Waterproof Fabric in a Running Shoe

Abstract

A running shoe includes a sole, an upper connected to the sole, a foot cavity defined at least in part with the upper, insulation incorporated into the upper adjacent to the foot cavity, and a waterproof fabric distally located with respect to the insulation and forming a protective exterior of the upper.

Claims

1. A running shoe, comprising: a sole; an upper connected to the sole; a foot cavity defined at least in part by the upper; a polyester liner formed in the upper adjacent to the foot cavity; insulation incorporated into the upper adjacent to the polyester liner; and a waterproof fabric distally located with respect to the insulation and forming a protective exterior of the upper.

2. The running shoe of claim 1, further comprising: a tongue connected to the upper; the tongue defining the foot cavity in part with the upper; and the waterproof fabric being incorporated in the tongue.

3. The running shoe of claim 2, wherein the waterproof fabric is incorporated on an exterior surface of the tongue.

4. The running shoe of claim 2, wherein the waterproof fabric incorporated into the tongue is adjacent to the foot cavity.

5. The running shoe of claim 2, further comprising a tongue gusset; the tongue gusset defining the foot cavity in part with the upper and the tongue; the tongue gusset including: a first side connected to the tongue; a second side connected to the upper; an inside surface adjacent to the foot cavity; and the waterproof fabric forming the inside surface.

6. The running shoe of claim 1, wherein the waterproof fabric is connected to the sole.

7. The running shoe of claim 1, wherein the waterproof fabric has a waterproof rating of at least 8,000 mm.

8. The running shoe of claim 1, wherein the waterproof fabric has a waterproof rating between 9,000 mm to 15,000 mm.

9. The running shoe of claim 1, wherein the waterproof fabric includes an air permeable membrane.

10. The running shoe of claim 1, wherein the waterproof fabric includes a polyurethane membrane.

11. The running shoe of claim 1, wherein the waterproof fabric transports moisture across its thickness through a diffusive mass transfer mechanism.

12. The running shoe of claim 11, wherein the waterproof fabric further transports moisture across its thickness through a convective mass transport mechanism.

13. A running shoe, comprising: a sole; an upper connected to the sole; a foot cavity defined at least in part by the upper; a polyester liner formed in the upper adjacent to the foot cavity; insulation incorporated into the upper adjacent to the polyester liner; a waterproof fabric distally located with respect to the insulation and forming a protective exterior of the upper; wherein the waterproof fabric transports moisture across its thickness through both a diffusive mass transfer mechanism and a convective mass transport mechanism; and wherein the waterproof fabric has a waterproof rating between 8,000 mm to 15,000 mm.

14. The running shoe of claim 13, further comprising: a tongue connected to the upper including the waterproof fabric being incorporated into the tongue; wherein the tongue defines the foot cavity in part with the upper.

15. The running shoe of claim 14, wherein the waterproof fabric is disposed on an outer surface of the tongue.

16. The running shoe of claim 14, wherein the waterproof fabric incorporated into the tongue is adjacent to the foot cavity.

17. The running shoe of claim 14, further comprising a tongue gusset; wherein the tongue gusset defines the foot cavity in part with the upper and the tongue; wherein the tongue gusset includes: a first side connected to the tongue; a second side connected to the upper; and an inside surface adjacent to the foot cavity, wherein the waterproof fabric forms the inside surface.

18. The running shoe of claim 13, wherein the waterproof fabric is connected to the sole.

19. The running shoe of claim 13, wherein the waterproof fabric includes an air permeable membrane.

20. A running shoe, comprising: a sole; an upper connected to the sole; a foot cavity defined at least in part by the upper; a polyester liner formed in the upper adjacent to the foot cavity; insulation incorporated into the upper adjacent to the polyester liner; a waterproof fabric distally located with respect to the insulation and forming a protective exterior of the upper. the waterproof fabric being connected to the sole; a tongue connected to the upper, wherein the tongue defines the foot cavity in part with the upper, and wherein the waterproof fabric forms an outer surface of the tongue; a tongue gusset further defining the foot cavity in part with the upper and the tongue; wherein the tongue gusset includes a first side connected to the tongue, a second side connected to the upper, an inside surface adjacent to the foot cavity, and the waterproof fabric forming the inside surface; wherein the waterproof fabric has a waterproof rating between 8,000 mm to 15,000 mm and includes an air permeable membrane that transports moisture across its thickness through both a diffusive mass transfer mechanism and a convective mass transport mechanism.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The accompanying drawings illustrate various embodiments of the present apparatus and are a part of the specification. The illustrated embodiments are merely examples of the present apparatus and do not limit the scope thereof.

[0028] FIG. 1 illustrates a side view of an example of a running shoe in accordance with the present disclosure.

[0029] FIG. 2 illustrates a top view of an example of a running shoe in accordance with the present disclosure.

[0030] FIG. 3 illustrates a bottom view of an example of a running shoe in accordance with the present disclosure.

[0031] FIG. 4 illustrates a back view of an example of a running shoe in accordance with the present disclosure.

[0032] FIG. 5 illustrates a side view of an example of a running shoe in accordance with the present disclosure.

[0033] FIG. 6 illustrates a side view of an example of a running shoe in accordance with the present disclosure.

[0034] FIG. 7A illustrates a front cross-sectional view of an example of a running shoe in accordance with the present disclosure.

[0035] FIG. 7B illustrates a rear cross-sectional view of an example running shoe in accordance with the present disclosure.

[0036] FIG. 8 illustrates an example of a cross section of an upper of a running shoe.

[0037] Throughout the drawings, identical reference numbers designate similar, but not necessarily identical, elements.

DETAILED DESCRIPTION

[0038] FIG. 1 depicts an example of a running shoe 100. In this example, the running shoe 100 includes a sole 102 and an upper 104 connected to the sole 102. The sole 102 and the upper 104 collectively form a foot cavity 106 that receives a foot of the user. The upper 104 includes a slit 108 that allows the size of the foot cavity 106 to vary as the user inserts and removes his or her foot. Further, a tongue 110 is connected to the upper 104 adjacent to the end of the slit 108. The tongue 110 fills the gap defined by the slit 108 when the user is wearing the running shoe 100. Eyelets 112 are incorporated into the upper 104 and define multiple openings in the upper 104 adjacent to the slit 108 that allow the user to tighten the foot cavity around his or her foot when the running shoe 100 is worn by the user.

[0039] The foot cavity 106 may include a sock liner that lines the bottom of the foot cavity 106. Also, the side walls of the foot cavity 106 may include other types of cushioning that reduce the jarring impacts when the user's shoe strikes the running surface and holds the upper snuggly against the user's feet throughout the running motion. In some cases, the cushioning lines the entire surface of the foot cavity's wall. In other examples, the cushioning is a subset of the foot cavity 106.

[0040] In this example, the running shoe's upper 104 includes a low top profile 116 where the upper terminates underneath or at the user's ankle. The low top profile 116 provides the running shoe with a lower weight and provides the user additional movement.

[0041] The protective exterior 118 of the upper 104 is made of a waterproof fabric. In the example of FIG. 1, the protective exterior 118 is connected to the sole 102 of the running shoe 100. The waterproof fabric may have a characteristic of having a waterproof rating between 8,000 mm to 15,000 mm. Further, the waterproof fabric includes an air permeable membrane. In some cases, the air permeable membrane is a polyurethane membrane. According to another embodiment, the waterproof fabric includes a rip stop nylon woven/nylon tricot having a top layer of nylon, an inner layer of polyurethane, and bottom layer of nylon, wherein the front layer of nylon is woven and the back layer of nylon is tricot. Alternatively, the waterproof fabric may include a top polyurethane layer backed by a nylon layer. According to one embodiment, the air permeable membrane has a weight of approximately 5.0 oz. per square yard. In one embodiment, the waterproof fabric exhibits the properties illustrated in Table 1 below.

TABLE-US-00001 TABLE 1 SPECIFICATION TEST TEST METHOD REQUIREMENT Shrinkage AATCC 135 Maximum Specification Length: 5% Width: 5% Colorfastness to ISO 105-C06 Minimum Specification LaunderingStain Nylon: 3 Colorfastness to ISO 105-X12 Minimum Specification: Rubbing Wet: 3 Dry: 4 Colorfastness to Light ISO 105-B02 Minimum Specification: 20 hrs 4 Durable Water AATCC 22-1980 Minimum Specification: Repellency 80 Colorfastness to Water- ISO 105 E01 Minimum Specification Stain Nylon: 3 Colorfastness to ISO 150-E04 Minimum Specification Perspiration Nylon: 3 Hydrostatic Pressure AATCC127-2008 Minimum Specification: (w/mesh) 24 Hour wash (no 10,000 Minimum detergent) 5,000 Minimum Air Permeability ASTM D 737 Minimum Specification: After 24 hrs 0.20 Maximum Specification: 1.00 Delamination 20 HRS Minimum Specification: PASS CPSC Flammability 16CFR 1610.37D Class 1 Fabrics Act Exemption

[0042] The air permeable membrane may exhibit a first characteristic of transporting moisture from within the shoe across the membrane's thickness through a diffusive mass transfer mechanism where the moisture build on the inside of the foot cavity causes the inside moisture to be transported across the air permeable membrane to equalize with the moisture concentration of the ambient environment outside of the foot. Additionally, the waterproof fabric exhibits a second characteristic of transporting moisture across its thickness through a convective mass transport mechanism. A convective mass transport mechanism includes transporting the inside moisture across the membrane with a gas carrier. In this case, the waterproof fabric can allow a small amount of air to pass through the waterproof fabric to accelerate the process of transporting moisture to the outside of the upper's protective exterior.

[0043] FIG. 2 depicts a top view of an example of a running shoe 200. In this example, a foot cavity 202 is defined by an upper 204 of the running shoe 200. A portion of a sock liner 206 is visible though an opening 206 in the upper 204 where the user inserts his or her foot. A tongue 208 is positioned within a slit defined in the upper 204. Adjacent to the slit's edges 212, eyelets 214 provide an opening for a shoe string 216 to tighten the upper 204 around the user's foot. In this example, the upper 204 includes a protective exterior 218 made of a waterproof fabric.

[0044] FIG. 3 depicts a bottom view of an example of a running shoe 300. In this example, the running shoe 300 has a sole 302 with a tread 304.

[0045] FIG. 4 depicts a back view of an example of a running shoe 400. In this example, the upper 402 is attached to the shoe's sole 404. A gaiter connection 406 is incorporated into the upper's protective exterior 408, which allows a gaiter to be attached to the running shoe 400. In some examples, the upper 402 includes a heel counter such as a plastic insert disposed between the layers that make up the upper. The heel counter reinforces the back portion of the upper and increases the user's support. In this example, the protective exterior 408 is made of a waterproof fabric. In some cases, the gaiter connection 406 includes Velcro, a button, a snap, a latch, or another type of mechanism that allows the gaiter to attach directly to the back portion of the running shoe.

[0046] FIG. 5 depicts a side view of an example of running shoe 500. In this example, the running shoe 500 includes an upper 502 that surrounds the user's ankle. The high-top profile of the upper 500 can provide additional lateral support to the user at the user's ankle joint. In this example, the upper 502 includes a protective exterior 504 made of a waterproof fabric.

[0047] FIG. 6 depicts an example of a running shoe 600. In this example, the running shoe 600 includes a sole 602 and an upper 604 connected to the sole 602. In this example, the upper 604 includes a protective exterior 606 made of a waterproof fabric.

[0048] FIG. 7A depicts a front cross-sectional view of an example of a running shoe 700 viewed from the toe portion of the running shoe. In this example, the running shoe 700 includes a sole 702 attached to an upper 704. The sole 702 includes an outsole 706 that contacts the surface upon which the user runs and a midsole 708 that is located adjacent to the foot cavity 710. The upper 704 includes a slit 712 that opens to make it easier for the user's foot to be inserted and removed from the foot cavity 710. A tongue 714 is positioned underneath the slit 712, and a gusset 716 connects an edge 718 of the tongue 714 to the inside surface 720 of the upper 704. As shown, the gusset 716 provides extra material to allow for added space when putting the running shoe 700 on.

[0049] FIG. 7B provides a rear cross-sectional view of an example running shoe 700 viewed from the heel portion of the shoe. FIG. 7B further illustrates the possible construction of the running shoe. As shown, at least portions of the upper 704 include multiple layers. An inner layer of the upper 704 that is adjacent to the foot cavity 710 includes a polyester liner 722, and a layer of insulation 723, and the outer water proof layer forms a protective exterior 724 of the upper 704. The protective exterior 724 is formed by a waterproof fabric. The tongue 714 includes the waterproof fabric on an inside surface 726 that is adjacent to the foot cavity 710 in the embodiment of FIG. 7A, while in FIG. 7B, the tongue construction includes an outer protective exterior 724, a foam layer of insulation 723, and an inner polyester liner 722. The placement of the outer protective exterior 724 on the tongue prevents any water take up that would weigh down the tongue and the shoe. Further, the gusset 716 also includes the waterproof fabric forming a protective exterior 724. As illustrated, the gusset 716 may include an outer polyester liner 722 and an inner protective layer made of the protective exterior material on its inside surface 728. Alternatively, the gusset 716 may be made entirely of the material forming the protective exterior 724, as illustrated on the right side of the exemplary running shoe 700.

[0050] FIG. 8 depicts an example of a cross section of the upper 800. In this example, the inside layer 802 is adjacent to the foot cavity 804. The protective exterior 804 includes a waterproof fabric that is distally located away from the foot cavity 804 on the opposite side of the inside layer 802. In some cases, the waterproof fabric includes a water proof rating of 8,000 mm to 15,000 mm. In these circumstances, the pore size of the waterproof fabric is large enough to allow water vapor in the foot cavity and/or moisture absorbed by the first layer to exit from the shoe through the waterproof fabric. However, the pore size in the waterproof fabric is small enough to exclude water particles that would come from the ambient environment such as water from rain, mud puddles, or other sources. Thus, water can move from the inside of the shoe to the outside through a diffusive mechanism, which is depicted in FIG. 8 at 806. The diffusive water transport mechanism 806 allows some water to be removed from the inside of the running shoe or from the inside layers of the running shoe.

[0051] The waterproof fabric that forms the protective exterior also includes a second, convective water transport mechanism 808. The convective water transport mechanism 808 is enabled due to the waterproof fabric being air permeable such that a small amount of air passes through the waterproof fabric from the outside of the running shoe and then leaves back out of the shoe through the waterproof fabric. This additional air circulation accelerates the removal of water moisture inside the foot cavity or water moisture inside the upper's insulation in the inside layer. The lines schematically representing the convective water transport mechanism 808 are thicker than the lines schematically representing diffusive water transport mechanism to depict that more water moisture is removed from the convective water transport mechanism 808 than through the diffusive water transport mechanism 806.

GENERAL DESCRIPTION

[0052] In general, the invention disclosed herein may provide users with a running shoe that has a waterproof layer that allows moisture on the inside of the running shoe to leave. By placing the waterproof fabric of the running shoe on the outside of the upper, water is prevented from making contact with the other layers of the upper. For example, conventional running shoes that have a waterproof layer buried under a protective layer have the characteristic of absorbing water in the protective layer, which makes the running shoe heavier. The principles of the present invention incorporate the waterproof layer into the protective exterior so that the running shoe does not absorb water from outside of the running shoe.

[0053] Further, the principles described herein also include using an air permeable waterproof fabric. Conventional running shoes that incorporate a breathable, waterproof material generally rely on just a diffusive water transport mechanism. The diffusive water transport mechanism works based on diffusion and draws water moisture out of the shoe because the outside of the running shoe has a drier climate than in the foot cavity. The diffusive water transport mechanism thus requires that a water moisture content build up in the foot cavity of the shoe before the water diffuses to the outside of the shoe. For example, the user's foot has to be wet from sweat or have water enter another way before the sweat/water is transported out of the running shoe. The principles described herein include using a waterproof fabric that exhibits the additional characteristic of having an additional water transport mechanism, namely a convective water transport mechanism. The convective water transport mechanism is enabled by having the waterproof fabric be an air permeable material that allows more air to pass through the waterproof fabric than conventional waterproof materials, which are impermeable to wind. The additional air circulation in the waterproof material of the current system allows the moisture in the shoe to be removed at an accelerated rate without the foot cavity needing to have a moisture build up. In other words, the convective water transport mechanism occurs regardless of the amount of moisture content on the inside of the running shoe. Thus, the user's foot stays drier than with conventional running shoes with other kinds of waterproof materials. In some examples, the waterproof fabric has a lower waterproof rating than conventional waterproof materials to enable the air circulation. To enable the air circulation while maintaining a degree of waterproofness, the waterproof material may have a waterproof rating of 8,000 mm to 15,000 mm. Often, commercial materials that purport to be waterproof have a waterproof rating of over 25,000 mm. But, these running shoes suffer from the user's foot still being wet from the user's own sweat. Thus, the waterproof fabric of the present invention allows the user to have a drier foot despite having a lower waterproof rating.

[0054] The running shoe of the present system and method may include a sole that is made up of two distinct layers, the outsole and the midsole. The outsole may contact the ground. The outsole may be made of a hard, abrasion resistant material that resists wear, provides traction, and allows flexibility

[0055] The outsole may include a rubber compound with a high carbon content at the heel and in the toe box areas. The outsoles can be constructed with studs or ridges to provide traction on slippery surfaces, such as wet grass or slick pavement. In some examples, the outsole can include transverse grooves in the toe box area so that the running shoe is more flexible in the toe box area when the user's weight is loaded against the ball of the user's foot while the heel is raised off of the ground. Generally, the wider the outsole, the greater stability the outsole provides the foot. But, the wide outsole also increases the weight of the shoe. In some examples, the running shoe may include an outsole that is just as wider or has a width that is less than 5.0 percent greater than width of the corresponding sections of the shoe. Having a narrow outsole reduces the weight of the running shoe.

[0056] The midsole of the sole is located above the outsole. The midsole is made of a material that provides cushioning. The total height of the midsole and outsole under the heel may be about 1.0 inch and the total height of the midsole and outsole under the toe box is about 0.6 inches. The difference in sole thickness between the heel and toe box in can reduce the strain on the user's Achilles tendon. This drop in the height of the sole from the heel to the toe box may affect how the user's foot strikes the ground. In some cases, the heel drop may range from 4 mm to 10 mm. The running shoe's sole may be thicker than the soles of shoes that are intended for walking or other types of activities.

[0057] The midsole may be constructed of various materials to provide cushioning. In some cases, the midsole is made of ethyl vinyl acetate (EVA) or polyurethane. EVA is a copolymer of ethylene and vinyl acetate that has microscopic air bubbles within it that makes it lightweight while providing a good amount of cushioning. Polyurethane also has a microscopic air bubble structure like EVA but is generally firmer and more resistant to compression than EVA.

[0058] Conventional uppers are made of a combination of lightweight nylon to reduce the running shoe's weight. The upper of a running shoe may also incorporates a stiff heel counter that is commonly stiffer than in other athletic shoes to help control excessive pronation or supination during running.

[0059] Any appropriate type of running shoe may be used in accordance with the principles described herein. For example, the running shoe may include a low-top profile where the upper terminates just below the user's ankle. While a low-top upper may provide less lateral stability, the running shoe is lighter. In other examples, the running shoe includes a high-top profile. In this example, the running shoe includes an upper that extends over the user's ankle.

[0060] The waterproof fabric forms the protective exterior of the upper. This prevents water from entering the shoe through the upper. The tongue of the running shoe may also include a waterproof fabric. In some circumstances the waterproof fabric of the tongue has the same characteristics as the waterproof fabric incorporated into the upper. The waterproof fabric may be located on the underside of the tongue that is adjacent to the foot cavity, which is in contrast to the waterproof fabric of the upper that is located on the outside of the upper. The tongue may be connected to the upper along the tongue's edges with a gusset. The gusset may also be lined with the waterproof material. In some cases, the gusset's waterproof fabric is located on the inside surface that is adjacent to the foot cavity. In other examples, the gusset's waterproof fabric is located on the outside surface of the gusset.

[0061] In some cases, the waterproof fabric includes a water proof rating of 8,000 mm to 15,000 mm. A mm rating refers to the amount of rainfall a fabric can withstand in a single day. Thus a 10,000 mm waterproof rating means the garment can withstand 10,000 mm of rainfall in a single day without letting moisture in. The higher the number, the more waterproof the fabric is. Many commercially available waterproof materials have a waterproof rating of over 25,000 mm.

[0062] The pore size of the waterproof fabric disclosed herein is large enough to allow water vapor in the foot cavity and/or water vapor absorbed by the first layer to exit through the waterproof fabric. But, the pore size in the waterproof fabric is small enough to exclude water particles that would come from the ambient environment such as water from rain, mud puddles, or other sources. Thus, water can move from the inside of the shoe to the outside through a diffusive mechanism. The diffusive water transport mechanism allows some water to be removed from the inside of the running shoe or from the inside layers of the running shoe.

[0063] The waterproof fabric that forms the protective exterior also includes a second, convective water transport mechanism. The convective water transport mechanism is enabled due to the waterproof fabric being air permeable such that a small amount of air passes through the waterproof fabric. This additional air circulation accelerates the removal of water moisture inside the foot cavity or water moisture inside the upper's insulation in the inside layer. Convective mass transport works largely via advection or the transport of water through air motion. The convective mass transfer does not require sweat build up. The waterproof fabric can transport air out of the shoe when the user's foot is inserted into the shoe or not.

[0064] The types of water that can be transported out of the shoe include the user's sweat, but also includes the water that gets into the user's running shoe through other mechanisms. For example, if the user runs through a flowing creek during his or her run, water may spill over the edge of the running shoe's upper and into the foot cavity. This water may get absorbed into the insulation layer of the upper, the user's sock, or pool within the foot cavity. The air permeability may actively transport this water out of the upper's insulation and/or the user's sock. Water that is pooled may also be removed through the waterproof fabric's air permeable characteristics.

[0065] As noted above, conventional waterproof/breathable uppers use a membrane bonded to the interior of the upper's linings forming waterproof bootie inside the athletic shoe. This membrane blocks moisture from entering the shoe while allowing feet to breathe. Shoes with these membranes keep feet dry in wet environments with a trade-off in breathability. Additionally, the non-waterproof exterior portions of traditional shoes then absorbs water and become weighed down, even though the moisture may not reach the wearer. In contrast, the present exemplary system excludes moisture from entering the shoe and weighing down the shoe unnecessarily. Additionally, by placing the waterproof/breathable upper on the exterior of the shoe, a more rigid material may be used, which would be unsuitable for use as an interior liner of the shoe. This characteristic allows for the use of the breathable waterproof fabric disclosed above.

[0066] For the purposes of this disclosure, the term air permeability refers to the amount of air that flows through a fabric. Generally, as air flows through a fabric, cooler air from the ambient environment is exchanged with warmer air within the running shoe's foot cavity on the inside of the fabric. This air exchange lowers the temperature inside the foot cavity, but because the user's foot stays dry, the user feels like his or her feet stay warmer. Air permeability is the opposite of windproof and is not the same thing as breathability.

[0067] For the purposes of this disclosure, the term breathable refers to a fabrics ability to allow internal moisture to escape the fabric. This movement is determined by the difference in humidity between the foot cavity and the ambient air outside the fabric. The movement of the internal moisture is controlled, in part, by the physical resistance of the fabric layers. The humidity difference can be affected by a user's activity level, which induces sweating, and the humidity in the ambient environment. The physical resistance of the fabric generally increases with fabric thickness. Thus, thicker layers are generally have more resistance and breathe less.

[0068] A fabric's wind resistance is usually measured in miles per hour (mph) or cubic feet per minute (cfm). Most commercially waterproof/breathable rainwear fabric is is promoted as 100 percent windproof. In the current disclosure, the waterproof fabric is less than 100 percent windproof.