Waterproof and water vapor permeable article of footwear

Abstract

The invention relates to a waterproof and water vapor permeable article of footwear. The waterproof and water vapor permeable article of footwear comprises a vamp, an insole, a spacer and a sole; wherein the upper comprises an outer material, a waterproof and water vapor permeable membrane laminated to an inner facing surface of the outer material, and wherein the spacer comprises a channel structure; wherein the spacer material is attached to the inwardly facing surface of the upper, and wherein the sole is an injection sole. A method of manufacturing such an article of footwear is also provided.

Description

Technical Field

[0001] The present invention relates to waterproof and water vapor permeable footwear articles, and more particularly to waterproof and water vapor permeable footwear articles and methods of making the same. Background Art

[0002] Waterproof and water vapor permeable footwear has many uses, such as outdoor sports and heavy-duty work, such as in the fields of firefighting, sanitary work, police, mechanics and defense. Such footwear is usually more rugged than everyday items, as they need to offer reliable protection against the elements, especially water and liquids.

[0003] Particularly in heavy-duty applications, it is desirable for footwear to reliably provide waterproofing during use. For example, in the field of fire safety, boots worn by firefighters must withstand large amounts of water and mechanical stress. Water infiltration may make the boots cold, heavy, and uncomfortable to wear, which may endanger the safety of the wearer. Heavy boots may prevent the wearer from moving quickly, and the uncomfortable feeling will distract attention from the surrounding environment.

[0004] Furthermore, waterproof and water vapor permeable footwear for use in heavy-duty work or outdoor applications often requires complex upper materials that can withstand high mechanical stresses. In particular, the area between the upper and the sole of a footwear article can present problems during manufacture and use, as this area is often where wear and damage can lead to water penetration.

[0005] One object of the present application is to provide a waterproof and water vapor permeable footwear article with reliable and durable waterproofness. Another object of the present application is to durably prevent the penetration of water while keeping the footwear article water vapor permeable to allow perspiration to dissipate to the outside of the footwear article. Finally, there is a need for an optimized process for manufacturing such a waterproof and water vapor permeable footwear article, thereby reducing the use of composite materials. Summary of the invention

[0006] The present invention provides a waterproof and water vapor permeable footwear article, comprising an upper, an insole, a spacer and a sole. The upper comprises at least an outer material and a waterproof and water vapor permeable membrane laminated to an inner-facing surface of the outer material. The spacer comprises a channel structure, and the sole is an injection molded sole. The spacer is attached to the inner-facing surface of the upper. Each channel of the spacer may comprise a plurality of openings on a surface of the upper facing the waterproof and water vapor permeable membrane.

[0007] The spacer may be selected from a spacer strip, a frame plate or a support plate. The spacer may be selected from a windowed plate with a spacer material or a windowed support plate with a spacer material. The spacer strip may be a strip comprising a plurality of channels perpendicular to the length of the strip. The spacer strip may include a flat area for sewing the spacer strip to another material. Each channel of the spacer strip may include a wall on at least 60% of its periphery. Each channel of the spacer strip may be open on the surface of the upper facing the waterproof and water vapor permeable membrane. Each channel in the spacer strip may extend vertically in the waterproof and water vapor permeable footwear article.

[0008] The frame plate may be in the shape of a footprint. The frame plate may include an opening in the center of the frame plate. The frame plate may include additional openings located along the perimeter of the frame plate. The frame plate may include raised portions separated by channels. The channels may be oriented from the opening in the center of the frame plate toward the perimeter of the frame plate. The channels of the frame plate may include walls on at least 60% of its perimeter. The channels of the frame plate may open on the surface of the upper facing the waterproof and water vapor permeable membrane. The channels may be located on the surface of the frame plate facing the sole of the waterproof and water vapor permeable footwear article. The channels may be located on the surface of the frame plate facing the waterproof and water vapor permeable membrane of the upper. The channels in the frame plate may extend horizontally in the waterproof and water vapor permeable footwear article.

[0009] The support plate (midsole plate, fixing plate) may be in the form of a toe area of ​​the frame plate. The support plate may include an opening located in the center of the support plate. The support plate may include additional openings located along the perimeter of the support plate. The support plate may include raised portions separated by channels. The channels may be oriented from the opening in the center of the support plate toward the perimeter of the support plate. The channels of the support plate may include walls on at least 60% of its perimeter. The channels may cover 60% of the surface of the support plate. The channels of the support plate may open on the surface of the upper facing the waterproof and water vapor permeable membrane. The channels may be located on the surface of the support plate facing the sole of the waterproof and water vapor permeable footwear article. The channels in the support plate may extend horizontally in the waterproof and water vapor permeable footwear article.

[0010] The fenestration board may be in the shape of a footprint. The fenestration board may have one or more openings in the center of the fenestration board. The spacer material is located on the surface of the fenestration board facing the interior of the waterproof and water vapor permeable footwear article. The spacer material may be attached to the fenestration board with an adhesive. The spacer material includes channels. The spacer material may include a fiber network with interconnected channels. The fenestration board may be smaller than the perimeter of the opening at the bottom end of the upper.

[0011] The fenestrated support plate may be the shape of the toe area of ​​the fenestrated support plate. The fenestrated support plate may have one or more openings in the center of the fenestrated support plate. The spacer material is located on the surface of the fenestrated support plate facing the interior of the waterproof and water vapor permeable footwear article. The spacer material may be attached to the fenestrated support plate with an adhesive. The spacer material includes channels. The spacer material may include a fiber network with interconnected channels. The fenestrated support plate may be smaller than the circumference (perimeter) of the opening in the toe area at the bottom end (lower end) of the upper.

[0012] The spacer may be attached to the bottom end of the waterproof and water vapor permeable membrane of the upper.The spacer may be attached to the surface of the waterproof and water vapor permeable membrane of the upper facing the interior of the footwear article.

[0013] The spacer may be attached to the upper with adhesive or seams.

[0014] The waterproof and water vapor permeable footwear article may further comprise an inner lining. The inner lining may comprise at least a lining textile piece. The inner lining may comprise at least a lining textile piece and a waterproof and water vapor permeable membrane. The inner lining may comprise a waterproof and water vapor permeable membrane sandwiched between two lining textile pieces. The inner lining may form a bootie together with the nonwoven. The bottom end of the inner lining may extend beyond the bottom end of the upper.

[0015] A method of manufacturing a waterproof and water vapor permeable article of footwear is also provided, comprising the steps of: - providing an upper comprising a waterproof and water vapor permeable membrane laminated to an interior-facing surface of an outer material, - attaching a spacer to an interior-facing surface of the waterproof and water vapor permeable membrane of an upper, wherein the spacer comprises a channel structure, and wherein the spacer is attached to the interior-facing surface of the upper, and - Injected sole polymer. The spacer may be any spacer described herein with respect to the waterproof and water vapor permeable article of footwear.

[0016] The method may further include the step of providing a lining. The lining may include at least a lining textile. The lining may include at least one lining textile and a waterproof and water vapor permeable membrane. The method may further include the step of attaching the lining to the insole. The footwear article described in the present patent application may be manufactured by the above method. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 A cross-sectional view of a waterproof and water vapor permeable article of footwear including a frame plate as a spacer is shown.

[0018] Figure 2 A cross-sectional view of a waterproof and water vapor permeable article of footwear including a liner and a frame panel is shown.

[0019] Figure 3 A cross-sectional view of a waterproof and water vapor permeable article of footwear including a liner, inner sleeve and a frame panel is shown.

[0020] Figure 4 A cross-sectional view of a waterproof and water vapor permeable article of footwear including a liner, a fenestration panel, and a spacer material is shown.

[0021] Figure 5 A cross-sectional view of a waterproof and water vapor permeable article of footwear including a spacer strip is shown.

[0022] Figure 6 A cross-sectional view of a waterproof and water vapor permeable article of footwear including a protective toe cap, a protective heel cap, a spacer strip, and a fenestrated support panel is shown.

[0023] Figure 7 A cross-sectional view of the toe area of ​​a waterproof and water vapor permeable article of footwear including a fenestrated support panel, a spacer material, and an inner liner is shown.

[0024] Figure 8 The frame plate is shown.

[0025] Fig. 9 A support plate is shown.

[0026] Fig.10 A top view of the spacer strip is shown. DETAILED DESCRIPTION

[0027] Although the making and use of various embodiments of the present invention are discussed in detail below, it should be understood that the present invention provides many applicable concepts of the present invention that can be implemented in various specific contexts. The specific embodiments discussed herein are only to illustrate the specific ways to make and use the present invention, and do not limit the scope of the present invention.

[0028] To facilitate understanding of the present invention, a number of terms are defined below. The terms defined herein have meanings as commonly understood by those of ordinary skill in the art to which the present invention relates. Terms such as "a", "an", and "the" are not intended to refer only to a single entity, but rather to include general categories that may be illustrated using specific examples thereof. The terms herein are used to describe specific embodiments of the present invention, but their use does not define the scope of the present invention unless outlined in the claims.

[0029] The term "waterproof and water vapor permeable article of footwear" refers to external coverings for the foot, such as shoes, boots, sandals, sneakers, sneakers, and the like.

[0030] The invention relates to a waterproof and water vapor permeable footwear article comprising an upper, an insole, a spacer and a sole.

[0031] The upper comprises a laminated outer material and a waterproof and water vapor permeable film. The upper may also comprise at least one textile layer between the outer material and the waterproof and water vapor permeable film. A backing layer may be laminated on one side of the waterproof and water vapor permeable film facing the inside of the footwear article. The backing layer may be an open mesh material or a textile layer. For the backing layer, the textile layer and the open mesh material refer to any material that allows the injected polymer material of the sole to fully penetrate the textile layer or the open mesh material. The textile layer is preferably a knitted fabric or a woven fabric. The openings between the fibers, filaments or yarns provide enough openings for the injected polymer sole material to penetrate and reach the waterproof and water vapor permeable film. The outer material and the waterproof and water vapor permeable film are laminated to each other so that the outer material and the waterproof and water vapor permeable film are attached over most of the surface. The upper may be composed of 2 layers, 3 layers or 4 layers of laminates (including waterproof and water vapor permeable laminates).

[0032] The outer material may be made of any material commonly used for this purpose. Examples include leather, synthetic leather and woven fabrics. Typically, woven fabrics include polyester, polypropylene, polyamide (e.g. nylon) or cotton. The outer material may be a laminate comprising two or more layers of the above materials.

[0033] Textile fabrics may include filaments or fibers such as monofilaments, or any mixture thereof. Fibers include natural fibers and synthetic fibers and any mixtures thereof. Natural fibers include cellulose types such as cotton, hemp or flax; animal fibers such as silk, angora, sheep wool, alpaca, cashmere, mohair and any combination thereof.

[0034] Synthetic fibers include fibers based on acrylic polymers, polyesters, polyolefins, polyurethanes, polyamides, and any combination thereof. The textile fabric may be a knitted fabric, a woven fabric, or a non-woven fabric. The fabric may be stretchable. The stretchability may be due to the use of stretchable yarns or fibers, such as those made from elastomers. The stretchability may be due to the way the yarns or fibers are knitted or woven.

[0035] As used herein, the term "knitted fabric" refers to any fabric or textile piece having the following construction: at least one yarn, thread or monofilament is formed into continuous rows of loops, which are called loop stitches. As each row progresses, new loops are pulled through existing loops. Active loop stitches remain on the needle until another loop can be passed through them.

[0036] During the knitting process, fabrics are made of interlaced loops of one or more yarns or filaments. Each yarn or filament thread follows a winding path called a "course", forming loops symmetrical to the winding path of the thread. When one loop is pulled over another, a loop stitch is formed. The loop stitch can be formed in a horizontal (weft knitting) or vertical (warp knitting) direction. The sequence of loop stitches in which each stitch hangs over the next stitch is called a "wale".

[0037] Weft knitting is a method of forming a fabric in which loops are made from a single yarn or filament in a horizontal manner, the interlacing of the loops occurring in the transverse direction, i.e. the wales are perpendicular to the courses of the yarn or filament. Weft knitting can be knitting using only one yarn or filament, or knitting using multiple yarns or filaments.

[0038] Warp knitting is a fabric forming method in which loops are made from each warp yarn or filament in a vertical manner along the length of the fabric, and the interlacing of the loops occurs in the length direction. In warp knitting, the wales and courses run in parallel. Each wale requires one yarn or filament, so multiple ends of multiple yarns or filaments are fed simultaneously into separate needles placed in the lateral direction.

[0039] Preferred knitted materials include fibers made of polyamide, such as nylon (PA6 or PA6.6) or polyester.

[0040] "Woven fabric" refers to a fabric or textile piece formed by weaving. Weaving is the process of forming a fabric by the interweaving of warp and weft yarns. The warp and weft yarns are substantially straight and extend parallel to each other, either longitudinally (warp) or transversely (weft).

[0041] "Nonwoven" is generally defined as a sheet or web structure in which a plurality of fibers or filaments are entangled by mechanical (mechanical), thermal or chemical means. The fibers are laid out in the form of a sheet or web, usually in a random configuration, and then combined mechanically (mechanically) such as by needle punching or hydroentanglement, or chemically by applying a binder to the sheet or web, or thermally by at least partially melting the fibers or filaments for bonding, either in the presence or absence of a binder.

[0042] In an embodiment, the upper can be a laminate comprising four layers. The outermost layer of the laminate can be made of microfibers. The outermost layer can be laminated to a nonwoven layer. On the surface opposite to the microfiber layer, the nonwoven layer can be laminated to a waterproof and water vapor permeable film. As the fourth layer, a textile layer can be laminated on the surface opposite to the nonwoven layer of the nonwoven waterproof and water vapor permeable film. This layer faces the inside of the footwear in the upper. This layer can be an open mesh material such as a knitted fabric. The open mesh structure allows the sole material to penetrate through the textile layer to the waterproof and water vapor permeable film. Preferably, the microfiber is made of polyamide or polyurethane. Preferably, the nonwoven layer is made of polyester or polyamide, such as nylon.

[0043] In an embodiment, the outer layer may have been treated to be durable water repellent (DWR). DWR is a treatment that coats, soaks or sprays a hydrophobic agent onto a fabric to make it water-repellent or hydrophobic. Preventing the fabric from being soaked by water avoids reducing the breathability of the functional layer.

[0044] The waterproofness of footwear can be determined by using the centrifuge test described in U.S. Pat. No. 5,329,807, which is incorporated herein by reference in its entirety. The centrifuge test can be performed for 30 minutes. If no leakage is found after 30 minutes, the footwear article is considered waterproof.

[0045] According to the Department of Defense Army Combat Boot Temperate Weather Specifications, the water vapor permeability of footwear can be evaluated by determining the full boot moisture vapor transmission rate test. The specifications are as follows: Water vapor permeability of the entire boot The boot breathability test should be designed to indicate the moisture vapor transmission rate (MVTR) through the test sample by means of the difference in moisture vapor concentration between the internal environment and the external environment. equipment a) The external test environment control system shall be capable of maintaining 23 (± 1) °C and 50% ± 2% relative humidity throughout the test duration. b) The weighing scale shall be capable of determining the weight of the test sample containing water to the nearest (±0.01) gram. c) The bag should 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 folding does not create air gaps; its MVTR must be much higher than the footwear to be tested; and it must be waterproof so that only moisture, not liquid water, contacts the interior of the footwear article. d) The internal heater used for the test sample should be able to uniformly control the temperature of the liquid water in the test sample at 35 (± 1) °C. e) The sealing method of the collar around the test specimen should be impermeable to both liquid water and water vapor. program a) Place the sample in the test environment and conditions for at least 12 hours. b) Insert the heating device into the water-retaining bag, then place the entire assembly into the opening of the test sample and fill it with water to a height of 5 cm measured from the inside sole. c) Seal the opening with plastic wrap around the collar near the top of the footwear and tape it closed with packing tape. d) Heat the water in the test sample to 35°C. e) Weigh the test sample and record it as Wi. f) After weighing, maintain the temperature in the test sample for at least 4 hours. g) After at least 4 hours, weigh the test sample again. Record the weight as Wf and the test duration as Td. h) Calculate the MVTR of the test sample in grams per hour according to the following formula: i)MVTR=(Wi–Wf) / Td. This test complies with ASTM D8041 (2016). For example, for a low ankle shoe with a European shoe size of 42, if the above calculated value is above 1.5 g / hour, the footwear is considered breathable. For larger or smaller shoe sizes, the limit value can be extrapolated based on the increased or decreased surface area of ​​the shoe.

[0046] A waterproof and water vapor permeable membrane is considered to have waterproof properties when it meets the requirements of DIN EN 343 (2010), i.e., the liquid water resistance test against hydrostatic pressure according to EN 20 811 (1992) produces a liquid water resistance Wp of 8000 Pa or more. The water vapor permeability of waterproof and water vapor permeable membranes is tested and defined in EN ISO 15496, also known as the "cup test". Place a 20 cm x 20 cm or round A sample of a waterproof and water vapor permeable film is placed on a container containing water and covered with a water vapor permeable and waterproof film. A cup filled with potassium acetate and covered with the same film is then placed on the sample. Water vapor enters the cup through the waterproof and water vapor permeable film, and the weight increase of the cup is then determined. If the water vapor permeability is greater than or equal to 0.01 g / (Pa m 2h) (g / Pa square meter hour), a waterproof and water vapor permeable film is considered to be permeable to water vapor or breathable. If the required sample size is not available, a smaller sample can be used for measurement, and the measurement uses a smaller sample cup containing half the potassium acetate content specified in the standard, that is, 50 grams instead of 100 grams, and mixed with 15.6 grams of water. The terms "permeability to water vapor (water vapor)" and "breathability" are used interchangeably herein.

[0047] Non-limiting examples of suitable synthetic polymer membranes that are waterproof and water vapor permeable include polyurethane, polytetrafluoroethylene (PTFE), expanded polytetrafluoroethylene (ePTFE), polyvinylidene fluoride (PVDF), fluorinated ethylene propylene (FEP), perfluoroalkoxyalkane (PFA), modified polytetrafluoroethylene polymers, tetrafluoroethylene (TFE) copolymers, polyolefins such as polypropylene and polyethylene, polyester sulfone (PES), polyesters, poly(p-xylene) (ePPX) as taught in U.S. Patent Publication No. 2016 / 0032069, U.S. Patent No. 9,926,416 to Sbriglia, U.S. Patent Application No. 2021 / 021 to Bell. No. 0317276 and Bell's PCT Patent Application No. 2020 / 28331, porous ethylene tetrafluoroethylene (eETFE) as taught in U.S. Patent No. 9,932,429 to Sbriglia, porous polylactic acid (ePLLA) as taught in U.S. Patent No. 7,932,184 to Sbriglia et al., porous vinylidene fluoride-co-tetrafluoroethylene or trifluoroethylene [VDF-co-(TFE or TrFE)] polymers as taught in U.S. Patent No. 9,441,088 to Sbriglia, and copolymers and combinations thereof.

[0048] The waterproof and water vapor permeable membrane may include at least one of expanded polytetrafluoroethylene (ePTFE), expanded polyethylene, expanded polypropylene, expanded polyolefin, polyurethane, polyester and copolyetherester, polyether, expanded polyether, polyamide, copolyetheramide and polyacrylate, and composites or multilayer laminates thereof. The waterproof and water vapor permeable membrane may be made of fluoropolymers, in particular of microporous expanded polytetrafluoroethylene (ePTFE).

[0049] The waterproof and water vapor permeable membrane of microporous polytetrafluoroethylene can be an expanded polytetrafluoroethylene membrane, such as disclosed in US 3,953,566 and US 4,187,390. Such membranes made of expanded polytetrafluoroethylene are available from WL Gore and Associates under the trade name The water vapor permeable and waterproof membrane may consist of a polyurethane coated microporous expanded polytetrafluoroethylene membrane made substantially in accordance with the teachings of US 4,194,041 and US 4,942,214, assigned to WL Gore and Associates of Elkton, Md. At least one additional support material, such as a knitted textile, may be present on one or both sides of the membrane.

[0050] In an embodiment, the waterproof and water vapor permeable membrane comprises a laminate of a membrane and a supporting layer or a membrane sandwiched between two supporting layers. The supporting layer may be a textile layer as described above. The supporting layer on the surface of the waterproof and water vapor permeable membrane facing the spacer may be only an open mesh material or an open textile layer. In this regard, an open textile layer and an open mesh material refer to any material that allows the injected polymer material of the sole to completely penetrate the open textile layer or the open mesh material. The open textile layer is preferably a knitted fabric or a woven fabric.

[0051] The waterproof and water vapor permeable membrane may be present over the entire length of the upper. Alternatively, the waterproof and water vapor permeable membrane may be present only in an area of ​​the upper surrounding the wearer's foot, such as from the sole to an area around the wearer's ankle, but no further.

[0052] The spacer comprises a plurality of channels. The spacer may be selected from a spacer strip, a frame plate, a support plate, a fenestrated plate with a spacer material, or a fenestrated support plate with a spacer material. The waterproof and water vapor permeable footwear article may comprise different spacers in different areas of the waterproof and water vapor permeable footwear article.

[0053] The channels in the spacer are adapted to allow the injected sole polymer to flow from the location of injection to, for example, the perimeter of the upper. The channels in the spacer may allow the injectable polymer of the sole to flow to the waterproof and water vapor permeable membrane of the upper and optionally to the waterproof and water vapor permeable membrane of the lining during injection (molding) of the sole, thereby sealing the waterproof and water vapor permeable footwear article from water ingress.

[0054] In the sense of the present invention, the term "channel" is used to describe a channel or conduit that allows the injectable polymer of the sole component to flow therethrough. The channel may have an inlet as well as an outlet for the injectable polymer. The channel provides an inner cavity through which the injectable polymer can flow during injection. There may be openings in the perimeter of the channel that allow the injectable polymer to flow toward the waterproof and water vapor permeable membrane of the upper and / or lining.

[0055] The channel in the spacer may extend horizontally in the finished article of footwear. The channel in the spacer may extend vertically in the finished article of footwear. Since the injected sole polymer is waterproof, the waterproof and water vapor permeable article of footwear is sealed against water ingress. In particular, the area between the waterproof and water vapor permeable membrane of the upper and the waterproof sole is durably sealed to waterproof the article of footwear.

[0056] In addition, in order to improve the flow of the injectable polymer during injection, the channel may include openings on its periphery. In these embodiments, the channel may be in the form of a groove. Alternatively, the channel may be formed between raised portions of the spacer material. The thickness of the raised portions may be at least 1.5 mm, preferably at least 3 mm. The diameter of the channel may be at least 1.5 mm, preferably at least 3 mm.

[0057] The channels may be grooves or spaces between raised portions of the spacer material and may have any suitable geometry such as, for example, square, rectangular, triangular, oval or circular diameters.

[0058] Alternatively, the channels may be formed by a three dimensional wavy pattern, where the channels are formed by the spaces between the grooves and 2 peaks on either side along the length of the spacer material.

[0059] In another embodiment, the channel may be formed in a spacer material used in conjunction with the fenestration plate or fenestration support plate. The spacer material comprises a fabric of interwoven fibers that provides channels to allow the injected polymer to enter and flow through the channels formed between the fibers of the fabric. The diameter of the channel may be at least 1.5 mm, preferably at least 3 mm.

[0060] The spacer material may be made of a polymer material, including polyvinyl chloride (PVC), ethylene vinyl acetate (EVA), polyurethane (PU), synthetic rubber (TR) or natural fibers, as discussed further above. The spacer material may be a nonwoven. The spacer material may be leather. The thickness of the spacer material may be at least 1 mm to allow the sole material to penetrate and flow through the channel of the spacer material.

[0061] The spacer material may be a spacer strip. The spacer strip may be provided as a ribbon comprising a plurality of channels perpendicular to the length of the ribbon. The spacer strip may be a ribbon comprising the above-mentioned channels, which span the width or a portion of the width of the strip. The spacer strip may include a portion without channels, which may extend in the longitudinal direction of the strip. This portion may be used to attach the spacer strip to the footwear article. The portion of the spacer strip not comprising the channels may have a smaller thickness than the rest of the spacer strip to facilitate attachment, for example, by a Strobel seam. The spacer strip may be made of a sufficiently bendable material that can conform to the contour of the footwear article.

[0062] The spacer strips may be cut to an appropriate length to conform to a portion or the entire circumference of the footwear article. The spacer strips may be used in at least a portion of the waterproof and water vapor permeable footwear article, such as at least a portion of the midfoot and / or heel portion of the footwear article. The spacer strips may be used in the midfoot and heel portions of the waterproof and water vapor permeable footwear article, while different spacers are used in the toe portion of the waterproof and water vapor permeable footwear article. The waterproof and water vapor permeable footwear article may include spacer strips located in the midfoot and heel portions of the waterproof and water vapor permeable footwear article, and a support plate or a window support plate may be used as a spacer in the toe area of ​​the waterproof and water vapor permeable footwear article.

[0063] Waterproof and water vapor permeable footwear articles may include a frame plate as a spacer. The frame plate may include the shape of a footprint. The frame plate may be a frame in the form of a footprint, with a large opening in the center of the frame plate. The sole polymer may be injected through the opening. On the frame, the frame plate may include a channel, which is oriented so that the inner cavity of the channel crosses the frame in the direction from the inside to the outside, for example, across the width of the frame. When injected through the opening in the center of the frame plate, the sole polymer enters the channel and flows through the frame toward the waterproof and water vapor permeable membrane of the lining and / or the upper. In addition, the frame plate may also include flat and / or raised portions to be attached to the upper. In another embodiment, the frame plate includes an opening in the frame except the channel to optimize the flow of the sole polymer injected. The opening may have different sizes and / or different geometric shapes, such as circular, square, triangular, oval, etc.

[0064] The spacer may also be a support plate. The support plate may be the toe portion of the frame plate. The positioning of the channels and / or other openings in the frame plate also applies to the support plate. The support plate may not include a central opening. The support plate may be shaped as the front portion of the footprint cut away in the midfoot area. The channels may be arranged so that their cavities extend from the cut line toward the outer edge of the support plate. The support plate may include a raised portion around the outer edge for attachment to an insole, lining and / or upper. The support plate may be bonded to the insole, lining and / or upper with an adhesive. The insole may be a mesh plate.

[0065] The spacer may be a fenestrated board having a spacer material. The fenestrated board may be in the shape of a footprint. The fenestrated board may include at least one opening. The sole polymer may be injected through the at least one opening. The fenestrated board may be flat. On a surface facing the interior of the waterproof and water vapor permeable footwear article, the fenestrated board includes a spacer material as described above. The spacer material may be attached to the fenestrated board. The spacer material may be adhered to the fenestrated board. The spacer material may be sewn to the fenestrated board. The spacer material may cover at least one opening of the fenestrated board. The spacer material may only cover the fenestrated board and not cover the at least one opening.

[0066] The spacer may be a fenestrated support plate having a spacer material. The fenestrated support plate has the same profile as the support plate. The fenestrated support plate may not have any raised portions. The fenestrated support plate may have at least one opening.

[0067] On the surface facing the interior of the waterproof and water vapor permeable footwear article, the fenestrated support plate includes a spacer material as described above. The spacer material may be attached to the fenestrated support plate. The spacer material may be sewn to the fenestrated support plate. The spacer material may be attached to the fenestrated support plate with an adhesive. The spacer material may cover at least one opening. The spacer material may only cover the fenestrated support plate without covering the at least one opening.

[0068] The spacer may be attached to the upper at the bottom end of the interior-facing surface of the upper. The spacer may be attached to the upper with an adhesive. The spacer may be sewn to the upper. The spacer may be located between the lining and the bottom end of the waterproof and water vapor permeable membrane of the upper.

[0069] The waterproof and water vapor permeable footwear article may include a different spacer in the toe area of ​​the waterproof and water vapor permeable footwear article than in the rest of the waterproof and water vapor permeable footwear article, such as the midfoot portion and / or the heel portion.

[0070] The waterproof and water vapor permeable footwear article may also include an inner lining. The inner lining may be located on the inner side of the upper. The inner lining may include at least one textile layer or a mesh material. The inner lining may include at least one textile layer and a waterproof and water vapor permeable membrane. The inner lining may be a laminate comprising a waterproof and water vapor permeable membrane sandwiched between two textile layers. The inner lining may be in the form of an inner sleeve. The inner lining may form an inner sleeve only in the toe area. A different material may be included at the bottom of the inner sleeve than at the side of the inner sleeve. The inner lining may be reinforced with different materials at the bottom of the inner sleeve. If the material at the bottom of the inner sleeve is different from the material on the side of the inner sleeve, the different materials may be sewn together. The bottom of the inner sleeve may be made of a nonwoven board.

[0071] When the lining is open at the bottom and comprises a waterproof and water vapor permeable membrane, the waterproof and water vapor permeable membrane faces the spacer. In order for the injected sole polymer to reach the waterproof and water vapor permeable membrane of the lining, any textile layer located between the waterproof and water vapor permeable membrane and the spacer must have an open textile structure or an open mesh structure as described for the upper.

[0072] The bottom end of the lining may extend beyond the bottom end of the upper.

[0073] The insole may be made of any suitable material, such as, for example, bonded leather, synthetic fabrics, thermoplastic polymers, fiberboard, or rubber. The insole may be a lasting board, a Strobel board, a mesh board, or a toe lasting board. The stiffness and hardness of the lasting board may be higher than the Strobel board. The Strobel board is typically a textile material to enable the spacer and / or liner to be sewn to the Strobel board. The toe lasting board is a smaller sized lasting board used to seal the inner sleeve between the toe lasting board and the seam stitching of the Strobel board and the inner sleeve.

[0074] Typical lasting adhesives such as hot melt adhesives or pressure sensitive adhesives may be used, for example copolyester or polyamide hot melt adhesives or polyurethane.

[0075] When the protective toe cap is used as a safety toe cap, which extends to the edge of the lasting board, the sole material that may not be sufficiently injected will be able to penetrate through the spacer to the waterproof and water vapor permeable membrane of the upper to seal the footwear. In order to improve the amount of injected sole material to reach the waterproof and water vapor permeable membrane, a lasting board including a window and a spacer material can be used as an insole. The spacer material can be attached to the upper surface of the insole around the window, facing the sole of the wearer's foot. The spacer material can have a raised edge around the window with a channel for the injected sole material to flow through, flowing to the waterproof and water vapor permeable membrane. Alternatively, it can be a mesh. The mesh can be glued to the window. The spacer material has a thickness of preferably at least 2 mm.

[0076] The sole may be made of a polymer material, such as polyurethane, thermoplastic polyurethane (TPU), or ethylene vinyl acetate (EVA), and is injected over the bottom of the footwear structure assembled on the last.

[0077] At the end of the manufacturing process, the footbed can be placed into a waterproof and water vapor permeable footwear article. The footbed can be made of a material that cushions the wearer's foot and provides a better fit and further insulation.

[0078] In an embodiment, the footbed may include two layers of material. The lower layer facing the sole may be made of, for example, polyurethane (PU), ethylene-vinyl acetate (EVA), and / or polyethylene (PE) foam. The upper layer facing the wearer's foot may be made of any material disclosed for linings. The footbed may be removable and not attached to the insole and / or lining.

[0079] Figure 1 A waterproof and water vapor permeable footwear article 10 is shown, which includes an upper 40, an insole 50 and a sole 90. A frame plate 60 is bonded to the underside of the insole 50 with an adhesive 80. The frame plate 60 can also be manufactured in one piece with the insole 50. The upper 40 includes at least an outer material 20 and a waterproof and water vapor permeable membrane 30. On the surface of the waterproof and water vapor permeable membrane 30 facing the interior of the footwear article 10, another open textile layer or an open mesh layer (not shown) is laminated.

[0080] The bottom end of the upper 40 is bonded to the frame plate 60 with a lasting adhesive 70. When the sole polymer is injected to mold the sole 90, the sole polymer will flow through the central opening of the frame plate 60. On the surface facing the sole 90, the frame plate 60 includes channels that guide the sole polymer from the central opening of the frame plate 60 toward the outside of the footwear. The polymer entering these channels will contact the waterproof and water vapor permeable membrane 30 of the upper 40 and form a waterproof joint. The channels are located in the raised portion around the central opening of the frame plate 60, and the injection of the sole polymer forms a sealing ring around the bottom of the footwear article 10, thereby permanently waterproofing the footwear article 10.

[0081] Figure 2 An alternative embodiment is shown. Figure 1 Compared with the embodiment, Figure 2 The embodiment of the present invention is double-lasted, thereby allowing two waterproof and water vapor permeable membranes to be sealed at the same time. The upper 40 includes an outer material 20 and a waterproof and water vapor permeable membrane 30. On the surface of the waterproof and water vapor permeable membrane 30 facing the interior of the footwear article 10, another textile layer or a mesh layer (not shown) may be laminated.

[0082] The waterproof and water vapor permeable footwear article 10 further comprises a lining 110. The lining 110 is a laminate of at least a lining textile 100 and a waterproof and water vapor permeable membrane 30. Alternatively, the lining 110 may be a laminate (not shown) comprising a waterproof and water vapor permeable membrane 30 sandwiched between two lining textiles 100.

[0083] In the first step, the lining 110 is attached to the bottom surface (lower side) of the insole 50 using a lasting adhesive 70. The lasting adhesive can be applied discontinuously so that the injected sole material can enter between the lining and the insole. Then, the frame plate 60 is attached to the outward-facing surface of the lining 110 using an adhesive 80. The adhesive must be compatible with the sole material, i.e., the adhesive and the sole material are fused. Alternatively, the adhesive can be applied in a dotted manner so that the sole material can flow around the adhesive point to the waterproof and water vapor permeable membrane of the lining. The frame plate includes raised portions around the inner perimeter, which intersect with the channel. Finally, the upper 40 is lasted to the frame plate 60 and attached with a lasting adhesive 70. The perimeter of the lining 110 can extend beyond the frame plate 60 and the upper 40. If desired, a protective toe cap (not shown) can be inserted between the lining 110 and the upper 40.

[0084] When the sole polymer is injected to mold the sole 90, the sole polymer will seal the perimeter of the lining 110, and in particular, when the lining 110 extends beyond the upper 40 and the frame plate 60, the sole polymer will form a seal with the waterproof and water vapor permeable membrane 30 of the lining 110. Further, the sole polymer will flow through the central opening of the frame plate 60 and then flow through the channel toward the waterproof and water vapor permeable membrane 30 of the upper 40. A sealing ring is formed around the bottom of the footwear article 10, thereby making the connection between the upper 40 and the sole 90 waterproof.

[0085] Figure 3 An embodiment of a waterproof and water vapor permeable article of footwear 10 is depicted, which includes a lining 110, an upper 40, an insole 50, and a sole 90. Figure 1 Compared with the waterproof and water vapor permeable footwear article 10 of the double last system (two times last finger), Figure 3 The waterproof and water vapor permeable footwear article 10 includes a Strobel board as the insole 50, and the bottom end of the lining 110 is sewn to the Strobel board 50 to form an inner cover.

[0086] The frame plate 60 is bonded to the bottom of the inner sleeve with adhesive 80. The frame plate 60 in this embodiment includes Figure 1The frame plate 60 in the upper is narrower than the frame plate 60 to allow the injected sole polymer to reach the waterproof and water vapor permeable membrane 30 of the upper 40 on both the inner perimeter and the outer perimeter of the frame plate 60. In addition, the injected sole polymer also reaches the waterproof and water vapor permeable membrane of the lining. This results in a seal between the sole and the waterproof and water vapor permeable membrane.

[0087] Once the frame plate 60 is attached to the inner sleeve, the upper 40 is lasted to the frame plate 60 using a lasting adhesive 70, and the sole 90 is molded by injection. Due to the presence of the frame plate 60, this configuration does not require a lasting plate for the lasting step.

[0088] Figure 4 Waterproof and water vapor permeable footwear article 10 and Figure 3 The embodiment of the present invention differs in that, as a spacer, a fenestration plate 150 and a spacer material 140 are used instead of a frame plate including channels on a frame. When the sole polymer is injected to mold the sole, the sole polymer enters through the openings in the fenestration plate 150 and flows through the spacer material 140. Due to the three-dimensional structure of the spacer 140, the injected sole polymer can contact the waterproof and water vapor permeable membrane 30 of the upper 40 and the lining 110. Under the foot of the wearer of the waterproof and water vapor permeable footwear article 10, a waterproof seal is provided where the upper 40 is lasted to the inner sleeve.

[0089] exist Figures 1 to 4 In all the embodiments shown, the upper 40 is lasted to the spacers so as to provide channels through which the injected sole polymer can flow to the waterproof and water vapor permeable membrane 30 of the upper 40 and, if present, the lining 110. The flow of the injected sole polymer can also be directed in another way by the spacers.

[0090] Figure 5 An embodiment is depicted in which a spacer strip 160 is sewn as a spacer to the bottom of the upper 40. The spacer strip 160 includes channels that direct the injected sole polymer through vertical channels to the waterproof and water vapor permeable membrane 30 of the membrane of the upper. The upper 40 is closed by a mesh panel 170, which is attached to the upper 40 and the spacer strip 160 by a separate seam.

[0091] However, it may not always be possible to attach a spacer strip along the entire perimeter of the waterproof and water vapor permeable footwear article 10. For example, heavy duty work boots often require the presence of a steel toe cap and / or a heel protective cap to protect the wearer's foot from mechanical impact. To meet these applications, different spacers may be used in different areas of the waterproof and water vapor permeable footwear article in this case. Figure 6 Such an embodiment is shown.

[0092] A protective toe cap 200 is located between the upper 40 and the lining 110 in the toe area, while a protective heel cap or standard heel cap (usually made of polyester nonwoven) 210 is positioned between the lining 110 and the upper 40 in the heel area. The lining 110 includes a lining textile 100 and a waterproof and water vapor permeable membrane 30. The bottom edge of the lining 110 is sewn to the nonwoven 220 so that an inner sleeve is formed. The upper 40 includes an outer material 20 and a waterproof and water vapor permeable membrane 30. In the heel area, the bottom edge of the upper 40 is sewn to the mesh 170. In the midfoot area, a spacer strip 160 is sewn to the bottom end of the upper 40, and then the mesh 170 is attached by a separate seam 120. In the toe area, the mesh 170 is bonded to the lining 110. The support plate 190 is attached to the mesh 170 with a lasting adhesive 70. The support plate 190 comprises a channel on the underside, which channel faces the sole 90. The upper 40 is then lasted to the support plate 190.

[0093] When the sole polymer is injected on the mesh plate 170, the spacer strip 160 will guide the injected sole polymer to the waterproof and water vapor permeable membrane 30 of the upper 40 and the lining 110 in the heel and midfoot areas via the vertical channels of the spacer strip 160. In the toe area, the injected sole polymer is guided by the channels of the support plate 190 to the waterproof and water vapor permeable membrane 30 of the lining 110 and the upper 40.

[0094] Alternatively, the window support plate 230 and the spacer material 140 may be used together to replace Figure 6 The support plate 190 in the embodiment of the present invention. Figure 7 Such an embodiment is shown in FIG. The spacer material 140 is attached to the fenestrated support plate 230 on the surface facing the inner sleeve formed by the liner 110 and the nonwoven 220. The bottom end of the upper 40 is then attached to the fenestrated support plate 230 using an adhesive 70. During injection, the sole polymer will flow through the openings in the fenestrated support plate 230 and then be distributed through the spacer material 140 toward the waterproof and water vapor permeable membrane 30 of the upper 40 and the liner 110, thereby providing a durable waterproof seal.

[0095] Figure 8 A frame plate 60 is shown with an opening in the center of the frame plate 60, the frame being in the form of a footprint around the opening. There are raised portions 270 on the frame, with channels 240 located between the raised portions 270. In the upper half of the frame plate 60, the raised portions are positioned toward the middle of the width of the frame, allowing space along the outer edge for attaching a waterproof and water vapor permeable membrane for the upper. In the lower half of the frame plate 60, the raised portions 270 have been moved toward the inner edge of the frame, and additional openings 250 have been added to the frame to increase the flow of the sole polymer during injection.

[0096] Fig. 9 An embodiment of a support plate 190 is shown. The contour of the support plate 190 is shaped to resemble the contour of the toe area of ​​the insole. The channels 240 are located between the raised portions 270, which guide the flow of the sole polymer during injection. For the windowed support plate 230, there is an opening in the center, leaving only a frame. The windowed support plate 230 can be the toe portion of the frame plate 60. To improve the flow of the injected sole polymer, the windowed support plate can include openings around the edges.

[0097] Fig.10 2 shows a spacer strip 160. The strip includes extended edges 260 that provide an area for attachment to the upper. These extended edges are located in the same plane as the seams that fasten the spacer strip 160 in the waterproof and water vapor permeable footwear article. The channel 240 is located between the raised portions 270.

Claims

1. Waterproof and water vapor permeable footwear, including: vamp, Insole, Spacers, and Soles; wherein the upper comprises at least an outer material and a waterproof and water vapor permeable membrane laminated to an inner-facing surface of the outer material, wherein the spacer comprises a channel structure; wherein the spacer is attached to an interior-facing surface of the upper; and Wherein, the sole is an injected sole.

2. The waterproof and water vapor permeable footwear article according to claim 1, characterized in that The spacers are selected from spacer strips, frame plates or support plates.

3. The waterproof and water vapor permeable footwear article according to claim 1, characterized in that The spacer is selected from a fenestration plate with a spacer material or a fenestration support plate with a spacer material.

4. The waterproof and water vapor permeable footwear article according to any one of claims 1 to 3, characterized in that The spacer is attached to the bottom end of the waterproof and water vapor permeable membrane of the upper.

5. The waterproof and water vapor permeable footwear article according to any one of claims 1 to 4, characterized in that The spacer is attached to the upper by adhesive or seams.

6. The waterproof and water vapor permeable footwear article according to any one of claims 1 to 5, characterized in that Also includes lining.

7. The waterproof and water vapor permeable footwear article according to claim 6, characterized in that The lining comprises at least a lining textile element, or at least a lining textile element and a waterproof and water vapor permeable membrane.

8. The waterproof and water vapor permeable footwear article according to claim 6 or 7, characterized in that The liner forms an inner cover together with the nonwoven.

9. The waterproof and water vapor permeable footwear article according to any one of claims 6 to 8, characterized in that The bottom end of the lining extends beyond the bottom end of the upper.

10. The waterproof and water vapor permeable footwear article according to any one of claims 1 to 9, characterized in that The channels of the channel structure extend horizontally in the waterproof and water vapor permeable article of footwear.

11. The waterproof and water vapor permeable footwear article according to any one of claims 1 to 9, characterized in that The channels of the channel structure extend vertically in the waterproof and water vapor permeable article of footwear.

12. The waterproof and water vapor permeable footwear article according to any one of claims 1 to 11, characterized in that Each of said channels comprises walls over at least 60% of their circumference.

13. A method of manufacturing a waterproof and water vapor permeable article of footwear comprising the steps of: - providing an upper comprising a waterproof and water vapor permeable membrane laminated to an interior-facing surface of an outer material, - attaching a spacer between the insole and the interior-facing surface of the waterproof and water vapor permeable membrane of the upper, wherein the spacer comprises a channel structure, and wherein the spacer is attached to the interior-facing surface of the upper, and -Injected sole polymer.

14. The method of manufacturing a waterproof and water vapor permeable article of footwear according to claim 13, characterized in that: Providing a liner is also included, and optionally wherein the liner includes at least a liner textile, or at least a liner textile and a waterproof and water vapor permeable membrane.

15. The method of manufacturing a waterproof and water vapor permeable article of footwear according to claim 14, characterized in that Also included is the step of attaching the liner to the insole.

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