fitting a sole, and optionally an upper, to the first and second liners, to thereby form the waterproof shoe.

12. A waterproof garment comprising a first liner and a second liner, with the first liner fitted within the second liner or vice versa, the first liner being seamless and having a waterproof layer formed on the surface of the first liner facing the second liner, wherein the waterproof layer is a cured resin layer.

13. A waterproof garment according to claim 12, wherein the first and second liners are seamless.

14. A waterproof garment according to claim 12, wherein the first and second liners are circular knitted liners in the form of closed tubes.

15. A waterproof garment according to claim 12, wherein the first and second liners are formed of a water permeable textile.

16. A waterproof garment according to claim 12, wherein the first liner is coated with the resin, and thereby rendered waterproof, across at least 90% of its surface area.

17. A waterproof garment according to claim 12, wherein the first liner has the cured resin layer thereon, forming a waterproof layer for the first liner, at least where it extends around a wearer's foot in use, up to at least the ankle.

18. A waterproof garment according to claim 12, wherein the first and second liners are attached to each other.

19. A waterproof shoe according to claim 12, wherein the shoe further comprises an upper, with the first and second liners therein forming a waterproof lining for the shoe.

20. A waterproof shoe according to claim 18, wherein the first and second liners together form an upper for the shoe.

21. A waterproof shoe according to claim 12, wherein the outermost of the first and second liners forms at least 50% of the outside upper surface of the shoe, and typically wherein the innermost of the first and second liners defines the foot-receiving interior of the shoe.

22. A waterproof shoe according to claim 12, the waterproof shoe further comprising a sole and optionally eyelets for laces.

23. A waterproof shoe according to claim 12, wherein the waterproof shoe is waterproofed at least up to the base of a wearer's ankle.

24. A method of constructing a waterproof shoe comprising: forming a first liner in the form of a bootie by stitching together at least two pieces of material, coating the first liner with a resin by one or more of painting the resin on the first liner, or brushing the resin on the first liner; curing the resin to thereby waterproof the first liner; covering the resin with a second liner in the form of a bootie; and attaching a sole and optionally an upper.

25. A waterproof shoe comprising a first liner and a second liner, with the first liner fitted within the second liner or vice versa, the first liner comprising at least two pieces of fabric sewn together and having a waterproof layer formed on the surface of the first liner facing the second liner, wherein the waterproof layer is a cured resin layer, with the second liner being a seamless circular knitted liner.

Description

DESCRIPTION OF THE DRAWINGS

[0156] An example embodiment of the present invention will now be illustrated with reference to the following Figures in which:

[0157] FIG. 1 is a schematic of combined liners in the shape of a bootie for a shoe;

[0158] FIG. 2 is a flowchart for a method of constructing a waterproof garment;

[0159] FIG. 3 is a schematic of a first liner for a shoe;

[0160] FIG. 4 is a schematic of the first liner of FIG. 3 coated with a resin and a layer of cured resin on the first liner;

[0161] FIG. 5 is a schematic of the first liner with a layer of cured resin of FIG. 4 being tested for defects;

[0162] FIG. 6 is a schematic of combined liners in the shape of a bootie for a shoe according to a second example; and

[0163] FIG. 7 is a schematic of a shoe with an upper and a sole.

DETAILED DESCRIPTION OF AN EXAMPLE EMBODIMENT

[0164] We will now describe a first example of a waterproof garment, specifically a shoe, and a method of making the garment with reference to FIGS. 1 to 5.

[0165] FIG. 1 shows a schematic of a cross-section view of combined liners (10) for a shoe (1A), a schematic of the combined liners (10) (1B), and an exploded cross-section view of the combined liners (10) (1C). The combined liners (10) comprises an inside liner (12), an outside liner (14) and a layer of cured resin (16) between the inside (12) and outside (14) liners. The dotted lines of FIG. 1B depict that the insider liner (12) and the layer of cured resin (16) are inside the outside liner (14). The inside liner (12) is made of a material which itself is water permeable and so not waterproof. However, the layer of cured resin (16) is water proof and this prevents liquid water from passing into the internal cavity of the combined liners (10), i.e. where a wearer's foot would be located when the shoe is worn, through the inside liner (12). That is, the layer of cured resin (16) causes the inside liner (12) to be waterproof. The combined liners (10) further comprise an opening (18) so that the combined liners (10) can be fitted onto a wearer's foot.

[0166] In this example, the inside liner (12) and outside liner (14) are each circular knitted liners. That is, the majority of the liner is composed of one continuous body of textile which is seamless, rather than made by stitching together a plurality of pieces of material. In contrast to methods of forming shoes by stitching laminates known in the art, the combined liners (10) therefore comprises a liner which is not formed from several pieces of material stitched together and does not require waterproof tape to cover the seams formed from the stitches in order to be waterproof.

[0167] The layer of cured resin is applied to the circular knitted liner (as will be described in further detail below). If both liners are a circular knitted liner, then the layer of cured resin may be on either liner (on the outer surface of the inner liner or the inner surface of the outer liner). The combined liners (10) therefore have the layer of cured resin between the two liners (usually extending into the surface of one of the liners) such that it is protected from abrasion or debris, for example from the wearer's foot or gravel which might otherwise accumulate on the outer surface of the lining, underneath any upper which may be present.

[0168] FIG. 1 also shows an exploded cross-section (1C) showing the distinct layers which make up the combined liners (10). In particular, the inside liner (12) comprises an inner surface (i.e. the surface facing towards the internal cavity of the combined liners (10)) and an outer surface. The outer surface of the inside liner (12) is in contact with the layer of cured resin (16). The outside liner (14) also comprises an inner surface and an outer surface, wherein the inner surface of the outside liner (14) is in contact with the layer of cured resin (16).

[0169] FIG. 2 shows a flowchart for constructing a waterproof garment, in this case a shoe. In step (100), a first liner is provided. In this example embodiment, the first liner is a circular knitted liner. Typically, this first liner is not waterproof. An example is shown in FIG. 3, wherein the first liner (30) is a liner for a shoe, such as the inside liner (12) of FIG. 1. Similar to the inside liner (12) of FIG. 1, the first liner (30) comprises an inner surface (32), an outer surface (34) and an opening (36).

[0170] The first liner of step (100) is then coated with a resin in step (102). The resin may, for example, be a thermosetting resin or a photo-sensitive resin. The coating process may be one of several different methods, including brushing, painting, spraying or dipping. That is, the resin is a viscous substance which can coat a surface of the first liner.

[0171] Optionally, excess resin may be removed from the first liner in step (104) while the resin remains viscous (i.e. before the resin is cured or has hardened). For example, the excess resin may be removed by brushing the excess off the liner; absorbing the excess; vibrating, shaking or spinning the liner; or by blowing air over the liner. This may result in a more uniform coating of resin on the first liner. This may also result in a thinner layer of resin.

[0172] Step (102), and optionally step (104), is followed by step (106) wherein the resin is cured. The curing process hardens the viscous resin to form a hardened layer. An example of steps (102) and (106) are depicted in FIG. 4, wherein the outer surface (34) of the first liner (30) of FIG. 3 is coated with a resin (40) and the resin is cured to form a layer of cured resin (42). That is, curing the resin causes the resin to become hardened. The layer of cured resin (42) thereby makes the first liner (30) waterproof.

[0173] The curing process depends on the resin used to coat the liner. For example, if the resin is a thermosetting resin then the curing process is a heat treatment, e.g. the liner is placed inside an oven. The oven may be preheated to a predetermined temperature and the liner is placed inside the oven for a predetermined length of time. Alternatively, the heat treatment may be use of a heat gun to cure the resin at local points on the liner, that is the curing process is localised.

[0174] If the resin is alternatively a photo-sensitive resin, the curing process is by subjecting the first liner to light. For example, the light may be UV light, e.g. from a UV light source. It may be that the whole liner is subjected to light at the same time, e.g. by placing the liner into a light box, or the curing process is localised.

[0175] The resin may be cured globally (i.e. the whole liner is subjected to the necessary curing treatment—e.g. the whole liner is placed inside an oven), or cured locally (i.e. sections of the liner is subjected to the necessary curing treatment—e.g. by use of a heat gun to cure a section of the coated liner).

[0176] Regardless of the resin used, the curing process causes the resin to cure (i.e. harden) to form a layer of cured resin (42). This layer of cured resin (42) covers the outer surface (34) of the first liner (30). The layer of cured resin (42) could alternatively cover particular portion(s) of the first liner (30). For example, a portion (e.g. a sleeve portion) around the opening (36) of the first liner (30) may be left uncoated by the resin (not shown).

[0177] Although the first liner (30) is depicted as being an inside liner in FIGS. 3-4, the present invention also recognises that the first liner (30) may be an outside liner in the finished product by turning the liners inside out.

[0178] After step (106), in some embodiments there is an additional step of coating the first liner for a second time with resin in step (108). The resin used for the second coating may be the same resin as that used for the first coating (step 102), or may be a different resin. For example, the resin used for the first coating may be a thermosetting resin whereas the resin used for the second coating is a photo-sensitive resin. The thickness of the second coating may be different from the first coating. The method would then proceed to step (110) in which the second coating is cured according to the type of resin used to form a second layer of cured resin. It may be that the whole liner is subjected to the curing process, or it may be that the curing process is localised. Optionally, the steps of (108) and (110) may be performed any number of times.

[0179] If a second or any number of additional coatings of resin is not applied, or after the second or any number of additional coatings of resin is cured (step 110), the method proceeds to step (112) in which the waterproofness of the first liner is tested. An example of testing the first liner is shown in FIG. 5. The testing process includes filling the first liner (30) with air, typically to a pressure of around 1 psi, and submerging (or dunking) the first liner (30) into a tank (50) of water (52) to inspect for any air bubbles (54) escaping from the first liner (30). If air escapes the first liner (30), then it is determined that there are defects (56) in the layer of cured resin. The first liner (30) is repaired (i.e. the defects are corrected) by applying a localised coating of resin over the defects (56) in step (114). The resin may be applied by any method described in relation to step (102).

[0180] The resin covering the defects in the first liner are then cured in step (116); cured by means in accordance with the resin used, e.g. a heat treatment for a thermosetting resin. It may be that particular resins are preferred for such localised coatings, e.g. a polyurethane glue. The liner is then retested to ensure that the faults have been correctly coated and that the liner is waterproof. The steps of (112)-(116) may be iterative until the liner has been determined to be waterproof. It may be that steps (112)-(116) are performed a maximum number of times—that is there may be a maximum number of times a liner is recoated and tested before it is determined to be un-repairable.

[0181] Once the liner has been determined to be waterproof, a second liner is pulled over the first liner (step 118). The second liner is also a circular knitted liner. The two liners are adhered together, e.g. by an adhesive or by stitches. For use of an adhesive, the adhesive is applied to the layer of cured resin and the inner surface of the second liner. The cured layer of resin could in principle be used to adhere the liners although it would be at risk of being damaged by the process of pulling the second liner over the first liner.

[0182] Thus, the first liner is an inner liner and the second liner is an outer liner, and the layer of cured resin is protected between the inner and outer liner. In some embodiments, the first and second liners are turned inside out together, so that the second liner is on the inside of the first liner, after the second liner has been fitted around the first liner having a layer of cured resin. The first and second liners still protect the layer of cured resin therebetween which provides a waterproof shoe.

[0183] Where the first liner is for a shoe, the construction of the waterproof shoe is completed by fitting the adhered liners with a shoe sole (step 120), FIG. 7 shows a completed shoe. It may be that the first and second liners function as a waterproof internal lining and the waterproof shoe is completed by fitting an upper in step (120). It may be that the first and second liners function as the upper of the finished shoe, in which case no upper is fitted in step (120). It may be that fitting the shoe sole includes fitting an in-sole into and an outsole onto the shoe. The outsole is fitted directly to the knitted base of the adhered liners (the base of the second liner, unless the first and second liners have been turned inside out in which case the outsole can be fitted directly to the knitted base of the first liner). The in-sole is fitted into the adhered liners, i.e. into the first liner (or second if the first and second liners have been turned inside out).

[0184] The upper and shoe sole are to be fitted according to practices known in the art. It is advantageous to have the waterproof cured layer sandwiched between the first and second liners where there is also an upper as, in known shoes (e.g. hiking shoes) with a waterproof bootie having an outer surface which is waterproof, and an upper, grit can penetrate the upper and cause damage to the waterproof bootie. In the present case, the outer liner will provide further protection for the waterproof cured layer.

[0185] The aesthetics of the shoe may then be altered, e.g. by applying additional fabrics to the outside of the shoe (not shown). The shoe may also be fitted with a topline. The topline may be formed using a part of the adhered liners. It may be that the part of the adhered liners used to form a topline was not coated with the resin during step (106). It may, alternatively or in addition, be that the second liner comprises a collar from which the topline is formed.

[0186] An example of the third and fourth aspects of the invention is now described with reference to FIG. 6. FIG. 6 shows combined liners (60) similar to the combined liners (10) of FIG. 1. However, the combined liners (60) of the third and fourth aspects comprises a first liner (62) which is made from at least two pieces of fabric sewn together. It may be that the fabric is not waterproof in itself. The first liner (62) has been formed by pieces of the fabric being stitched together (64). The stitches are depicted as dotted lines, and may run along the bottom and back of the first liner (62).

[0187] The combined liners (60) also comprise a second liner (66), which is a circular knitted liner, and a layer of cured resin (68) between the first (62) and second liners (66). Whereas the combined liners (10) of FIG. 1 was coated by a resin by means of brushing, painting, dipping or spraying the resin, the combined liners (60) of FIG. 6 was coated by a resin by means of either brushing or painting the resin onto the first liner (62). The resin and the curing process may be the same as those described in relation to the combined liners (10) of FIG. 1 above. The remainder of the process and other features of the shoe correspond to those described above in relation to the first example.

[0188] FIG. 7 shows a completed shoe (70) comprising an upper (72). The upper (72) may be the combined liners (10) of FIG. 1 or the combined liners (60) of FIG. 6. The upper (72) comprises an inner surface (74) for receiving a wearer's foot and an outer surface (76). The inner surface (74) is the first liner as described above in relation to FIGS. 1 and 6. The outer surface (76) may be the second liner as described above in relation to FIGS. 1 and 6. Alternatively, the outer surface (76) may be a material covering the second liner (for example a knitted, leather or textile upper). The shoe further comprises a sole (78) fitted to the bottom of the upper (72). A topline is formed around the opening of the upper (72). The topline is shown as being a stitching, although any other form of topline known in the art is also envisaged.

[0189] The example embodiment is described in terms of the waterproof garment being a shoe. It will be appreciated by the person of ordinary skill that this is exemplary and that construction of other waterproof garments is possible by the described invention.