Conformable Booties, Shoe Inserts, and Footwear Assemblies Made Therewith, and Waterproof Breathable Socks

Abstract

Waterproof, breathable socks, booties, shoe inserts, and footwear assemblies containing the shoe inserts are provided. The booties and shoe inserts include a laminate of a seamless ePTFE membrane and at least one textile. The bootie is conformable over a range of sizes and shoe shapes, and may be shaped to fit numerous sizes and shapes of asymmetrical shoe lasts. The bootie may shrink to fit, or, alternatively, be stretched to fit, an asymmetrical last having a desired size to form a shoe insert. Such a conformable bootie eliminates the need to have multiple sizes of shoe inserts correlating to particular shoe sizes. In embodiments where the ePTFE is seamless and continuous, the shoe insert eliminates the need for a waterproof seam tape, which is conventionally used to make shoe inserts waterproof. Methods of forming the socks, booties, and shoe inserts are also provided.

Description

FIELD OF THE INVENTION[0001]The present invention relates generally to shoe inserts, and more specifically, to waterproof, breathable booties that are conformable over a range of shoe sizes. Shoe inserts incorporating the booties and methods of making the conformable seamless booties and shoe inserts are provided. Footwear assemblies and waterproof, breathable socks are also provided.BACKGROUND OF THE INVENTION[0002]Waterproof, breathable footwear is typically formed of an upper material which is both air permeable and water permeable. The outer layer of the upper material may be leather and / or a textile fabric. Waterproofness is achieved through the use of a waterproof, water-vapor permeable functional material that is arranged within the shoe. In the footwear art, materials which are both waterproof and water vapor permeable are commonly referred to as “functional” materials. The functional layer may be made of an expanded polytetrafluoroethylene (ePTFE) material available from W....

AI Technical Summary

Benefits of technology

The present invention is a shoe insert that has a seamless ePTFE membrane. This ePTFE membrane provides better breathability and comfort for the user compared to shoes made with traditional shoe inserts that are sewn together and sealed. The shoe insert closely conforms to the inside of the shoe, reducing air gaps and improving the fit. The bootie is also conformable over a range of shoe sizes and shapes. Additionally, the sole portion of the shoe can also have breathability. The invention also results in less wrinkling, which further enhances wear comfort.

Problems solved by technology

It is difficult to sew the functional layer directly to the upper and / or sole material of the footwear.

One problem that often results when forming such waterproof, breathable footwear is that the insertion of the shoe insert often results in a poor fitting shoe (i.e., the shoe insert has a different fit (shape or size) to that of the already sized upper) and / or poor attachment between the shoe insert and the shoe upper material, which results, among other things, in a less than desirable appearance of the inside of the footwear (i.e., the shoe insert appears wrinkled or pulls away from the upper).

An additional problem is that because of the multiple laminate pieces or panels needed for manufacturing an article of waterproof footwear, flexibility may be severely compromised.

A further problem is that sealing the seamed portions of the shoe insert to make the shoe waterproof may compromise the breathability and flexibility of the shoe and contribute to the poor fit of the shoe insert.

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