WATERPROOF FOOTWEAR GASKET AND RELATED METHOD OF MANUFACTURE

Abstract

A footwear construction is provided including a waterproof gasket formed between components of the footwear. The footwear can include an upper including a first layer and a waterproof functional second layer adjacent the first layer. A waterproof functional insole includes a perimeter that is disposed adjacent the first layer and/or the second layer. A thread extends through the first layer, sewn through it, and is located between the insole and the second layer, and adjacent the perimeter. The thread is melted to form a waterproof gasket between the second layer and the insole, along the perimeter. Alternatively, the first layer is surrounded with a hot melt flange stitched to an insole. A waterproof functional second layer seals the first layer and flange. A gasket panel can be disposed over the hot melt flange and insole, which can include insole stitching joining the same. Related methods also are provided.

Claims

1. An article of footwear comprising: an upper including a first layer having an interior surface and an exterior surface, with a first layer disposed between the interior surface and the exterior surface, the first layer having a first edge; a waterproof functional second layer adjacent at least one of the interior surface and the exterior surface of the first layer, the second layer having a second edge; a waterproof functional insole having a perimeter, approximating an outline of a human foot, the perimeter terminating at a third edge, the third edge adjacent at least one of the second edge and the first edge; and a polymeric thread extending over the interior surface, through the first layer body and the exterior surface, the polymeric thread engaging the second layer and the perimeter, wherein the polymeric thread is in a melted form and fused to the second layer and the perimeter to form a waterproof gasket between the second layer and the waterproof functional insole.

2. The article of footwear of claim 1, comprising: a structural stitch extending through the first layer, the second layer and the insole.

3. The article of footwear of claim 2, wherein the polymeric thread forms the waterproof gasket along at least one of the first edge, the second edge and the third edge, wherein the structural stitch extends transversely through the gasket.

4. The article of footwear of claim 3, wherein the gasket is disposed adjacent the first edge and the second edge, wherein the gasket has a width, wherein the width is less than 20 mm.

5. The article of footwear of claim 1, wherein the insole is in the form of a waterproof Strobel board, wherein the Strobel board includes the third edge, wherein the third edge is abutted against the first edge to form a butt seam, and wherein the polymeric thread is in melted form and fused to the third edge and to the first edge.

6. The article of footwear of claim 1, wherein the first layer and the second layer form a laminate, wherein the first layer is a textile layer including a plurality of textile strands with interstitial spaces therebetween, wherein the polymeric thread extends adjacent the textile strands and through the interstitial spaces, and wherein the polymeric thread is melted to entrap the textile strands and to at least partially fill the interstitial spaces.

7. The article of footwear of claim 6, wherein the first layer and the second layer are bent outward from a longitudinal axis, wherein the first edge and the second edge are aligned one above the other.

8. The article of footwear of claim 1, comprising: a liner joined with an interior surface of the waterproof functional second layer and facing inward to form a footwear void, wherein the structural stitch penetrates the liner.

9. The article of footwear of claim 1, wherein the waterproof functional insole includes an insole interior surface and a waterproof functional fourth layer adjacent the insole interior surface, wherein the polymeric thread is melted and fused to the waterproof functional second layer and to the waterproof functional fourth layer.

10. The article of footwear of claim 9, wherein the polymeric thread is melted to form a continuous gasket between the insole and the waterproof functional second layer around the perimeter, wherein the polymeric thread is melted inside the first layer between the interior surface and the exterior surface of the first layer, and encapsulates strands inside the first layer.

11. An article of footwear comprising: an upper including a first layer and a waterproof functional second layer adjacent the first layer, a waterproof functional insole having a perimeter, the perimeter being positioned adjacent at least one of the first layer and the second layer, a thread extending between the waterproof functional insole and the waterproof functional second layer, and wherein the thread is in melted form to provide waterproof gasket between the waterproof functional second layer and the waterproof functional insole.

12. The article of footwear of claim 11, comprising: a structural stitch extending through the waterproof functional second layer and the waterproof functional insole, wherein the structural stitch extends transversely through the gasket, wherein a first segment of the structural stitch is parallel to a first segment of the thread extending through the first layer, wherein a second segment of the structural stitch is parallel to a second segment of the thread extending along the first layer, wherein the first and second segment of the structural stitch are transverse to one another, and wherein the first and second segment of the thread are transverse to one another.

13. The article of footwear of claim 11, wherein the waterproof functional insole has a longitudinal axis and an insole width perpendicular to the longitudinal axis, wherein the gasket has a gasket width, and wherein a ratio of the gasket width to the insole width is less than 1:4.

14. The article of footwear of claim 11, comprising: an outsole disposed below the first layer and the waterproof functional insole, wherein the thread is not fused to the outsole.

15. The article of footwear of claim 14, wherein the structural stitch is a zig zag stitch passing back and forth between a first edge of the first layer and a perimeter of the waterproof functional insole.

16. The article of footwear of claim 15, wherein the insole is in the form of a Strobel board including a third edge adjacent the perimeter, wherein the third edge is abutted against the first edge to form a butt seam, and wherein the thread is melted and fused to the third edge and to the first edge.

17. The article of foot wear of claim 11, wherein the first layer is a textile layer including a plurality of textile strands with interstitial spaces therebetween, wherein the thread extends adjacent the textile strands and through the interstitial spaces, and wherein the thread is melted to entrap the textile strands and to at least partially fill the interstitial spaces.

18. A method of making an article of footwear, the method comprising: providing an upper having a U-shaped outer perimeter, the upper including a first layer and a waterproof functional second layer adjacent the first layer; sewing a thread repeatedly through the first layer around the outer perimeter; positioning a waterproof functional insole having an insole perimeter adjacent at least one of the first layer and the second layer; and melting the thread to form a waterproof gasket between the waterproof functional second layer and the waterproof functional insole with the melted thread.

19. The method of claim 18 comprising: sewing a structural stitch through the first layer, the waterproof functional second layer and the waterproof functional insole, wherein the structural stitch extends transversely through the gasket, wherein a first segment of the structural stitch is parallel to a first segment of the thread extending through the first layer, wherein a second segment of the structural stitch is parallel to a second segment of the thread extending along the first layer, wherein the first and second segment of the structural stitch are transverse to one another, and wherein the first and second segment of the thread are transverse to one another.

20. The method of claim 19 comprising: heating the thread to at least 150 degrees Fahrenheit so that the thread melts and encapsulates adjacent strands in the first layer, and adheres to a surface of the waterproof functional second layer.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0026] FIG. 1 is a perspective view of an upper for footwear with a waterproof gasket thread applied in a current embodiment;

[0027] FIG. 2 is an exploded view of the upper with a gasket formed in a Strobel construction for joining with a sole assembly;

[0028] FIG. 3 is a close up view, taken at III from FIG. 1, showing the upper with the gasket thread applied to a first layer and a second layer of a laminate separated partially from the first layer;

[0029] FIG. 4 is a close up view of the gasket thread applied to the upper before melting, taken along lines IV-IV in FIG. 1;

[0030] FIG. 5 is a section view of the gasket applied between an upper and a waterproof functional insole, with an outsole included, in footwear;

[0031] FIG. 6 is a close up section view of the gasket thread melted and fused to a waterproof functional layer of the upper and the insole;

[0032] FIG. 7 is a section view of the melted and fused gasket thread filling interstitial spaces between strands in a layer;

[0033] FIG. 8 is a close up section view of the gasket thread melted and fused between an insole and a waterproof functional layer of the upper of a first alternative embodiment;

[0034] FIG. 9 is a close up section view of the gasket thread melted and fused between an insole and a waterproof functional layer of the upper of a second alternative embodiment;

[0035] FIG. 10 is a perspective view of an upper for footwear with a hot melt flange of a third alternative embodiment;

[0036] FIG. 11 is a close up view, taken at XI from FIG. 10, showing the upper with the hot melt flange stitched to a first layer and a second layer of a laminate being applied over the hot melt flange, the stitching and the first layer to form a waterproof barrier over the stitching;

[0037] FIG. 12 is a close up view of the laminate with the waterproof barrier taken along lines XII-XII in FIG. 10; and

[0038] FIG. 13 is a section view of the upper joined with an insole with insole stitching and a gasket panel forming a waterproof barrier over the insole, insole stitching and hot melt flange.

DESCRIPTION OF THE CURRENT EMBODIMENTS

[0039] A current embodiment of the footwear is illustrated in FIGS. 1-9, and generally designated 10. This footwear 10 generally includes an upper 20 joined with a sole assembly 30 having a thread 40 that forms a waterproof gasket 50 between various panels and components of the footwear to form a waterproof enclosure inside the footwear. The footwear 10 includes a foot void 20V, defined by the upper 20, and a sole assembly 30, configured to securely and comfortably hold a human foot. The foot is received through a foot opening 200 defined by the upper 20.

[0040] Although the current embodiments are illustrated in the context of a hiking boot or water resistant shoe, they may be incorporated into any type or style of footwear, including performance shoes, hiking shoes, trail shoes and boots, work boots, all-terrain shoes, barefoot running shoes, athletic shoes, running shoes, sneakers, conventional tennis shoes, walking shoes, multisport footwear, casual shoes, dress shoes or any other type of footwear or footwear components. It also should be noted that directional terms, such as “vertical,” “horizontal,” “top,” “bottom,” “upper,” “lower,” “inner,” “inwardly,” “outer” and “outwardly,” are used to assist in describing the invention based on the orientation of the embodiments shown in the illustrations.

[0041] Further, the terms “medial,” “lateral” and “longitudinal” are used in the manner commonly used in connection with footwear. For example, when used in referring to a side of the shoe, the term “medial” refers to the inward side (that is, the side facing the other shoe) and “lateral” refers to the outward side. When used in referring to a direction, the term “longitudinal direction” refers to a direction generally extending along the length of the shoe between toe and heel, and the term “lateral direction” refers to a direction generally extending across the width of the shoe between the medial and lateral sides of the shoe. The use of directional terms should not be interpreted to limit the invention to any specific orientation. Further, as used herein, the term “arch region” (or arch or midfoot) refers generally to the portion of the footwear or sole assembly corresponding to the arch or midfoot of the wearer's foot; the term “forefoot region” (or forefoot) refers generally to the portion of the footwear forward of the arch region corresponding to the forefoot (for example, including the ball and the toes) of a wearer's foot; and the term “heel region” (or heel) refers generally to that portion of the footwear rearward of the arch region corresponding to the heel of the wearer's foot.

[0042] FIGS. 1 and 4 show an exemplary layout for an upper 20 of the current embodiment of footwear 10, which can be in the form of a light hiking boot or shoe. The upper 20 can include an exterior surface 20E and an opposing interior surface, which generally faces inward, toward the users' foot and an internal foot void 20V. The upper can also include a lateral side 20L and a medial side 20M disposed on opposite sides of a longitudinal axis LA of the upper and footwear in general. Although the construction of the upper 20 may vary, the upper 20 of the illustrated embodiment generally includes a vamp 20V (or toe box) that transitions to and can be integral with one or more quarters or panels, including a lateral panel 20P along the lateral side 20L, a medial panel 20N along the medial side 20M, and heel panels 20H that can be joined along a seam in the heel. The vamp 20V generally forms the forefoot portion of the upper 20 and the panels form the arch and heel portions of the upper 20. The various pieces of the upper 20 may be manufactured from any combination of pieces of a wide range of materials, such as leather, synthetic leather, mesh, canvas, textile (e.g. woven, knit, bonded), fabric and molded components.

[0043] In the embodiment illustrated herein, the vamp, lateral panel, medial panel, and heel panels are contiguous and form a unitary upper 20. This upper can include a first layer 21 that can include an interior surface 21I and an exterior surface 21E. The first layer optionally can be a unitary textile. Such a textile can be woven, knit, mesh, nonwoven, felt constructions, etc. Textiles can be produced from natural fibers such as cotton, or from synthetic fibers such as polyesters, polyamides, polypropylenes, polyolefins and/or blends thereof. As shown, the first layer can be knit from multiple individual strands that form interconnect loops that extend between or from the exterior to the interior in a predetermined manner. Between the individual strands and their loops, interstitial spaces or voids are formed in the first layer. The first layer can be formed by a knitting process, such as circular knitting, flat knitting, raschel knitting or any other knitting processes and the fusible monofilament strand can extend throughout the entire first layer. The textile upper layer 21 can be formed of unitary knit construction, for example, when formed as a one-piece element through a knitting process. That is, the knitting process substantially forms the, various shapes and structures of the textile upper and the layer without the need for significant additional manufacturing steps or processes. Although portions and edges of the upper and the first layer can be joined to each other (e.g., a seam joining the heel panels 20H) following the knitting process, the textile layer of the upper remains formed of unitary knit construction because it can be formed as a one-piece knit element.

[0044] The textile first layer 21 can be formed as a knit element produced via a mechanical knitting process performed on an automated knitting machine. Optionally, the knitting machine can be a circular knitting machine, such a.s a sock or tube knitting machine. Alternatively, the knitting machine can be a flat knitting machine or a jacquard raschel knitting machine. The knitting process can produce the knitted tube, and can incorporate a variety of different knit patterns in the knitted tube and/or the textile upper layer 21. With regard to knit patterns, the strands forming the textile upper layer 21 can have one type of knit pattern in one area and another type of knit pattern in another area. Depending upon the types and combinations of knit patterns utilized, areas of the textile upper layer 21 can have a plain knit structure, a mesh knit structure, a rib knit structure, and various combinations thereof, for example. Different types of knit patterns can be incorporated into specific locations of the textile upper layer 21 to modify the physical properties or aesthetics of the upper 20 in general, such as elasticity, air permeability, stiffness and abrasion-resistance.

[0045] In other embodiments, the upper 20 can be a multi-panel upper with the first layer formed as a vamp, lateral panel, medial panel, and heel panels sewn or otherwise joined together. The upper 20 can further include various trim, cushioning and reinforcing elements (not shown), such as, but not limited to, a toe bumper provided to reinforce the vamp, a pull tab provided to help pull the footwear 10 onto the wearer's foot, and/or a heel counter can be fitted into the heel region to reinforce the heel panels and seam, and to increase support.

[0046] Referring to FIG. 4, the footwear 10 can include a sole assembly 30 can include one or more different components, such as a base 31 defining a foot-shaped perimeter 32. The sole assembly 30 can further include an outsole 33 configured to include a ground contacting surface which itself may include multiple treads, lugs, spikes, cleats and/or other features designed to enhance traction between the footwear 10 and the underlying surface. Generally, regardless of which components are present, the sole assembly 30 can form the bottom-most portion of the footwear 10.

[0047] The upper 10 can be constructed in a laminate form, and can include the first layer 21 as mentioned above, and a second layer 22. This second layer can include an interior surface 22I and an exterior surface 22E as shown in FIG. 3. There, the interior surface can be joined with the exterior surface 21E of the first layer. The edges 21R and 22R of the respective layers also can be coterminous and aligned with one another when the first layer and second layer are joined. These layers can be joined with a cement or an adhesive, or can be joined via a coating, carrier and/or special material disposed on the interior 22I or otherwise included in the second layer. As described below, the second layer also can cover and at least partially conceal the segment of the gasket 50 thread that is disposed on or adjacent or over the exterior surface 21E of the first layer. The thread itself can be melted, fused, bonded or otherwise joined with the second layer, in particular the interior 22I.

[0048] Waterproof functional layers or a waterproof functional insole described herein optionally can be and/or include a water vapor permeable functional layer comprising a polymeric membrane material. This membrane can be water vapor permeable or breathable. As used herein, water vapor permeable and breathable can be used interchangeably and mean that the functional layer has a water vapor coefficient RET of less than 200 m.sup.2Pa/W. Breathable polymeric membranes can be breathable via pores in the membrane or through a solution diffusion mechanism. Some examples of breathable polymeric membranes optionally can be polyurethane, polyester, polyether, polyamide, polyacrylate, copolyether ester and/or copolyether amides.

[0049] The footwear also can include an insole 40. The insole can be a waterproof functional insole. The insole 40 generally can be in the shape of the bottom of a human foot, and can extend from a forefoot region, through an arch region and to a heel region. Of course, the insole can be shorter than the full length of the footwear, and can instead extend only in one or two of these regions in some applications. The insole 40 can include a longitudinal axis LA and an insole width 1W taken perpendicular to the longitudinal axis. The insole optionally can be a knitted, woven or nonwoven material, or EVA or other polymer foam material. Optionally, the insole can be constructed from polyester, nylon, polyacrylic, polyolefin, polyurethane, polyvinyl, cotton, acetate, rayon, olefin, acrylic and/or wool. Further optionally, a waterproof film can be included as part of the insole. This film can be a polyvinyl chloride, rubber, neoprene and/or any other stretchable, flexible film.

[0050] Further optionally, as illustrated, the insole 40 can be in the form of a waterproof functional Strobel board, incorporated into a Strobel construction with the upper as described below. The insole 40 can include a perimeter 44 that is positioned adjacent and/or directly engaging the edge of the upper 20, or more particularly the first layer 21 and the second layer 22 where included. The perimeter 44 can terminate at a third edge 43. This third edge 43 can be configured to engage and/or can be abutted against the first edge 21R of the first layer and/or the second edge 22R of the second layer in the Strobel construction as described below.

[0051] As mentioned above and shown in FIGS. 1-5, the footwear can include a waterproof gasket 50. This gasket can be formed via one or more threads of polymeric material threaded through one or more of the layers or components described herein. The thread can be a polymeric thread, constructed from or including a polymer or other material that can melt. Optionally, the thread can be constructed from thermoplastic polyurethane, polyester, polyether, polyvinyl or other polymers. The thread can be heated, fused and/or melted to form a waterproof gasket between one layer and another, between a layer and the insole, and/or between one component and another. As shown in FIGS. 1, 3 and 4, the gasket is shown in a form of a thread 55, before it is heated, melted and/or fused to anything. This thread can be a continuous, elongated thread, optionally of a monofilament structure or a twisted structure, that is sewn repeatedly through the first layer, from one side to the other, through the body of the first layer. For example, as shown in FIGS. 3 and 4, the thread 55 can include multiple first segments 51 that can extend through the body 21B of the first layer 21, generally extending from the interior surface 21I to the exterior surface 21E of the first layer. The first segments of the thread can extend through the interstitial spaces among individual strands in the first layer body when the first layer is in a textile form, and in some cases, also can penetrate and/or intersect those individual strands in the first layer. The first segments also can extend parallel to the strands in the first layer body 21B that extend from the interior to the exterior of the first layer.

[0052] The thread 55 can include multiple second segments 52 that extend along and/or across a portion of the exterior surface 21E of the first layer. Multiple ones of these second segments can crisscross one another in a transverse manner on or over the interior of the layer. The thread can also include multiple third segments 53 that extend along and/or across a portion of the interior surface 21I of the first layer. Multiple ones of these third segments can crisscross one another in a transverse manner on or over the exterior of the layer. The second and third segments can lay against and/or directly engage the interior and exterior surfaces. The second and third segments also can be transverse, optionally perpendicular or angled relative to the first segments, depending on the orientation of the sewing machine and the thread as it is sewn to the upper first layer 21.

[0053] The thread 55, and the resulting gasket 50, can be disposed adjacent the first edge 21R and the second edge 22R. In this position, the thread can be inset a preselected distance D1 from the edge 21R of the first layer through which it is sewn. This distance can be optionally less than 10 mm, less than 5 mm, less than 2 mm, less than 1 mm, between 0.1 mm and 10 mm inclusive, between 0.1 mm and 5 mm inclusive, or between 0.1 and 2 mm inclusive. The distance can be selected so that the thread passes through the body of the layer, and optionally not over the edge 21R. Of course, in some cases, the thread and the first segment can be placed adjacent and contact that edge.

[0054] As shown in FIG. 4, with the thread 55 on the interior 21I of the first layer, it optionally can contact the exterior 22E of the second layer. This exterior 22E can thus contact and/or engage both the threads 55 and the remaining portion of the interior surface 21I of the first layer. When the thread 55 melts, it thus can bond to, join with and/or adhere to the exterior 21E of the second layer to form a waterproof gasket or barrier therewith. This can be the case in locations where the thread melts and fuses or bonds to other components.

[0055] Optionally, the upper 20 can include a liner 23 as shown in FIG. 6. This liner can be disposed on or joined with an interior surface 22I of the second layer. The liner can be a textile or fabric, and can be configured to engage a wearer's foot or sock when placed in the internal void 20V of the footwear 10. The liner also can be coterminous with the second and third layers, and can include a similar edge aligned with the edges of those layers.

[0056] As mentioned above, the waterproof gasket 50 can be implemented in a Strobel construction, which is illustrated in FIGS. 5-6. There, the gasket 50 already has been formed after the thread is heated, is melted and fuses or bonds with edges and components. In particular, the upper 20 is bent and folded so that the edges 21R and 22R are placed adjacent and abutting the third edge 43 of the insole 40 formed around the perimeter 44 of the insole, which again can be a waterproof functional insole in the form of a Strobel board. In this construction, to join the insole 40 and the upper 20, a structural stitch 60 can be sewn through the perimeter around the edge of the insole board. This structural stitch 60 also can be sewn through the upper 20, and in particular, the first layer 21, second layer 22 and lining 23 if included. The stitch 60 can be in a zig-zag pattern, and can penetrate the insole completely, from the exterior to the interior. The stitch 60 also can penetrate the first and second layers of the upper completely, from the respective interiors to the exteriors of each layer. Optionally, the structural stitch can be a zig-zag stitch passing between a first edge of the first layer and a perimeter of the waterproof functional insole.

[0057] This structural stitch 60 further can extend through the gasket 50. In particular, the gasket 50 can include an inner perimeter 50I and an outer perimeter 50O. The gasket can define a gasket width GW between these perimeters. This width can be slightly greater than a width of the thread 55 when sewn or applied to the first layer 21, as the thread material can melt and bleed or flow outward. In some cases, the thread can melt enough that it flows through the edge 21R of the first layer, and becomes visible and prominent beyond that edge. As explained below, this can assist the melted thread to fuse and bond with other components such as the insole. As shown, the outer perimeter 50O can be closer to the edge 21R of the first layer 21.

[0058] The structural stitch 60 shown in FIG. 6 can extend through the gasket 50 between the inner perimeter 50I and the outer perimeter 50O. In some cases, the structural stitch can include a first stitch segment 61 that extends generally parallel to an unmelted first thread segment 51, and/or the edge 21R of the first layer, extending through the body of the first layer 21. The structural stitch 60 can include a second stitch segment 62 that extends generally parallel to an unmelted second thread segment 52, extending on the exterior surface of the first layer and/or the exterior surface 21E itself. The structural stitch 60 can further include a third segment 63 that extends generally parallel to an unmelted third thread segment 53, that extends along the interior 21I of the first layer 21, or parallel to the interior surface 21I itself. Optionally, the structural stitch extends transversely through the gasket. In some cases, the stitch 60 can extend perpendicular to the gasket when it is in its melted and fused form. Further optionally, the second and third stitch segments can be transverse to the first stitch segment. Likewise, with the thread 55, the second and third thread segments can be transverse to the first thread segment.

[0059] The gasket 50 as mentioned above can be completed or formed when the threads 55 are melted and fused to various components of the footwear. For example, as shown in FIGS. 6 and 7, the thread 55 can be melted via heat treatment to form the darker shaded area or other means as described below. When melted, the thread can flow through the first layer, contacting and encapsulating various strands 26 in the first layer. For example, where the first layer is a textile layer including multiple textile strands 26 with interstitial spaces 27 therebetween, as it melts and starts to flow, the thread extends adjacent and between the textile strands 26 and through the interstitial spaces 27. When the thread 55 is melted and later cures and solidifies, the thread can entrap, encapsulate and/or bond to the textile strands and at least partially fill the interstitial spaces, shown as melted fingers 58 and via darker shading in FIGS. 6 and 7. The thread also can flow around and adjacent the structural stitch 60 and the segment 61, to entrap, encapsulate and/or bond to it. In this way, the melted thread, forming the gasket, forms a waterproof barrier and structure around the stitch so that water does not seep through the first layer adjacent that stitch. Optionally, the threads can be melted to form the gasket after the structural stitch is placed.

[0060] As further shown in FIGS. 6 and 7, the gasket 50 sealingly engages the waterproof functional second layer 22 and the waterproof functional insole 40, which again can be in the form of a waterproof Strobel board. Generally, the polymeric thread can be melted and fused to or bonded to the second layer and the perimeter to form the waterproof gasket between the waterproof functional second layer and the waterproof functional insole. In particular, when it cures, the melted thread 55 of the gasket engages and bonds to the exterior surface 22E of the second layer to form a waterproof region or seal 28. Further, after it cures, the melted thread 55 of the gasket also can engage and bond to the third edge 43 of the insole 40, which is abutted against the first edge 21R to form a butt seam in the Strobel construction. In doing so, the melted thread can flow into and entrap, encapsulate and/or bond to strands and/or material of the insole at the edge. As shown, the thread is melted, and when cured, fused to the perimeter and/or third edge 43 and the first edge 21R to form another waterproof region or seal 29. These waterproof regions 28 and 29 can be generally contiguous, and optionally can be transverse to one another. Optionally, some of the melted thread 55 and thus the gasket 50 can flow as an extension 50H to an area around the holes 60H formed in the insole 40 by the structural stitch 60 as shown in FIG. 6. In this manner, the gasket 50 can also seal and/or plug these holes created by the structural stitch. In other cases, the melted thread material can flow through the edge 43 of the insole and to the internal holes around the structural stitch.

[0061] As shown, the regions 28 and 29 can be optionally angled relative to one another, for example, generally perpendicular to one another. As will be appreciated, to form the region 29, the melted thread material can bleed or seep out the first edge and/or the interior surface 21I of the first layer, to contact the first edge, as well as in some cases the second edge 22R. In so doing, the melted thread can flow and then cure against the exterior surface 22E of the second layer and bond mechanically and chemically to that layer to form the region 28. As mentioned above, the first edge and the second edge can be aligned one above the other in this construction.

[0062] As mentioned above, the gasket can have a gasket width GW. This gasket width can be taken on one side of the longitudinal axis of the footwear as shown in FIG. 5. This width can be the width of the gasket on one side of a longitudinal axis of the footwear and/or the layer to which the thread is attached. The gasket width GW can be optionally less than 30 mm, less than 20 mm, or less than 10 mm. The gasket width can be selected so that it does not become too wide and prone to cracking when the insole and/or layers are repeatedly bent or placed under load. The gasket width also can be in a ratio relative to the insole width IW to provide a waterproof region or barrier where the various edges and waterproof functional layers meet, and yet still allow the insole to adequately flex. The ratio of the gasket width to the insole width can be optionally less than 1:2, less than 1:4, less than 1:6, less than 1:8, less than 1:10 or less than 1:12. Other ratios can be selected depending on the target rigidity of the insole and the thickness of the gasket from the interior to the exterior of the layer in which the thread is initially disposed.

[0063] A method of manufacturing the footwear 10 herein is also provided. On a high level, the method can include: providing an upper having a U-shaped outer perimeter, the upper including a first layer and a waterproof functional second layer adjacent the first layer; sewing a thread repeatedly through the first layer around the outer perimeter; positioning a waterproof functional insole having an insole perimeter adjacent at least one of the first layer and the second layer; and melting the thread to form a waterproof gasket between the waterproof functional second layer and the waterproof functional insole. For example, the upper 20 can be formed with the first layer 21, second layer 22 and lining 23 joined with one another, optionally as a laminate as discussed above, or as separate components. The upper can be placed on a foot shaped last and formed. The insole can be joined with the upper lower allowance 27 at the edges 21R and 22R of the first and second layers via the structural stitch 60, which can pass through the region around the edge 21R including the thread 55. The structural stitch can be sewn through the first layer 21, the waterproof functional second layer 22 and the waterproof functional insole 40. The structural stitch 60 can extend transversely through the region with the thread 55, and thus the gasket 50 after the thread is melted and forms the gasket.

[0064] Optionally after the insole is joined with the upper, the region around the thread 55 can be heated, which can cause the thread to melt and fuse (which also can include bond) to the various components around the thread. This heating can include heating the thread to at least 200 degrees Fahrenheit, at least 250 degrees Fahrenheit, at least 300 degrees Fahrenheit, at least 350 degrees Fahrenheit, at least 400 degrees Fahrenheit, or between 250 to 425 degrees Fahrenheit, inclusive. Such heating can cause the thread to melt and encapsulates adjacent strands in the first layer, and adhere to a surface of the waterproof functional second layer. Some of the thread can remain intact as segments, but much of the thread can melt to form an amorphous flowing material that penetrates the interstitial spaces between the strands of the first layer and/or the insole or other layers, embedding in, encapsulating and/or bonding to those strands and structures. After the melted thread does this, it is effectively cured and fused to those strands and structures of the upper and the insole, forming the waterproof gasket as described above.

[0065] Optionally, the thread 55 forming the gasket 50 can be melted and fused to the various components of the upper 20 and the insole 40 before the sole assembly 30 is joined with the upper. Thereafter, the sole assembly 30 can be joined with the formed upper and insole. This securement can be achieved with cement and/or adhesives that secure the sole assembly to the upper. With the gasket already being formed when the sole assembly is joined, the thread that forms the gasket generally does not melt and fuse to the outsole.

[0066] A first alternative embodiment of the footwear and waterproof gasket thereof is shown in FIG. 8. This embodiment is similar in structure, function and operation to the embodiment above with several exceptions. For example, in this construction, the upper 120 can include a first layer 121 joined with a second layer 122 and an optional liner 123. The first edge 121R and second edge 122R can be aligned one above the other. Thread 155 that forms a gasket 150 after melting and fusing can be sewn through the first layer as with the embodiment above.

[0067] In this construction, however, the waterproof functional insole 140 can include a waterproof functional film 141 joined with an insole body 142 that may or may not be waterproof. This film can be a waterproof functional fourth layer adjacent the insole interior surface 140I. The exterior 121E of the first layer can be placed on, atop and/or engaging the insole interior 140I, and the film and its interior surface 141I. The upper lower allowance 127 can be stitched and secured to the insole around a perimeter 144 via the structural stitch 160 that passes through the thickness of the upper and the insole, with the first and second layers stacked atop the insole 140, rather than butted edge to edge with the insole. This can generally form an overlap seam between the first layer and the insole.

[0068] The threads can be melted and fused to the second layer exterior surface 122E above the first layer 121. The threads 155 also can be melted and fused to the insole 140, and the interior surface 141I of the waterproof functional fourth layer, shown as a film 141, under the first layer to form the waterproof gasket 150. The respective surfaces are thus sealed and bonded to one another, rather than the edges of the layers and insole. Optionally, the gasket waterproof regions or seals 128 and 129 optionally can be noncontiguous. The region 128 can be above the first layer, while the second region 129 can be below the first layer. The regions also can be parallel to one another, located on opposite surfaces of the layer 121. These regions also both can be penetrated by the structural stitch 160, with the melted and fused gasket sealing around that stitch and the hole it creates in the layers and insole.

[0069] A second alternative embodiment of the footwear and waterproof gasket thereof is shown in FIG. 9. This embodiment is similar in structure, function and operation to the embodiment above with several exceptions. For example, in this construction, the upper 220 can include a first layer 221 joined with a second layer 222 and an optional liner 223. The first edge 221R and second edge 222R can be aligned one above the other. Thread 255 that forms a gasket 250 (the darker shaded area) after melting and fusing can be sewn through the first layer as with the embodiment above. The structural stitch 260 in this embodiment can extend through the first and second layers, and the insole, securing these elements to one another.

[0070] In this construction, however, the lower allowance 227 can be turned or bent outward from the longitudinal axis LA of the insole. The edges 221R and 222R can be aligned with and above the edge 243 of the waterproof functional insole 240, to form a plain seam. The insole can include an interior surface 240I. The interior surface 221I in this embodiment can engage and contact that interior surface 240I. When the gasket 250 is formed by melting and fusing the thread 255, the seal 229 forms between the interior surface 221I and the interior surface 240I. The seal 228 also forms between the first layer and the second layer as described in the other embodiments above. The melted threads also seal around the structural stitch 260 and the hole created when that stitch is sewn through the layers.

[0071] A third alternative embodiment of the footwear and waterproof gasket thereof is shown in FIGS. 10-13. This embodiment is similar in structure, function and operation to the embodiment above with several exceptions. For example, in this construction, the upper 320 can include a first layer 321 joined with a second layer 322, which can be a waterproof functional layer, and with an optional liner 323. In this construction, however, the lower allowance 327 can include a hot melt flange surrounding a perimeter 321P of the first layer and joined directly to the perimeter.

[0072] As shown in FIGS. 11 and 12, the upper 320 can include a first layer 321 having a first perimeter 321P, which can surround the first layer. A hot melt flange 370 can be secured around the first perimeter 321P to the first layer 320. The hot melt flange can be constructed from polyurethane, thermoplastic adhesive, cement, glue, plasticizers, tackifiers, antioxidants, waxes, oils, resins, fillers, UV inhibitors and/or polymers. Certain optional polymers can include ethylene-vinyl acetate (EVA), polyolefins, polyamides and polyesters, styrene block copolymers, polyethylene, butyl rubbers, polyvinyl acetate and copolymers, ethylene-methyl acrylate (EMA) and/or ethylene n-butyl acrylate (EnBA) to name a few. The hot melt flange can be in a flat, extruded sheet form, and cut or shaped to conform to the first perimeter 321P, abutting edge to edge with that perimeter. The hot melt flange 370 can be added to the perimeter and can extend the upper past the perimeter a distance D4 that can be optionally about 5 mm to about 50 mm, about 10 mm to about 30 mm, about 10 mm to about 20 mm, or about 15 mm.

[0073] With reference to FIGS. 11 and 12, the hot melt flange 370 can be secured or joined with the first perimeter 321P via a perimeter stitching 350. This stitching optionally can be structural stitching or thread as described in the embodiments above, rather than a fusible thread. The stitching can be applied in a zig-zag configuration as shown, or cross stitched or other patterns. Of course, the perimeter and hot melt flange can be joined with other methods, and in some cases, the hot melt flange can be heated, melted and bonded directly to the perimeter 321P or first layer 321 in general. The perimeter stitching can extend through the first layer and the hot melt flange to join the first layer and the hot melt flange.

[0074] The perimeter stitching 350 can extend over the interior surfaces 370I and 321I of the flange and first layer. To seal apertures in the flange due to the stitching and to seal over the stitching section 353 external to the flange and first layer, a waterproof functional second layer 322 like that described in the embodiments above can be disposed over the interior surfaces 379I and 321I. This can form a waterproof barrier region 377 shown in FIG. 12, so that water or liquids cannot penetrate into the stitching apertures or between the hot melt flange and first layer perimeter, or through the first layer if that is not waterproof. Generally, this waterproof functional second layer 322 can lay over and can be joined with the first layer, the hot melt flange and the first perimeter, as well as the perimeter stitching 350 and in particular the section 353 thereof. After this second layer is applied, the first layer, second layer and hot melt flange can form a composite panel or laminate 378.

[0075] With reference to FIGS. 12 and 13, the first layer 321 can include a first layer edge 321E and a first layer interior or inner surface 321I as mentioned above. The hot melt flange 370 can include a flange edge 370E and a flange interior or inner surface 370I. The first layer edge 321E and the flange edge 370E can be abutted against one another. The perimeter stitching 350 can crisscross the first layer edge and the flange edge, as well as the respective interior and exterior surfaces, to join the first layer edge and the flange edge. As mentioned above, the waterproof functional second layer 322 can be bonded to and coextensive with the first layer inner surface and the flange inner surface. The waterproof functional second layer also can cover and bond over the perimeter stitching, the inner surface of the first layer and the inner surface of the hot melt flange to form a waterproof barrier 377 over the perimeter stitching and apertures formed by the perimeter stitching in the flange and the first layer.

[0076] The composite panel 378 that forms part of the upper 320 can be joined with an insole 340 as shown in FIG. 13. The insole 340 can be any insole or Strobel board as described in connection with the embodiments above. Optionally, in this embodiment, however, the insole might not be a waterproof functional insole, that is, it might not be waterproof. The insole 340 can include a second perimeter 340P that is positioned adjacent and/or abutting the first layer, the second layer and/or the hot melt flange, or generally the end of the composite panel 378. The insole can be stitched to the composite panel 378 with insole stitching 360. This insole stitching 360 can extend through and join the insole and the hot melt flange, and generally the insole and the panel 378. The insole stitching can be optionally structural stitching or thread as described in the embodiments above, rather than a fusible thread. The stitching can be applied in a zig-zag configuration as shown, or cross stitched or other patterns. Of course, the insole 340 and hot melt flange 370 or panel 378 can be joined with other methods, and in some cases, the hot melt flange can be heated, melted and bonded directly to the perimeter 321P or first layer 321.

[0077] The insole stitching 360 can extend around the perimeter of the insole 340. Optionally, the insole stitching 360 can be distal from and not traverse the first perimeter 321P or the perimeter stitching 350. The insole stitching can be separated a distance D5 from the perimeter stitching. The distance D5 can be optionally about 5 mm to about 50 mm, about 10 mm to about 30 mm, about 10 mm to about 20 mm, or about 15 mm.

[0078] The insole stitching 360 also can include a section 363 that extends over the insole exterior or outer surface 340O and the first layer exterior or outer surface 370O. This section can form apertures as it re-enters the respective insole and flange. To address these apertures, and/or to form a waterproof barrier over the exterior 340O of the insole where it is not itself waterproof, a gasket panel 380 can be secured or joined with the insole 340 and part of the panel 378. This gasket panel 378 can be bonded, fused, glued, cemented or otherwise joined with these elements in an optionally waterproof manner. The gasket panel can extend over and can be bonded to the insole exterior surface 340O, the first layer exterior surface and the insole stitching 360 or Strobel stitch where included to form a waterproof barrier 379 over apertures formed by the insole stitching, and optionally over the remainder of the exterior surface 340O of the insole. Further optionally, the gasket panel, the hot melt flange and the waterproof functional second layer form a continuous waterproof barrier so water or other liquids cannot enter the footwear.

[0079] The gasket panel 380 can include an outer gasket perimeter or edge 380E. This edge 380E can be located outward from the insole stitching 360 so it can cover and waterproof that stitching as well as the abutment of the panel 378 and the perimeter 340P of the insole 340. The gasket panel edge also can be located between the insole stitching 360 and the perimeter stitching 350, optionally without extending over the perimeter stitching 350 because that is already waterproofed with barrier 377 on the interior of the layer 321 and by the hot melt flange 370. The gasket panel can be made from a film, membrane or sheet of polyurethane, rubber, polymer silicone or other waterproof material described herein.

[0080] A method of making an article of footwear of the third alternative embodiment shown in FIGS. 10-13 also is provided. Generally the method can include providing an upper 320 having an outer perimeter, the upper including a first layer 321 having a first layer perimeter 321P, a hot melt flange 370 joined around the first layer perimeter, and a waterproof functional second layer 322 overlapping and adjacent the first layer and the hot melt flange; positioning an insole 340 having an insole perimeter 340P adjacent at least one of the first layer and the second layer; sewing an insole stitching 360 through the hot melt flange 370 and the insole 340 to join the hot melt flange and the insole; and placing a gasket panel 380 over the insole stitching, hot melt flange and the insole to form a waterproof barrier 379 there.

[0081] Optionally, the hot melt flange can be heated to at least partially melt the hot melt flange and bond it to the first layer, the waterproof functional second layer and/or the insole. In turn, this can enhance the rigidity of the hot melt flange. In some cases, the hot melt flange can be selectively heated and cooled in different regions or areas around the perimeter to provide controlled stiffened or softened regions around the footwear. The various components and features of the embodiments herein can take on a variety of aesthetic forms, shapes and sizes. Although a particular component or feature can have a function, that feature can be expressed in different aesthetic manners to form an artistic design and/or purely ornamental design.

[0082] The following additional Statements illustrate further embodiments, the numbering of which is not to be construed as designating levels of importance. Moreover, it is to be understood that the Statements of embodiments recited below are provided in conjunction with and in addition to the embodiments described above, as well as those claimed even farther below. Alternative embodiments that result from combining, integrating, and/or omitting features of the embodiments of the Statements below or any other embodiment described herein may also be within the scope of the present invention.

[0083] Statement A: An article of footwear comprising: an upper including a first layer having a first perimeter; a hot melt flange secured around the first perimeter to the first layer; a waterproof functional second layer laying over and joined with the first layer, the hot melt flange and the first perimeter; an insole having a second perimeter, the second perimeter being positioned adjacent at least one of the first layer, the hot melt flange and the second layer; an insole stitching extending through and joining the insole and the hot melt flange; and a gasket panel extending over and joined with the insole, the insole stitching and the hot melt flange, wherein the gasket panel, the hot melt flange and the waterproof functional second layer form a waterproof barrier so liquid cannot enter the footwear.

[0084] Statement B: The article of footwear of Statement A, wherein the insole stitching is distal from and does not traverse the first perimeter.

[0085] Statement C: The article of footwear of any preceding Statement comprising: a perimeter stitching extending through the first layer and the hot melt flange to join the first layer and the hot melt flange.

[0086] Statement D: The article of footwear of any preceding Statement comprising: wherein the insole stitching does not traverse the perimeter stitching and is distal from the perimeter stitching.

[0087] Statement E: The article of footwear of any preceding Statement, wherein the first layer includes a first layer edge and a first layer inner surface, wherein the hot melt flange includes a flange edge and a flange inner surface, wherein the waterproof functional second layer is bonded to and coextensive with the first layer inner surface and the flange inner surface.

[0088] Statement F: The article of footwear of any preceding Statement, wherein the first layer edge and the flange edge are abutted against one another, wherein a perimeter stitching crisscrosses the first layer edge and the flange edge to join the first layer edge and the flange edge distal from the insole stitching.

[0089] Statement G: The article of footwear of any preceding Statement, comprising: a perimeter stitching cross crossing the first perimeter and joining the first layer and the hot melt flange, wherein the perimeter stitching lays above an inner surface of the first layer and above an inner surface of the hot melt flange, wherein the waterproof functional second layer covers and is bonded over the perimeter stitching, the inner surface of the first layer and the inner surface of the hot melt flange to form a waterproof barrier over a plurality of apertures formed by the perimeter stitching.

[0090] Statement H: The article of footwear of any preceding Statement, wherein the insole includes an insole exterior surface, wherein the hot melt flange includes a hot melt flange exterior surface, wherein the insole stitching extends over the insole outer surface and the hot melt flange exterior surface, wherein the gasket panel extends over and is bonded to the insole exterior surface, the hot melt flange exterior surface and the insole stitching to form a waterproof barrier over a plurality of apertures formed by the insole stitching.

[0091] Statement I: A method of making an article of footwear, the method comprising: providing an upper having a U-shaped outer perimeter, the upper including a first layer having a first layer perimeter, a hot melt flange joined around the first layer perimeter, and a waterproof functional second layer overlapping and adjacent the first layer and the hot melt flange; positioning an insole having an insole perimeter adjacent to at least one of the first layer and the second layer; sewing an insole stitching through the hot melt flange and the insole to join the hot melt flange and the insole; and placing a gasket panel over the insole stitching, hot melt flange and the insole to form a waterproof barrier there.

[0092] Statement J: The article of footwear of any preceding Statement, comprising: heating the hot melt flange to at least partially melt the hot melt flange and bond to at least one of the first layer, the waterproof functional second layer and the insole.

[0093] Statement K: The article of footwear of any preceding Statement comprising: stitching the hot melt flange to the first layer perimeter with a perimeter stitching before said sewing the insole stitching step.

[0094] Statement L: The article of footwear of any preceding Statement, wherein the perimeter stitching is distal from the insole stitching, wherein the insole stitching does not traverse the first layer perimeter.

[0095] Directional terms, such as “vertical,” “horizontal,” “top,” “bottom,” “upper,” “lower,” “inner,” “inwardly,” “outer” and “outwardly,” are used to assist in describing the invention based on the orientation of the embodiments shown in the illustrations. The use of directional terms should not be interpreted to limit the invention to any specific orientation(s).

[0096] The above description is that of current embodiments of the invention. Various alterations and changes can be made without departing from the broader aspects of the invention as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. This disclosure is presented for illustrative purposes and should not be interpreted as an exhaustive description of all embodiments of the invention or to limit the scope of the claims to the specific elements illustrated or described in connection with these embodiments. For example, and without limitation, any individual element(s) of the described invention may be replaced by alternative elements that provide substantially similar functionality or otherwise provide adequate operation. This includes, for example, presently known alternative elements, such as those that might be currently known to one skilled in the art, and alternative elements that may be developed in the future, such as those that one skilled in the art might, upon development, recognize as an alternative. Further, the disclosed embodiments include a plurality of features that are described in concert and that might cooperatively provide a collection of benefits. The present invention is not limited to only those embodiments that include all of these features or that provide all of the stated benefits, except to the extent otherwise expressly set forth in the issued claims. Any reference to claim elements in the singular, for example, using the articles “a,” “an,” “the” or “said,” is not to be construed as limiting the element to the singular. Any reference to claim elements as “at least one of X, Y and Z” is meant to include any one of X, Y or Z individually, any combination of X, Y and Z, for example, X, Y, Z; X, Y; X, Z; Y, Z, and/or any other possible combination together or alone of those elements, noting that the same is open ended and can include other elements.