Conformable waterproof breathable socks and methods therefor

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

[0001] field of invention [0002] The present invention relates generally to shoe liners and, more particularly, to a waterproof, breathable bootie that is compliant across a range of shoe sizes. Booties incorporating a shoe liner and methods of making a compliant bootie and shoe liner are provided. Footwear components and waterproof breathable socks are also provided. [0003] Background of the invention [0004] Waterproof and breathable footwear is generally formed from breathable and water permeable upper materials. The outer layer of upper material may be leather and / or textile fibers. Water resistance is achieved through the use of waterproof, water vapor permeable functional materials placed inside the shoe. In the field of footwear, materials that are both waterproof and water vapor permeable are often referred to as "functional" materials. Such functional layers are commercially available from W.L. Gore and Associates, Inc., Elkton, Md., Elkton, Md., under the tra...

AI Technical Summary

Problems solved by technology

[0007] One problem that often arises when forming such waterproof, breathable footwear is that inserting the shoe liner often results in a shoe that does not fit (i.e., the shoe liner has a different fit (shape or size) than the upper that has been cut) and and / or a weak attachment between the shoe lining and the upper material which results in a less than ideal appearance to the shoe interior (i.e., the shoe lining wrinkles or detaches from the shoe upper)

[0008] There is also the problem that since multiple laminated sheets or panels are required for articles of footwear intended to be waterproof, elasticity can be severely compromised

Another problem is that sealing the seam of the shoe liner to make the shoe waterproof may affect the breathability and elasticity of the shoe and cause the shoe liner to fit poorly

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