FOOTWEAR ASSEMBLY

Abstract

Disclosed is a footwear assembly (10) for forming at least part of an upper assembly of footwear, the footwear assembly defining an instep opening (8) and comprising: a water vapor permeable and waterproof functional layer (12) having a first elasticity, and a collar layer (14) attached to the water vapor permeable and waterproof functional layer (12) such as to define at least part of the instep opening (8), the collar layer (14) having a second elasticity.

Claims

1. Footwear assembly for forming at least part of an upper assembly of footwear, the footwear assembly defining an instep opening and comprising: a water vapor permeable and waterproof functional layer having a first elasticity, and a collar layer attached to the water vapor permeable and waterproof functional layer such as to define at least part of the instep opening, the collar layer having a second elasticity.

2. The footwear assembly according to claim 1, wherein the collar layer has elastic properties in more than one direction.

3. The footwear assembly according to claim 1, wherein the second elasticity is equal to, or larger, than a predetermined threshold.

4. The footwear assembly according to claim 1, wherein the second elasticity is equal to, or larger, than the first elasticity.

5. The footwear assembly according to claim 1, wherein the collar layer extends along at least 30% of the instep opening, particularly along at least 60% of the instep opening, particularly along at least of the instep opening.

6. The footwear assembly according to claim 1, wherein the collar layer is attached to the water vapor permeable and waterproof functional layer by means of an elastic seam.

7. The footwear assembly according to claim 6, wherein the elastic seam is formed by a thread having a third elasticity.

8. The footwear assembly according to claim 6, wherein the elastic seam is formed by a stitch pattern providing elastic characteristics.

9. The footwear assembly according to claim 6, wherein the elastic seam extends along at least 30% of the circumference of the instep opening, particularly along at least 60% of the circumference of the instep opening, particularly along at least of the circumference of the instep opening.

10. The footwear assembly according to claim 1, wherein the first elasticity and the second elasticity are measured in the same direction.

11. The footwear assembly according to claim 1, wherein the first elasticity and the second elasticity are measured in a direction parallel to the horizontal direction.

12. The footwear assembly according to claim 6, wherein the water vapor permeable and waterproof functional layer and the collar layer are attached to each other via a seam and the first elasticity and the second elasticity are measured in a direction parallel to the seam.

13. The footwear assembly according to claim 6, wherein a composite sample piece made of the water vapor permeable and waterproof functional layer and the collar layer attached to each other by a seam has a fourth elasticity, the fourth elasticity being equal to, or larger, than a predetermined threshold.

14. The footwear assembly according to claim 1, wherein the water vapor permeable and waterproof functional layer has the configuration of a laminate made up with a water vapor permeable and waterproof membrane and a textile layer attached to the water vapor permeable and waterproof membrane.

15. The footwear assembly according to claim 14, wherein the textile layer has an elastic textile configuration.

16. The footwear assembly according to claim 14, wherein the textile layer comprises elastic filaments.

17. The footwear assembly according to claim 1, wherein the water vapor permeable and waterproof functional layer includes a water vapor permeable and waterproof film made of a fluoropolymer, particularly ePTFE.

18. The footwear assembly according to claim 1, wherein the collar layer is water vapor permeable, but not waterproof.

19. The footwear assembly according to claim 1, having the configuration of an upper lining.

20. The footwear assembly according to claim 1, having the configuration of a water vapor permeable and waterproof sock.

21. The footwear assembly according to claim 1, having the configuration of a water vapor permeable and waterproof upper lining attached to a waterproof upper bottom.

22. The footwear assembly according to claim 1, wherein the water vapor permeable and waterproof functional layer extends to a height of at least 20% of the height of the footwear assembly, particularly to a height of at least 65% of the footwear assembly, particularly to a height of at least 95% of the footwear assembly.

23. The footwear assembly according to claim 1, wherein the collar layer comprises elastic extensions on its side opposite the water vapor permeable functional layer, the extensions being configured to be folded over and attached to an upper material layer, such as to form a backing layer covering openable portions, tongue portions and/or gusset portions of the upper material layer.

24. Upper assembly of footwear, the upper assembly comprising: an upper material layer surrounding at least an upper portion of a foot, and a footwear assembly comprising a water vapor permeable and waterproof functional layer having a first elasticity, and a collar layer attached to the water vapor permeable and waterproof functional layer such as to define at least part of the instep opening, the collar layer having a second elasticity, wherein the footwear assembly forms an upper lining arranged on an inner side of the upper material layer, the upper lining being independent of the upper material layer to such extent that the upper lining at least in the region of the first functional layer and the elastic collar is able to adapt its shape independent of the upper material layer.

25. The upper assembly according to claim 24, wherein the upper material layer and/or the upper lining is configured to be attached to an upper bottom layer in such a way as to form a waterproof and water vapor permeable upper assembly.

26. The upper assembly according claim 24, wherein the upper material layer comprises at least one openable portion, tongue portion and/or gusset portion, and the collar layer of the upper lining comprises elastic extensions on its side opposite the water vapor permeable and waterproof functional layer, the extensions being folded over and attached to the upper material layer, such as to form a backing layer covering the at least one openable portion, tongue portions and/or gusset portions of the upper material layer.

Description

[0037] The invention will be described in more detail in the following by way of exemplary embodiments which are sown in the figures. These show:

[0038] FIG. 1 shows a highly simplified and schematic view of a footwear assembly having the configuration of a water vapor permeable and waterproof functional layer bootie for a low cut shoe;

[0039] FIG. 2 shows a highly simplified and schematic view of a footwear assembly having the configuration of a water vapor permeable and waterproof functional layer bootie for a mid cut shoe;

[0040] FIG. 3 shows a highly simplified and schematic view of a footwear assembly having the configuration of a water vapor permeable and waterproof functional layer bootie for a high cut shoe;

[0041] FIG. 4 shows a highly simplified and schematic view of a footwear assembly having the configuration of a water vapor permeable and waterproof functional layer bootie for a mid cut shoe with an upper material layer attached to the footwear assembly;

[0042] FIG. 5 shows a highly simplified and schematic view of the footwear assembly of FIG. 4 in a view from the from tip of the footwear; and

[0043] FIG. 6 shows a highly simplified and schematic view of a mid cut footwear comprising the footwear assembly of FIGS. 4 and 5, in a completed state.

[0044] FIGS. 1 to 3 show highly simplified and schematic views of a footwear assembly 10 having the configuration of a water vapor permeable and waterproof functional layer bootie. FIG. 1 shows a bootie for a low cut shoe. FIG. 2 shows a bootie for a mid cut shoe, and FIG. 3 shows a bootie for a high cut shoe. The following considerations relate to all embodiments shown in FIGS. 1 to 3, unless explicit reference is taken to only one of the Figs.

[0045] The footwear assembly 10 (bootie) comprises a water vapor permeable and waterproof functional layer laminate 12, as described above, and a collar layer 14. The collar layer 14 is attached to the functional layer laminate 12 such as to form an upper portion of the footwear assembly 10 and surrounding an instep opening 8. The collar layer 14 is attached to the water vapor permeable and waterproof functional layer laminate 12 by an elastic seam 18. The collar layer 14 is made from an elastic fabric having elasticity in two dimensions, namely the warp and weft directions of the fabric. The collar layer 14 is made from a fabric having required elastic characteristics to allow easy donning and doffing, particularly applying only moderate forces and not requiring to open any laces or zippers. However, the collar layer 14 is not waterproof.

[0046] The water vapor permeable and waterproof functional layer 12 is a laminate formed by a water vapor permeable and waterproof membrane and a textile layer attached to the water vapor permeable and waterproof membrane. The water vapor permeable and waterproof functional membrane may be made from expanded PTFE which is attached to a supporting textile layer according to the teaching of U.S. Pat. No. 5,804,011. The microporous polytetrafluoroethylene membrane is a membrane of expanded polytetrafluoroethylene as taught in U.S. Pat. Nos. 3,953,566 and 4,187,390, to Gore. The water vapor permeable and waterproof functional layer may be composed of a polyurethane coated microporous expanded polytetrafluoroethylene membrane made substantially according to the teachings of U.S. Pat. No. 4,194,041 and U.S. Pat. No. 4,942,214 assigned to W.L. Gore and Associates, Inc, in Elkton, Md. The membrane may also be made of polyurethane (PU), polyether ester (PES), polyethylene or combinations of these materials.

[0047] Water Vapor Permeability (WVP) as used herein concerning the functional layer may be tested as defined in EN ISO 15496 (2004), also known as the Cup Test. A 2020 cm or 100 mm sample of functional layer or functional layer 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 functional layer into the cup, whose weight increase is then determined. The functional layer is considered water vapor permeable or breathable if the WVP is greater than or equal to 0.01 g/(Pa*m.sup.2*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. In case a smaller cup is used, the applied area in the calculation needs to be adjusted, accordingly.

[0048] A functional layer may be considered waterproof in case a 100 cm.sup.2 sample of the material under investigation is able to withstand a water ingress pressure of at least 0.05 bar. Particularly, the material may even withstand a water pressure of at least 1 bar. The method for carrying out this test is described in the ISO Standard No. 811 (1981) (EN 20811 (1992)).The measurement is carried out by exposing a 100 cm.sup.2 sample of the material under investigation to a rising water pressure. For this purpose, distilled water having a temperature of 202 C. is used. The rise in the water pressure is 603 cm H.sub.2O/min. The water ingress pressure of the sample under investigation is that pressure at which water passes through the opposite side of the sample under investigation. If a 100 cm.sup.2 sample cannot be obtained, a smaller sample may be used for the measurement. There is a linear correlation between sample size and water ingress pressure, so that the water ingress pressure may be calculated for a 100 cm.sup.2 sample.

[0049] The water vapor permeable and waterproof membrane is attached to a textile layer in such a way that the water vapor permeable and waterproof functional layer 12 has the configuration of an elastic laminate having at least one direction of elasticity, usually in the machine direction. In some configurations, the water vapor permeable and waterproof functional layer may have elasticity in two directions, as shown in U.S. Pat. No. 5,804,011, for example. To impose elastic characteristics to the laminate, the textile layer may have an elastic textile configuration, e.g may be made as a knit having an elastic knit pattern (like a tricot, warp knit, or similar knit pattern). In such case the textile need not necessarily include elastic threads to provide the desired elastic characteristics. However, in a number of configurations, it may be helpful if the textile layer comprises elastic filaments, e.g. made from elasthane to further enhance the elasticity of the textile layer. In FIGS. 1 to 3, the main direction of elasticity of the water vapor permeable and waterproof functional layer 12 is indicated by the arrow A. The main direction of elasticity of the water vapor permeable and waterproof functional layer 12 is directed in the direction where the most elongation and flexibility is required when donning or doffing a footwear article with the footwear assembly 12 having the configuration of a bootie. Tests have shown that such direction of most elongation and flexibility is the direction from the heel to the toe of the bootie for all bootie configurations shown in FIGS. 1 to 3.

[0050] In all embodiments shown in FIGS. 1 to 3, the main direction of elasticity of the functional layer laminate 12 and the main direction of elasticity of the collar layer 14 are directed parallel to the direction A in which most flexibility and elongation is required for donning and doffing. Also the elastic seam 18 connecting the functional layer laminate 12 with the collar layer 14 is directed parallel to such direction A in which most flexibility and elongation is required for donning and doffing. The elastic seam 18 has the configuration of a zig zag stitch which provided for elasticity irrespective of whether an elastic thread is used to carry out the stitches.

[0051] There is a difference between the low cut bootie 10 shown in FIG. 1, the mid cut bootie 10 shown in FIG. 2, and the high cut bootie 10 shown in FIG. 3 with respect to the height where the most elongation and flexibility is required when donning or doffing. In the low cut bootie 10 (see FIG. 1), the most flexibility is required at a height substantially equal to the height of the instep opening 8, as the bootie only extends up to a height slightly below the ankle of the foot and roughly up to the height of the instep of the foot. Also for the mid cut bootie 10 shown in FIG. 2, the most flexibility for donning and doffing is required at a height roughly equal to the height of the instep of the foot. However, in this configuration, the bootie extends up to a height slightly above the ankle of the foot, and hence the height of maximum elongation and flexibility is at some distance below the height of the instep opening 8. For the high cut bootie 10 shown in FIG. 3, the bootie extends up to a height well above the ankle of the foot. In this configuration, it has turned out that the height of maximum elongation for donning and doffing is only slightly above the ankle of the foot, and thus is substantially lower than the height of the instep opening 8. In all embodiments as shown in FIGS. 1 to 3, the functional layer laminate 12 extends up to such a height that the elastic seam 18 connecting the functional layer laminate 12 and the collar layer 14 is roughly in the same height as the height of maximum elongation when donning or doffing a footwear including the respective bootie 10. Such configuration allows to optimally use the elasticity provided by the collar layer 14 to provide flexibility for donning and doffing, and fit the foot in the region around the ankle, when the footwear is used. It is however important in such configuration that the seam 18 provides sufficient elasticity to avoid losing the additional elasticity provided by the collar layer 14.

[0052] Moreover, the configuration of the height of the elastic seam 18 as shown in FIGS. 1 to 3 allows the waterproof functional layer laminate 12 to extend up to a height as far as possible, thereby ensuring maximum waterproofness of the footwear. This even applies for the low cut bootie of FIG. 1, since in this configuration the functional layer laminate may extend almost up the maximum height of the bootie (e.g. the functional layer laminate may extend up to 90%, or even up to 95%, of the height of the bootie below the instep opening 8). For the mid cut bootie of FIG. 2, the functional layer laminate may extend up to about 70% to 90%, in most cases up to about 75 to 85%, of the height of the bootie 10 at the instep opening 8. However, in absolute height this is still the same height, or even higher, than with the low cut bootie 10, in any case the functional layer laminate 12 always may extend up to a height roughly comparable to the instep of the foot. With respect to the high cut bootie 10 shown in FIG. 3, in order to allow easy donning and doffing it is advisable to allow the collar layer 14 to extend at a substantial vertical portion below the instep opening 8, down to a height slightly above the ankle of the foot where the maximum elongation during donning and doffing will be required (see the constriction in the bootie cross section visible in FIG. 3). Therefore, the functional layer laminate will extend into much less height when expressed in relative terms with respect to the height of the instep opening, roughly up to a height of 60% to 80%, particularly up to a height of 65% to 75% of the height of the instep opening. However, such height is still well above the ankle and thus provides for sufficient waterproofness.

[0053] In the embodiments shown in the FIGS. 1 to 3 the footwear assembly 10 forms an upper lining bootie to be attached to the inner side of an upper material 30 (see FIGS. 4-6) of an upper assembly. The upper lining bootie 10 has a sock shape configuration formed by two of the water vapor permeable and waterproof functional layers 12 and an upper bottom functional layer 22. As more clearly visible in FIG. 5 the water vapor permeable and waterproof functional layer 12 forms one of two upper side parts 12 of the bootie 10. Both upper side parts 12, 12 are connected with each other by a longitudinally extending seam 13 which is sealed by a seam tape (not shown). The upper bottom layer functional layer 22 is connected to each of the two water vapor permeable and waterproof functional layers 12, 12 also by way of seams which are sealed by respective seam tapes (not shown).

[0054] Also visible in FIGS. 1 and 2 is a tongue portion 16 formed by the collar layer 14. The tongue portion 16 is also connected to the water vapor permeable and waterproof functional layer laminate 12 by way of an elastic seam 20. As more clearly shown in FIGS. 4 to 6, the tongue portion 16 comprises an extension portion 26 which is folded over at the instep opening 8 such that the folded over section 26 may be connected to the inner side of an upper material 30, and thus forms a water gusset portion (see particularly FIGS. 4 and 5). As the material of the collar layer 14 is highly elastic, such water gusset portions 26 allow a foldfree fit of the tongue portion 26 to the foot at each time, including donning and doffing. Conventional water gussets, which would lead to folds, are completely superfluous. This increases comfort.

[0055] FIG. 4 shows a highly simplified and schematic view of a mid cut footwear assembly having the configuration of a water vapor permeable and waterproof functional layer bootie 10 for a mid cut shoe with an upper material layer 30 attached to the footwear assembly. FIG. 5 shows a highly simplified and schematic view of the footwear assembly of FIG. 4 in a view from the toe portion of the footwear. FIG. 6 shows a highly simplified and schematic view of the mid cut footwear comprising the footwear assembly of FIGS. 4 and 5, in a completed state.

[0056] As can be seen in FIGS. 4 to 6, the upper material layer 30 is attached to the footwear assembly 10 in the region of the instep opening 8. Thus, it is particularly helpful in case the collar layer 14 comprises elastic extensions 24, 26, 28 on its side opposite the water proof and water vapor permeable functional layer 12. These extensions 24, 26, 28 are be configured to be folded over and attached to the upper material layer 30 on an inner side thereof. Thereby, the extensions 24, 26, 28 form a backing layer covering openable portions (like the zipper portion 32 of the upper material 30 visible in FIG. 6), tongue portions and/or water gusset portions of the upper material layer 30. In such configurations, the collar layer 14 may be folded over at the periphery of the instep opening 8 such that the extensions 24, 26, 28 extend from the instep opening 8 downwards. The extensions may be arranged between the upper material and the footwear assembly. The downwards extending portions 24, 26, 28 are attached to the inner side of the upper material layer 30 and thereby allow to cover any openable portions in the upper material layer 30 by an elastic layer on the inner side. This is a particularly elegant design to cover openings or slits in the upper material 30, which would otherwise have to be covered by some flexible material. E.g. water gusset portions required laterally from a tongue in conventional footwear designs might be replaced completely by such folded over extensions 24, 26 of the elastic collar layer. The same applies to any portions in the upper material layer where zippers 32 are provided. The slits in the upper material being created when the zipper 32 is opened might be easily backed by the elastic material of the folded over extensions 28 of the collar layer 14.