Abstract
A method for waterproofing footwear (2), the footwear (2) including an upper assembly (4) having an outer construction (6) and a sole (8), includes providing a waterproof, breathable bootie (10) having a waterproof, breathable laminate construction, the waterproof, breathable laminate construction comprising a functional layer (54) and at least one textile layer (56, 58); inserting the waterproof, breathable bootie (10) into an inner space (12) of the outer construction (6) and the sole (8), when the outer construction (6) and the sole (8) are in an assembled state; and fixing the waterproof, breathable bootie (10) in position in the inner space (12) of the outer construction (6) and the sole (8).
Claims
1. A method comprising: providing a waterproof, breathable bootie having a waterproof, breathable laminate construction, wherein the waterproof, breathable laminate construction comprises a functional layer and at least one textile layer, inserting the waterproof, breathable bootie through a collar of a footwear wherein the waterproof, breathable bootie is inserted into an inner space of the footwear, after the inner space of the footwear has been closed, and permanently fixing the waterproof, breathable bootie in position in the inner space of the footwear by attaching the waterproof, breathable bootie to the footwear in a donning region of the footwear, and attaching the waterproof, breathable bootie to the footwear in at least one further attachment region of the footwear to permanently waterproof the footwear.
2. A method according to claim 1, wherein the inserting of the waterproof, breathable bootie takes place after the inner space has been formed by an upper assembly of the footwear.
3. A method according to claim 2, wherein the inserting of the waterproof, breathable bootie takes place after a sole of the footwear has been applied to the upper assembly, or wherein the inserting of the waterproof, breathable bootie takes place; before a sole of the footwear is applied to the upper assembly.
4. A method according to claim 1, wherein the inserting of the waterproof, breathable bootie takes place after the inner space has been jointly formed by an upper assembly of the footwear and a sole of the footwear.
5. A method according to claim 1, wherein the waterproof, breathable bootie consists of the waterproof, breathable laminate construction.
6. A method according to claim 1, wherein the attaching of the waterproof, breathable bootie to the footwear in the donning region of the footwear comprises adhering an adhesive tape of the waterproof, breathable bootie, arranged in a collar region of the waterproof, breathable bootie, to the donning region of the footwear.
7. A method according to claim 1, wherein the attaching of the waterproof, breathable bootie to the footwear in the donning region of the footwear comprises sewing the waterproof, breathable bootie in a collar region thereof to the donning region of the footwear.
8. A method according to claim 1, wherein the attaching of the waterproof, breathable bootie to the footwear in the donning region of the footwear comprises attaching the waterproof, breathable bootie to the footwear at a distance of at least 2 cm from a sole portion of the inner space.
9. A method according to claim 1, wherein the attaching of the waterproof, breathable bootie to the footwear in at least one further attachment region of the footwear comprises attaching the waterproof, breathable bootie to the footwear in at least one of a toe region of the footwear and a heel region of the footwear.
10. A method according to claim 9, wherein the attaching of the waterproof, breathable bootie to the footwear in at least one further attachment region of the footwear comprises adhering the waterproof, breathable bootie to the 25 footwear in at least one of the toe region of the footwear and the heel region of the footwear.
11. The method according to claim 1, wherein the step of permanently fixing the waterproof, breathable bootie in the inner space of the footwear comprises adhering the waterproof, breathable bootie to the footwear substantially all around its outer surface.
12. The method according to claim 1, wherein the step of inserting the waterproof, breathable bootie into the inner space comprises arranging the waterproof, breathable bootie on a last and inserting the last together with the waterproof, breathable bootie into the inner space.
13. The method according to claim 12, wherein the last is expandable; and wherein the step of permanently fixing the waterproof, breathable bootie in position in the inner space comprises expanding the last within the inner space; wherein the last comprises at least two last portions; and wherein the step of expanding the last within the inner space comprises spacing the at least two last portions.
14. The method according to claim 12, wherein the last is heatable; and wherein the step of permanently fixing the waterproof, breathable bootie in position in the inner space comprises heating the last, when inserted into the inner space.
15. The method according to claim 12, wherein the step of permanently fixing the waterproof, breathable bootie in position in the inner space comprises applying pressure to the last from outside of an upper assembly of the footwear and/or from outside of a sole of the footwear, wherein the step of applying pressure to the last from outside of the upper assembly and/or from outside of the sole comprises at least one of: applying pressure to an instep portion of the upper assembly via an instep pressuring device, applying pressure around a heel portion of the upper assembly via a forked heel pressuring device, applying pressure to the sole via a sole pressure plate, and applying pressure around an entirety of the upper assembly and sole via a bag around the footwear and the last.
16. The method according to claim 1, wherein the waterproof, breathable bootie is at least partly elastic.
17. The method according to claim 16, wherein the waterproof, breathable bootie is elastic at least in a mid-foot portion thereof, in particular at least in a mid-foot portion that extends along at least 50% of a length from a tip of the waterproof, breathable bootie to a rear of the waterproof, breathable bootie, and/or wherein the waterproof, breathable bootie is elastic at least in a top portion thereof, in particular at least in a top portion that extends along at least 40%, in particular along at least 50%, of a circumference of the waterproof, breathable bootie.
18. The method according to claim 1, wherein the waterproof, breathable laminate construction comprises a one-piece functional layer and at least one textile layer, wherein the one-piece functional layer is a seamless, one-piece functional layer, or wherein the waterproof, breathable laminate construction comprises multiple waterproof, breathable laminate pieces, wherein each of the multiple waterproof, breathable laminate pieces comprises a functional layer piece and at least one textile layer piece, or wherein the waterproof, breathable laminate construction comprises multiple functional layer pieces and at least one textile layer.
19. The method according to claim 2, wherein the upper assembly has an upper material wherein the upper assembly has one of: i) a mono tongue, wherein part of the upper material forms a tongue of the footwear, ii) a separate tongue, wherein a tongue piece is attached to the upper material and iii) a gusset-type tongue, wherein a tongue piece is attached to the upper material via an intermittent bridge piece, and wherein the step of permanently fixing the waterproof, breathable bootie in position in the inner space comprises attaching the waterproof, breathable bootie to said one of the mono tongue, the separate tongue, and the gusset-type tongue.
20. A footwear produced in accordance with the method of claim 1.
Description
[0072] Further exemplary embodiments of the invention are described below with reference to the accompanying drawings, wherein:
[0073] FIG. 1 illustrates an exemplary embodiment of providing a waterproof, breathable bootie, as may be used in methods for waterproofing footwear in accordance with exemplary embodiments of the invention, by depicting various process steps in a schematic manner;
[0074] FIG. 2 illustrates a method for waterproofing footwear in accordance with an exemplary embodiment of the invention by depicting various process steps in a schematic manner;
[0075] FIG. 3 illustrates a method for waterproofing footwear in accordance with another exemplary embodiment of the invention by depicting various process steps in a schematic manner;
[0076] FIG. 4 shows footwear in accordance with various exemplary embodiments of the invention, made waterproof by methods for waterproofing footwear in accordance with exemplary embodiments of the invention, in schematic, longitudinal cross-sectional views;
[0077] FIG. 5 shows footwear in accordance with various exemplary embodiments of the invention, made waterproof by methods for waterproofing footwear in accordance with exemplary embodiments of the invention, in schematic, transverse cross-sectional views;
[0078] FIG. 6 shows various tongue constructions, as may be present in footwear in accordance with exemplary embodiments of the invention, in a schematic manner;
[0079] FIG. 7 shows exemplary embodiments of waterproof, breathable laminates, to be used in waterproof, breathable booties for methods for waterproofing footwear in accordance with exemplary embodiments of the invention.
[0080] FIG. 1 illustrates an exemplary embodiment of providing a waterproof, breathable bootie 10, which may be used for methods for permanently waterproofing footwear in accordance with exemplary embodiments of the invention. FIG. 1A depicts a bootie trimming tool 80 in a schematic side view. The bootie trimming tool 80 is generally sock-shaped. It has trim marks 82, which indicate the desired length of the bootie for a footwear model in question.
[0081] FIG. 1B depicts the bootie trimming tool 80 of FIG. 1A together with a waterproof, breathable bootie 10 in a schematic side view. The waterproof, breathable bootie 10 has been slid over the bootie trimming tool 80 and is shown arranged on the bootie trimming tool 80. In other words, the bootie trimming tool 80 is arranged within the waterproof, breathable bootie 10 in FIG. 1B. The waterproof, breathable bootie 10 has a waterproof, breathable laminate construction comprising a functional layer and at least one textile layer. In the exemplary embodiment of FIG. 1, the waterproof, breathable laminate construction comprises a seamless, one-piece functional layer and a textile layer attached to one side thereof, as described in detail above. It is pointed out that any other suitable kind of waterproof, breathable bootie may be used as well.
[0082] With the help of the trim marks 82 of the bootie trimming tool 80, a trim line 86 is provided on the waterproof, breathable bootie 10. The trim line 86 may be drawn or embossed on the waterproof, breathable bootie 10 or provided in any other suitable manner.
[0083] FIG. 10 depicts the waterproof, breathable bootie 10 without the bootie trimming tool 80 and illustrates the cutting of the waterproof, breathable bootie 10 along the trim line 86 via a stylized pair of scissors 88. In the exemplary embodiment of FIG. 1, the waterproof, breathable bootie 10 is originally too long for the footwear model in question, i.e. the leg portion of the waterproof, breathable bootie 10 extends too far up. Using such a waterproof, breathable bootie 10 may be beneficial in terms of manufacturing efficiency, because one kind of waterproof, breathable bootie 10 may be used for different footwear models. For example, the waterproof, breathable bootie 10, as depicted in FIG. 1B, may be used for both low ankle shoes and boots, depending on the trimming. The waterproof, breathable bootie 10 may be used for one shoe size, but different shoe models. It is also possible that the waterproof, breathable bootie has sufficient elasticity to be used for various shoes sizes, such as a nominal shoe size and one or two shoe sizes bigger.
[0084] FIG. 1D illustrates the sewing of an adhesive tape 14 to the waterproof, breathable bootie 10. The adhesive tape 14 is arranged along the opening of the waterproof, breathable bootie 10. It may also be arranged somewhat spaced from the opening of the waterproof, breathable bootie 10. In either case, the adhesive tape 14 is considered to be is arranged in a collar region of the waterproof, breathable bootie 10. The sewing of the adhesive tape 14 to the waterproof, breathable bootie 10 is illustrated by zigzag line 90. The adhesive tape 14 comprises a thermoplastic glue, such as thermoplastic polyurethane. The resulting waterproof, breathable bootie 10 is thus configured to be attached to the inner space of footwear by inserting the waterproof, breathable bootie 10 into the inner space and activating the thermoplastic glue of the adhesive tape 14.
[0085] FIG. 2 illustrates a method for permanently waterproofing footwear in accordance with an exemplary embodiment of the invention by depicting various process steps in a schematic manner. FIG. 2A is a schematic side view. In FIG. 2A, a waterproof, breathable bootie 10 is provided on a last 20. The last 20 is the first last used in the process described with respect to FIG. 2, as will become apparent below.
[0086] The last 20 is an expandable and heatable last. The last 20 is depicted in a non-expanded state in FIG. 2A. The last 20 has a forward last portion 24 and a rearward last portion 26. The forward last portion 24 and the rearward last portion 26 are movable with respect to each other. In particular, the space between the forward last portion 24 and the rearward last portion 26 may be increased in the front-to-rear direction of the last. The last 20 may also be referred to as a split last. Both the forward last portion 24 and the rearward last portion 26 are supported by a last support arm structure 28. The last support arm structure allows for the last 20 to float, such that any structure arranged on the last does not have to be supported from the bottom. It is also possible that the forward last portion 24 and the rearward last portion 26 are coupled to each other via an extendable cylinder or any other suitable expanding mechanism.
[0087] FIG. 2A further depicts a sole pressure plate 30. The sole pressure plate 30 is movable in a vertical direction. It is also possible that the support arm structure 28 is movable in a vertical direction. The sole pressure plate 30 is configured to exert pressure onto the underside of the last 20 and any interposed structure, i.e. any interposed part of the footwear. In FIG. 2A, the sole pressure plate 30 is depicted as spaced from the last 20.
[0088] As stated above, a waterproof, breathable bootie 10 is provided on the last 20. The waterproof, breathable bootie 10 may be the waterproof, breathable bootie 10 as described above with respect to FIG. 1. It may also be any other suitable kind of waterproof, breathable bootie 10.
[0089] The waterproof, breathable bootie 10, as depicted in FIG. 2A, comprises an adhesive tape 14 in its collar region. The adhesive tape 14 is depicted with a dotted pattern. In addition, the waterproof, breathable bootie 10 comprises a bootie-side adhesive patch 16 in a toe region of the waterproof, breathable bootie 10. The bootie-side adhesive patch 16 is provided both on the front side and the underside of the waterproof, breathable bootie 10 in the toe region. The bootie-side adhesive patch 16 may be applied via spraying or brushing. An exemplary adhesive for the bootie-side adhesive patch 16 is latex-based adhesive Technicoll® 9222-1.
[0090] FIG. 2B depicts the last 20 and the waterproof, breathable bootie 10 inserted into footwear 2. In other words, in between the depictions of FIGS. 2A and 2B, the footwear 2 has been slid over the last 20, having the waterproof, breathable bootie 10 arranged thereon. FIG. 2B is also a schematic side view.
[0091] The footwear 2 has an upper assembly 4, having an outer construction, and a sole 8. To the inside of the upper assembly 4 and the sole 8, there is an inner space 12. This inner space 12 may be referred to as the inner space 12 of the footwear 2. The last 20 and the waterproof, breathable bootie 10 are depicted as inserted into the inner space 12.
[0092] Further, a footwear-side adhesive patch 18 in the heel region of the inner space 12 is provided. The footwear-side adhesive patch 18 is provided on the rear portion of the inner space 12, i.e. on the portion of the inner space 12 that extends upwards behind the heel of the user, and the rear of the sole portion of the inner space. The footwear-side adhesive patch 18 may be applied via spraying or brushing. An exemplary adhesive for the footwear-side adhesive patch 18 is latex-based adhesive Technicoll® 9222-1.
[0093] FIG. 2C illustrates a first step of fixing the waterproof, breathable bootie 10 in position in the inner space 12. In other words, FIG. 2C illustrates a first step of attaching the waterproof, breathable bootie 10 to the footwear 2. FIG. 2C is also a schematic side view.
[0094] As compared to the situation in FIG. 2B, the forward last portion 24 and the rearward last portion 26 are spaced. As a consequence, the waterproof, breathable bootie 10 is pushed towards the front and the back of the outer construction of the upper assembly 4. In addition, the sole pressure plate 30 is moved against the sole 8. Given the pressure exerted by the last 20 and the sole pressure plate 30 and given the inherent stability of the footwear 2, the waterproof, breathable bootie 10 is pushed against the upper assembly 4 and against the sole 8. At the same time, the last 20 is heated. Via exertion of pressure and heating, the bootie-side adhesive patch 16 in the toe region and the footwear-side adhesive patch 18 in the heel region bond the waterproof, breathable bootie 10 and the upper assembly 4. In this way, the waterproof, breathable bootie 10 is fixed in position in the inner space 12 of the footwear 2. It is pointed out that, depending on the specific footwear construction in question, the waterproof, breathable bootie 10 may be attached to one or all or a subset of the outer construction of the upper assembly 4, a hidden portion of the upper assembly 4, such as an assembly insole thereof, and the sole 8. While the exertion of pressure and heating, as depicted in FIG. 2C, is primarily intended to activate the bootie-side adhesive patch 16 in the toe region and the footwear-side adhesive patch 18 in the heel region, the adhesive tape may also experience some preliminary positional fixing.
[0095] In the exemplary embodiment of FIG. 2C, the last 20 is heated to about 78° C., the forward last portion 24 and the rearward last portion 26 are spread apart with a pressure of about 2.5 bar, and the sole pressure plate is pressed against the sole 8 with a pressure of about 4 bar. These temperature and pressure values are maintained for about 15 min. It is pointed out that the temperature and pressure values may depend on the footwear in question, the adhesive used, the tooling used, and other factors. For example, the forward last portion 24 and the rearward last portion may be spread apart with a pressure of between 0.5 bar and 7 bar. Also, the sole pressure plate may be pressed against the sole with a pressure of between 1 bar and 5 bar.
[0096] FIG. 2D illustrates the fixing of the adhesive tape 14 in position in the inner space 12 of the footwear 2. The footwear 2 and the waterproof, breathable bootie 10 are arranged on another last 22 in FIG. 2D. This other last 22 is also referred to as second last 22 herein, as it is used in a second step of fixing the waterproof, breathable bootie 10 in position. The last 22 is not expandable. In particular, the last 22 is not a split last in the exemplary embodiment of FIG. 2D. Rather, the last 22 provides a continuous structure to the inside of the adhesive tape 14 arranged in the collar region of the waterproof, breathable bootie 10. Further, the last 22 is heatable. The last 22, the footwear 2, and the waterproof, breathable bootie 10 are depicted in a schematic side view on top of FIG. 2D and in a schematic horizontal cross-sectional view on the bottom of FIG. 2D.
[0097] In the process step depicted in FIG. 2D, pressure is exerted onto the last 22 from outside of the footwear via an instep pressuring device 32 and via a forked heel pressuring device 34. The instep pressuring device 32 and the last 22 form a press for a forward portion of the collar region of the waterproof, breathable bootie 10, thus helping in the creation of the attachment between the adhesive tape 14 of the waterproof, breathable bootie 10 and the upper assembly 4 in that part. The forked heel pressuring device 34 and the last 22 form a press for a rearward portion and the left and right side portions of the collar region of the waterproof breathable bootie 10, thus helping in the creation of the attachment between the adhesive tape 14 of the waterproof, breathable bootie 10 and the upper assembly 4 in that part.
[0098] In the exemplary embodiment of FIG. 2D, the last 22 is heated to between 20° C. and 130° C. The instep pressuring device 32 and the forked heel pressuring device 34 are pushed against the outer construction of the upper assembly 4 with a pressure of between 0.2 bar and 5 bar. These temperature and pressure values are maintained for about 3 min. It is pointed out that the temperature and pressure values may depend on the footwear in question, the adhesive used, the tooling used, and other factors.
[0099] Similar to the forked heel pressuring device 34, a dome-shaped toe region pressuring device may be used, which may exert pressure on the upper assembly 4 and, potentially, to the sole, with a suitable last extending into the toe box of the footwear 2.
[0100] While it has been described with respect to FIG. 2 that the attachments in the toe region and heel region are achieved first, before the attachment via the adhesive tape 14 is effected, it is pointed out that this order may also be reversed. In particular, the waterproof, breathable bootie 10 and the footwear 2 may be arranged on the last 22, depicted in FIG. 2D, first, with the attachment via the adhesive tape 14 being effected, before placing the waterproof, breathable bootie 10 and the footwear onto the last 20, depicted in FIGS. 2A to 2C, where the attachments in the toe region and the heel region are made. It is also possible to have a single last that allows for all attachments operations. In particular, this single last may be shaped to form a solid structure at substantially all positions where the attachment between the waterproof, breathable bootie 10 and the upper assembly and/or sole takes place.
[0101] FIG. 3 illustrates a method for permanently waterproofing footwear 2 in accordance with another exemplary embodiment of the invention by depicting various process steps in a schematic manner. FIG. 3A is a schematic side view. In FIG. 3A, a last 23 is depicted. The last 23 is a heatable last. It has a heating device 36 and an electric cord 38, with which the heating device 36 is provided with electric power.
[0102] FIG. 3B depicts a waterproof, breathable bootie 10 arranged on the last 23 of FIG. 3A. FIG. 3B is also a schematic side view. The waterproof, breathable bootie 10 comprises an adhesive tape 14 in the collar region of the waterproof, breathable bootie 10. It further comprises a bootie-side adhesive patch 16 in the toe region and a bootie-side adhesive patch 16 in the heel region of the waterproof, breathable bootie 10.
[0103] FIG. 3C depicts the last 23 and the waterproof, breathable bootie 10 of FIG. 3B inserted into footwear 2. FIG. 3C is also a schematic side view. In particular, the last 23 and the waterproof, breathable portion 10 are inserted into an inner space of the footwear 2, in particular into an inner space formed by an upper assembly 4 of the footwear 2 and a sole 8 of the footwear 2.
[0104] FIG. 3D depicts the beginning of an arrangement of a bag 39 around the last 23, the waterproof, breathable bootie 10, and the footwear 2. FIG. 3D is also a schematic side view. While depicted in a schematic two-dimensional manner, it is understood that the bag 39 forms a three-dimensional structure around the last 23, the waterproof, breathable bootie 10, and the footwear 2.
[0105] FIG. 3E depicts the components of FIG. 3D, with the bag 39 having been evacuated. FIG. 3E is also a schematic side view. Due to the evacuation of the bag 39, the bag 39 conforms to the outer shape of the footwear 2 and the last 23, thus exerting an all-around pressure onto the footwear 2 against the last 23. The pressure onto the footwear 2 may be further increased by increasing the air pressure around the bag 39 above atmospheric pressure. At the same time, the last 23 is heated, thus activating the adhesive tape 14 and the bootie-side adhesive patches 16 in the toe and heel regions. An effective fixing in position of the waterproof, breathable bootie 10 in the inner space of the upper assembly 4 and the sole 8 takes place. The evacuation may be carried out with any suitable source of suction. The application of additional pressure from outside of the bag may be carried out with any suitable pressure source, such as within a pressurized air chamber.
[0106] FIG. 4 shows footwear 2 in accordance with various exemplary embodiments of the invention, made waterproof by methods for permanently waterproofing footwear in accordance with exemplary embodiments of the invention. The footwear 2 of FIG. 4 is shown in schematic, longitudinal cross-sectional views. The footwear 2 of FIG. 4 may be made waterproof in accordance with any of the methods described herein, in particular with any of the methods described above with respect to FIGS. 1 to 3.
[0107] FIG. 4A shows footwear 2 in accordance with an exemplary embodiment of the invention, depicted in a longitudinal cross-sectional view, with the cross-sectional plane of FIG. 4A running substantially through the center of the footwear 2. The footwear 2 comprises an upper assembly 4 and a sole 8. The footwear 2 is of a lasted construction. The upper assembly 4 comprises a breathable upper material 40, such as leather, suede, textile or any other suitable material, and an assembly insole 44. The breathable upper material 40 is perimetrically lasted onto the assembly insole 44 from the bottom. In particular, the breathable upper material 40 is glued onto the bottom of the assembly insole 44 around its perimeter with a lasting glue.
[0108] The upper assembly 4 further comprises a tongue 42. In the exemplary embodiment of FIG. 4A, the tongue 42 is an originally separate structure from the breathable upper material 40 and is attached thereto, e.g. via sewing or gluing. It is also possible that the tongue 42 and the breathable upper material 44 are integrally formed from a continuous piece of material. The breathable upper material 40 and the tongue 42 form an outer construction 6 of the footwear 2. In general, the outer construction 6 of the footwear 2 may be a single integrated structure, such as a three-dimensional knit, or may be assembled from various originally separate pieces of a breathable material, as is for example common in leather shoes/boots.
[0109] The upper assembly 4 further comprises a collar 5. The collar 5 forms the upper end of the upper assembly 4. It surrounds the foot insertion opening.
[0110] In the exemplary embodiment of FIG. 4A, the sole 8 is a solid structure of a non-breathable material, e.g. a solid plastic structure. In the exemplary embodiment of FIG. 4A, the sole 8 is injected onto the lower side of the upper assembly 4, forming a strong bond to the lasted portion of the upper material 40 and to the assembly insole 44 in the process of injection. The sole 8 may also be glued to the lower portion of the upper assembly 4. It is further possible that the sole 8 is made from inherently breathable materials, such as leather, and/or that the sole has a structure that allows for breathability through the sole, as will be described below.
[0111] A waterproof, breathable bootie 10 is arranged in an inner space 12 of the footwear 2. In particular, the waterproof, breathable bootie 10 is arranged in the inner space 12, as provided by the upper assembly 4 and the sole 8. With the footwear 2 of FIG. 4A having a lasted construction, the waterproof, breathable bootie 10 is provided in the inner space 12, as provided by the outer construction 6 and the assembly insole 44. The waterproof, breathable bootie 10 has been inserted into the inner space 12 and fixed in position in the inner space 12, as described in any of the exemplary embodiments above. The waterproof, breathable bootie 10 is a sock-like structure. Being arranged in the inner space 12, the waterproof, breathable bootie 10 may also be referred to as a shoe insert. The waterproof, breathable bootie 10 may be any suitable waterproof, breathable bootie, in particular any kind of waterproof, breathable bootie as described herein. In the exemplary embodiment of FIG. 4A, the upper end of the waterproof, breathable bootie 10 is at the same height as the upper end of the outer material 40. It is also possible that the upper end of the waterproof, breathable bootie 10 ends below the upper end of the outer material 40 or extends above the upper end of the outer material 40.
[0112] The footwear 2 has a forefoot portion 90, a mid-foot portion 92, and a rearfoot portion 94. The forefoot portion 90, the mid-foot portion 92, and the rearfoot portion 94 are separated by dashed lines in FIG. 4A. The forefoot portion 90 may also be referred to as a toe region of the footwear. The rearfoot portion 94 comprises a heel region 96 in its lower portion. The footwear further comprises a donning region 98. The donning region 98 may be an upper portion of the rearfoot portion 94 or may extend both in an upper portion of the rearfoot portion 94 and an upper portion of the mid-foot portion 92.
[0113] The waterproof, breathable bootie 10 is attached to the breathable upper material 40, to the tongue 42, and to the assembly insole 44 in the forefoot portion/toe region 90, in the heel region 96, and the donning region 98. In particular, the waterproof, breathable bootie is fixed in position by various adhesive elements, as will be described below.
[0114] The waterproof, breathable bootie 10 is attached to the breathable upper material 40 and the tongue 42 in the donning region 98 via an adhesive tape 14, which surrounds the circumference of the waterproof, breathable bootie 10. The waterproof, breathable bootie 10 is further attached to the breathable upper material 40 and to the assembly insole 44 in the heel region 96 via two bootie-side adhesive patches 16. Yet further, the waterproof, breathable bootie 10 is attached to the breathable upper material 40 and to the assembly insole 44 in the toe region 90 via two bootie-side adhesive patches 16. The attachment may have been achieved, as described above with respect to FIGS. 1 to 3. All of the adhesive tape 14 and the bootie-side adhesive patches 16 may comprise heat activated adhesive. It is understood that the arrangement of the adhesive elements is exemplary in nature and that the positional fixation of the waterproof, breathable bootie 10 may be achieved via other adhesive arrangements as well. Also, while the adhesive patches 16 have been described as bootie-side adhesive patches, because they had been applied to the waterproof, breathable bootie 10 before bonding, it is also possible that footwear-side adhesive patches may be used. A combination of bootie-side adhesive patches and footwear-side adhesive patches is possible as well. In the exemplary embodiment of FIG. 4A, the waterproof, breathable bootie 10 extends somewhat higher than the adhesive tape 14. However, it is also possible that the adhesive tape 14 forms the uppermost portion of the waterproof, breathable bootie 10, as shown in FIGS. 1 to 3 above.
[0115] In the exemplary embodiment of FIG. 4A, the waterproof, breathable bootie 10 is free of attachments to the remainder of the upper assembly 4 in the mid-foot portion 92. In particular, in the exemplary embodiment of FIG. 4A, the waterproof, breathable bootie 10 is neither attached to the outer construction, comprising the breathable upper material 40 and the tongue 42, nor to the assembly insole 44 in the mid-foot portion 92. In this way, the waterproof, breathable bootie 10 is free to move with respect to the surrounding elements of the upper assembly 4 in the mid-foot portion 92. This provides a comfortable fit to the user. The waterproof, breathable bootie 10 may further be elastic, at least in said mid-foot portion. In that way, the bootie may conform well to the user's foot.
[0116] FIG. 4B shows footwear 2 in accordance with another exemplary embodiment of the invention. The footwear 2 of FIG. 4B is very similar to the footwear 2 of FIG. 4A. Like elements are denoted with like reference numerals, and reference is made to the description thereof above. In the exemplary embodiment of FIG. 4B, the waterproof, breathable bootie 10 extends above the collar 5. In other words, the foot insertion portion of the waterproof, breathable bootie 10 extends further upwards then the foot insertion portion of the outer construction 6. This extension of the waterproof, breathable bootie 10 may provide for a more convenient, more sock-like feel to the user of the footwear 2.
[0117] FIG. 4C shows footwear 2 in accordance with yet another exemplary embodiment of the invention. The footwear 2 of FIG. 4C is very similar to the footwear 2 of FIG. 4A. Like elements are denoted with like reference numerals, and reference is made to the description thereof above. In the exemplary embodiment of FIG. 4C, the upper end of the waterproof, breathable bootie 10 is wrapped around the collar 5 of the upper assembly 4. The wrapped around portion of the waterproof, breathable bootie 10 is attached to the outer upper end of the outer construction 6 via additional bootie-side adhesive patches 16. The attachment via these additional bootie-side adhesive patches 16 may be effected at the same time as the attachment via the adhesive tape 14. It is also possible that the adhesives are activated separately. Further, it is possible that additional footwear-side adhesive patches are provided instead of the additional bootie-side adhesive patches 16. The wrapped around portion of the waterproof, breathable bootie 10 may provide a particularly convenient insertion of the foot for the user, as the foot is led into the waterproof, breathable bootie 10 in a funnel-like manner.
[0118] FIG. 4D shows footwear 2 in accordance with yet another exemplary embodiment of the invention. The footwear 2 of FIG. 4D is very similar to the footwear 2 of FIG. 4A. Like elements are denoted with like reference numerals, and reference is made to the description thereof above. In the exemplary embodiment of FIG. 4D, the waterproof, breathable bootie 10 is sewn to the upper assembly 4 via a sewn seam 15 in the donning region 98 of the footwear 2. Instead of relying on the adhesive tape 14, the sewn seam 15 achieves the attachment between waterproof, breathable bootie 10 and footwear 2 in the donning region 98. It is also possible that a weld between the waterproof, breathable bootie 10 and the upper assembly 4 is provided as an alternative means of attachment.
[0119] FIG. 5 shows footwear 2 in accordance with various exemplary embodiments of the invention, made waterproof by methods for permanently waterproofing footwear in accordance with exemplary embodiments of the invention, in schematic, transverse cross-sectional views. In particular, FIG. 5A shows the footwear 2 of FIG. 4A along the cross-sectional plane indicated by A-A in FIG. 4A. The cross-sectional plane of FIG. 5A cuts through the mid-foot portion 92 roughly in the middle thereof. As stated above, the sole 8 is a solid structure, such as an injected plastics structure in the exemplary embodiment of FIGS. 4A and 5A.
[0120] FIG. 5B shows footwear 2 in accordance with another exemplary embodiment of the invention. The footwear 2 of FIG. 5B is a variation of the footwear 2 of FIGS. 4A and 5A. In particular, while the upper assembly 4 of the footwear 2 of FIG. 5B is the same as the upper assembly 4 of FIGS. 4A and 5A, the sole 8 of the footwear 2 of FIG. 5B is a variation of the sole 8 of FIGS. 4A and 5A. FIG. 5B shows a cross-sectional view analogous to the cross-sectional view of FIG. 5A.
[0121] The sole 8 of the footwear 2 of FIG. 5B is a breathable sole. In particular, the sole 8 is of a breathable structure. The sole 8 has a circumferential portion 60 and stabilizing bars 62. The stabilizing bars 62 and the circumferential portion 60 may be integrally molded from a plastics material. While the stabilizing bars 62 are depicted as longitudinal bars in the cross-sectional view of FIG. 5B, the stabilizing bars 62 may be arranged in different directions. In particular, the stabilizing bars 62 may form a stabilization grid within the circumferential portion 60. The stabilizing bars 62/the stabilization grid may extend over one or more portions of the sole 8, e.g. over a forefoot portion of the sole 8 and/or over a heel portion of the sole 8.
[0122] In between the stabilizing bars 62/stabilizing grid, there are provided water vapor discharge holes 66. The water vapor discharge holes 66 are comparably large in diameter and thus allow for the discharge of large amounts of water vapor through the sole 8. The water vapor discharge holes 66 extend substantially vertically though the sole 8. Above the water vapor discharge holes 66, there is provided a barrier material 64. In particular, the barrier material is provided between the circumferential portion 60 of the sole 8, below the assembly insole 44, and above the stabilizing bars 62. The barrier material is breathable, i.e. water vapor permeable, and protects the upper assembly 4 there above from foreign objects that may penetrate through the water vapor discharge holes 66.
[0123] The footwear 2 of FIG. 5B allows for water vapor discharge through the breathable upper material 40 as well as through the sole 8. Water vapor can travel from the underside of the wearer's foot through the waterproof, breathable bootie 10, through the assembly insole 44, through the barrier material 64, and through the water vapor discharge holes 66 to an outside environment of the footwear 2. With the bootie being having a breathable, waterproof laminate construction, the wearer's foot is protected from water, also from water entering through the water vapor discharge holes 66.
[0124] FIG. 5C shows footwear 2 in accordance with yet another exemplary embodiment of the invention. The footwear 2 of FIG. 5C is a variation of the footwear 2 of FIGS. 4A and 5A. In particular, while the upper assembly 4 of the footwear 2 of FIG. 5C is the same as the upper assembly 4 of FIGS. 4A and 5A, the sole 8 of the footwear 2 of FIG. 5C is a variation of the sole 8 of FIGS. 4A and 5A. FIG. 5C shows a cross-sectional view analogous to the cross-sectional view of FIG. 5A.
[0125] The sole 8 of the footwear 2 of FIG. 5C is a breathable sole, as is the sole 8 of the footwear 2 of FIG. 5B. While the sole 8 of FIG. 5B relies on water vapor discharge towards the bottom of the sole, the sole 8 of FIG. 5C relies on water vapor discharge towards the lateral sides of the sole. The bottom surface of the sole 8 of FIG. 5C is free of water vapor discharge holes. However, it is also possible that the sole of footwear in accordance with exemplary embodiments of the invention has water vapor discharge holes towards the bottom and towards the side.
[0126] The sole 8 of FIG. 5C has a structure or material for allowing air flow through it, generally indicated with reference numeral 68. The structure or material 68 may be any suitable structure or material that allows for air flow there through and, thus, allows for the transport of water vapor, coming from the inside of the shoe, towards the lateral sides and out of the shoe. The structure or material 68 may for example be a channel structure or a spacer fabric or a granulate fill or any other suitable structure or material. The sole 8 further comprises a plurality of water vapor discharge holes 66. In the cross-sectional view of FIG. 5C, two of the plurality of water vapor discharge holes 66 are shown. It is understood that a suitable number of water vapor discharge holes 66 may be arranged around the periphery of the sole 8.
[0127] The water vapor discharge holes 66 are provided from the structure or material 68 towards the lateral sides of the sole 8. In particular, the water vapor discharge holes 66 are substantially horizontal in the exemplary embodiment of FIG. 5C. Further, the water vapor discharge holes 66 are substantially circular in cross-section in the exemplary embodiment of FIG. 5C. However, the water vapor discharge holes may have any suitable cross-section.
[0128] The footwear 2 of FIG. 5C also allows for water vapor discharge through the breathable upper material 40 as well as through the sole 8. Water vapor can travel from the underside of the wearer's foot through the waterproof, breathable bootie 10, through the assembly insole 44, into and through the structure or material 68, and through the water vapor discharge holes 66 to an outside environment of the shoe. Due to the straight air flow path between the left and right sides of the sole 8, an efficient water vapor discharge through the sole 8 may be achieved. With the bootie being having a breathable, waterproof laminate construction, the wearer's foot is protected from water, also from water entering through the water vapor discharge holes 66.
[0129] FIG. 6 shows various tongue constructions, as may be present in footwear in accordance with exemplary embodiments of the invention, in a schematic manner. FIG. 6 shows schematic top views of the respective tongue constructions. FIG. 6A depicts a portion of the upper material 40 of the upper assembly 4 and an originally separate tongue 42. The tongue piece 42 is attached to the upper material 40. In particular, the tongue 42 is sewn to the upper material 40. FIG. 6B depicts a portion of the upper material 40 of the upper assembly 4. In the embodiment of FIG. 6B, the tongue 42 is an integral part of the upper material 40. It can be said that the outer construction has a mono tongue. FIG. 6C depicts a portion of the upper material 40 of the upper assembly 4, a tongue 42, and an intermittent bridge piece 46. Both the upper material 40 and the tongue 42 are attached to the intermittent bridge piece 46. In particular, both the upper material 40 and the tongue 42 are sewn to the intermittent bridge piece 46. The method of waterproofing footwear, including the inserting of the waterproof, breathable bootie 10 and fixing the waterproof, breathable bootie 10 in position, as described in any of the embodiments above, is applicable to footwear having all of the depicted tongue constructions. The fixing of the waterproof, breathable bootie 10 may be adapted to the tongue construction of the footwear in question.
[0130] FIG. 7 shows exemplary embodiments of waterproof, breathable laminates, to be used in waterproof, breathable booties for methods for waterproofing footwear in accordance with exemplary embodiments of the invention. FIG. 7A shows a waterproof, breathable three-layer laminate 51. The three-layer laminate 51 has a functional layer 54, which is an ePTFE membrane in the exemplary embodiment of FIG. 7A, a first textile layer 56, and a second textile layer 58. The first and second textile layers 56, 58 are knitted layers in the exemplary embodiment of FIG. 7A.
[0131] FIG. 7B shows a waterproof, breathable two-layer laminate 51. The two-layer laminate 51 has a functional layer 54, which is an ePTFE membrane in the exemplary embodiment of FIG. 7B, and a textile layer 56, which is a knitted layer in the exemplary embodiment of FIG. 7B. The laminate 51 can be used in any orientation for the waterproof, breathable bootie 10, i.e. the two-layer laminate 51 can be used with the functional layer 54 facing the wearer's foot and with the textile layer 56 facing the wearer's foot.
Test Methods and Definitions
[0132] A functional layer and a laminate are considered to have waterproof characteristics in case the requirements specified in DIN EN 343 (2010) are met, i.e. a test of the liquid water resistance with respect to hydrostatic water pressure according to EN 20 811 (1992) yields a liquid water resistance Wp of 8000 Pa, or more.
[0133] Water vapor permeability, as used herein concerning the functional layer and the laminate comprising the functional layer, is tested and defined in EN ISO 15496, also known as the “Cup Test”. A 20×20 cm or Ø 100 mm sample of the waterproof, breathable laminate is placed onto a container containing water and covered with a membrane. Then a cup containing potassium acetate and being covered by the same membrane is placed on the sample. Water vapor passes through the laminate into the cup, whose weight increase is then determined. The laminate is considered water vapor permeable or breathable if the water vapor permeability is greater than or equal to 0.01 g/(Pa*m2*h). If the required size of the sample cannot be obtained, a smaller sample may be used for the measurement using a smaller cup containing half the amount of potassium acetate specified in the Norm, i.e. 50 g instead of 100 g and mixed with 15.6 g of water. The terms water vapor permeability and breathability are used interchangeably herein. Accordingly, the waterproof, breathable laminate may also be referred to as waterproof, water vapor permeable laminate.
[0134] The waterproofness of footwear may be determined by use of the Centrifuge test described in U.S. Pat. No. 5,329,807, and incorporated by reference herein in its entirety. The centrifuge tests may be carried out for 30 minutes. The footwear article is considered to be waterproof if no leakage is seen after 30 minutes.
[0135] The breathability of footwear may be assessed in accordance with the determination of the Whole Boot Moisture Vapor Transmission Rate Test in accordance with the Department of Defense Army Combat Boot Temperate Weather Specifications. The specifications are as follows:
[0136] Whole Boot Breathability
[0137] The boot breathability test shall be designed to indicate the Moisture Vapor Transmission Rate (MVTR) through the test sample by means of a difference in concentration of moisture vapor between the interior and the exterior environment.
[0138] Apparatus
[0139] a. The external test environment control system shall be capable of maintaining 23 (±1) ° C. and 50%±2% relative humidity throughout the test duration.
[0140] b. The weight scale shall be capable of determining the weight of test samples filled with water to an accuracy of (±0.01) gram.
[0141] c. The water holding bag shall be flexible so that it can be inserted into the test sample and conform to the interior contours; it must be thin enough so that folds do not create air gaps; it must have much higher MVTR than the footwear product to be tested; and it must be waterproof so that only moisture vapor contacts the interior of the footwear product rather than liquid water.
[0142] d. The internal heater for the test sample shall be capable of controlling the temperature of the liquid water uniformly in the test sample to 35 (±1) ° C.
[0143] e. The sealing method around the collar of the test sample shall be impervious to both liquid water and water vapor.
[0144] Procedure
[0145] a. Place sample in test environment and condition for at least 12 hours.
[0146] b. The heating device is inserted into the water holding bag and the complete assembly is then placed into the test sample opening and filled with water to a height of 5 cm measured from inside sole.
[0147] c. Seal opening around the collar with plastic wrap around the top of the footwear and tape over using packaging tape.
[0148] d. Heat water in test sample to 35° C.
[0149] e. Weigh test sample and record as Wi.
[0150] f. Hold temperature in test sample after weighing for a minimum of 4 hours.
[0151] g. After a minimum of 4 hours, reweigh test sample. Record weight as Wf and test duration as Td.
[0152] h. Calculate MVTR of the test sample in grams/hour from the equation below:
MVTR=(Wi−Wf)/Td.
[0153] This test is in accordance with ASTM D8041 (2016).
[0154] For example, for a low ankle shoe of European shoe size 42, the footwear may be considered breathable if above calculated value is above 1.5 grams/hour. For larger/smaller shoe sizes, said limit value may be extrapolated in accordance with the increased/decreased surface area of the shoe.
[0155] The waterproofness and the breathability of the bootie as a whole may also be determined by use of the Centrifuge test and the Whole Boot Moisture Vapor Transmission Rate Test, respectively, as laid out above.
[0156] The elasticity of the laminate and of the bootie may be measured according to DIN EN 14704-1 (July 2005), method A. The test may be carried out as set out therein, while using test samples of the following configuration: Test sample width=25 mm, test sample testing length=50 mm (testing length referred in DIN EN as gauge length, the length of the sample between the tensile machine clamps), whole length of test sample=100-150 mm. The test sample is subject to 3 to 5 consecutive test cycles. In each test cycle, the test sample is subject to a constant extension of 30% of said gauge length, in samples cut circumferentially and 10% of said gauge length in samples cut longitudinally to the formed bootie, and the maximum force of the last cycle is measured. The extension and retraction rate of the sample should be set to 250 mm/min. The specimen length is measured after final cycle finishes by laying it on a flat surface and measuring the length between applied reference markers within the gauge length with a calibrated ruler. The elastic recovery expressed in % is calculated through subtracting the final length between applied reference markers from the original length between said reference markers, dividing then by the original length between said reference markers, and finally multiplying the result by 100. Otherwise, test conditions are as set out in DIN EN 14704-1 (July 2015), method A. Elasticity is defined as a property of material in which the material extends at the application of a force or extension and recovers towards its original length after removing the applied force or extension. The elasticity of the specimen is therefore determined via measuring the force recorded during applied extension (or vice versa) and the ability of the material to recover towards its original length after said applied force or extension has been removed.
[0157] While the invention has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.
