Waterproof and water vapor permeable footwear

Abstract

The present application relates to a waterproof and moisture-vapor-permeable footwear article comprising an upper, an insole, a spacer, and a sole, wherein the upper comprises an outer material and a waterproof and moisture-vapor-permeable membrane laminated to an interior-facing surface of the outer material, the spacer comprises a channel structure, a spacer material is attached to the interior-facing surface of the upper, and the sole is an injection-molded sole. Additionally, a method of manufacturing such a footwear article is provided.

Description

[Technical Field]

[0001] FIELD OF THE INVENTION The present invention relates to waterproof, water vapor permeable footwear articles, and more particularly to waterproof, water vapor permeable footwear articles and methods for making same. [Background technology]

[0002] Waterproof and water vapor permeable footwear articles are used for a variety of purposes, such as outdoor sports and heavy-duty work in fields such as firefighting, health care, law enforcement, machinery and defense, etc. Such footwear articles are typically much more rugged than everyday articles because they must provide reliable protection from the elements, particularly water and fluids.

[0003]

[0003] It is desirable for footwear articles to reliably provide waterproofing during use, particularly in heavy-duty fields. For example, in the field of firefighting, the boots worn by firefighters must withstand large amounts of water and mechanical stress. Water penetration can make the boots cold, heavy, and uncomfortable, potentially compromising the safety of the wearer. Heavy boots can inhibit the wearer's ability to move quickly, while discomfort can distract the wearer from their surroundings.

[0004] Furthermore, waterproof and water vapor permeable footwear articles used for heavy work or outdoor applications often require complex upper materials that can withstand high mechanical stresses. In particular, the area between the upper and sole of the footwear article can pose problems during manufacturing and use, as wear and tear can cause water ingress.

[0005] It is an object of the present application to provide a waterproof, water vapor permeable footwear article that provides reliable and durable waterproofing. A further object of the present application is to provide a footwear article that is water vapor permeable, allowing sweat to evaporate from the footwear article to the outside while durably preventing water intrusion. And finally, there is a need to optimize the manufacturing method for such waterproof, water vapor permeable footwear articles while reducing the use of complex materials. Summary of the Invention

[0006] The present invention provides footwear including a waterproof, water vapor permeable membrane including an upper, an insole, a spacer, and a sole. The upper includes at least an outer material and a waterproof, water vapor permeable membrane laminated to an inner-facing surface of the outer material. The spacer includes a channel structure, and the sole is an injection-molded sole. The spacer is attached to the inner-facing surface of the upper. The channel of the spacer may include an opening on the surface of the upper facing the waterproof, water vapor permeable membrane.

[0007] The spacer may be selected from a spacer tape, a frame board, or a glue board. The spacer may be selected from a window board with a spacer material, or a window glue board with a spacer material. The spacer tape may be a tape including a channel perpendicular to the length of the tape. The spacer tape may include a flat area for sewing the spacer tape to another material. The channel of the spacer tape may include a wall around at least 60% of its perimeter. The channel of the spacer tape may be open on a surface facing the waterproof, moisture vapor permeable membrane of the upper. The channel of the spacer tape may extend vertically within the waterproof, moisture vapor permeable article of footwear.

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

[0009] The adhesive board can be in the shape of the toe area of the frame board. The adhesive board can include an opening in the center of the adhesive board. The adhesive board can include additional openings disposed along the periphery of the adhesive board. The adhesive board can include raised portions separated by channels. The channels can be oriented from the opening in the center of the adhesive board toward the periphery of the adhesive board. The adhesive board channels can include walls around at least 60% of their periphery. The channels can cover 60% of the adhesive board surface. The adhesive board channels can be open to a surface facing the waterproof and moisture vapor permeable membrane of the upper. The channels can be located on a surface of the adhesive board facing the sole of the waterproof and moisture vapor permeable footwear article. The adhesive board channels can extend horizontally in the waterproof and moisture vapor permeable footwear article.

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

[0011] The window cladding board can be shaped like a toe area of the window cladding board. The window cladding board can have one or more openings in the center of the window cladding board. The spacer material is disposed on a surface of the window cladding board facing the interior of the waterproof, water vapor permeable footwear article. The spacer material can be attached to the window cladding board by adhesive. The spacer material includes channels. The spacer material can include a fiber network with interconnected channels. The window cladding board can be smaller than the circumference of the opening in the toe area of the lower end of the upper.

[0012] The spacer can be attached to a lower edge of the waterproof, water vapor permeable membrane of the upper.The spacer can be attached to a surface of the waterproof, water vapor permeable membrane of the upper that faces the interior of the article of footwear.

[0013] The spacer may be attached to the upper by adhesive or by a seam.

[0014] The waterproof and moisture-vapor-permeable footwear article may further include a liner. The liner may include at least a lining textile. The liner may include at least a lining textile and a waterproof and moisture-vapor-permeable membrane. The liner may include a waterproof and moisture-vapor-permeable membrane sandwiched between two liner textiles. The liner may form a bootie together with the nonwoven fabric. The lower end of the liner may extend beyond the lower end of the upper.

[0015] Additionally provided is a method for making a waterproof and water vapor permeable footwear article, the method comprising: providing an upper including a waterproof and water vapor permeable membrane laminated to an interior-facing surface of an exterior material; - attaching a spacer to the interior-facing surface of the waterproof and water vapor permeable membrane of the upper, wherein the spacer includes a channel structure and is attached to the interior-facing surface of the upper; - injection molding a sole polymer. The spacer can be any one of the spacers described herein in connection with the waterproof and water vapor permeable article of footwear.

[0016] The method may further include providing a liner. The liner may include at least one liner textile. The liner may include at least one liner textile and a waterproof, water vapor permeable membrane. The method may further include attaching the liner to an insole. The footwear articles described in this patent application may be manufactured by the above method. [Brief explanation of the drawings]

[0017] [Figure 1] FIG. 1 shows a cross section of a waterproof, water vapor permeable article of footwear that includes a frame board as a spacer.

[0018] [Figure 2]FIG. 2 shows a cross section of a waterproof, water vapor permeable article of footwear including a liner and a frame board.

[0019] [Figure 3] FIG. 3 shows a cross section of a waterproof, moisture vapor permeable footwear article including a liner bootie and a frame board.

[0020] [Figure 4] FIG. 4 shows a cross section of a waterproof, water vapor permeable article of footwear including a liner, a window board, and a spacer material.

[0021] [Figure 5] FIG. 5 shows a cross section of a waterproof, water vapor permeable article of footwear including a spacer tape.

[0022] [Figure 6] FIG. 6 shows a cross section of a waterproof, water vapor permeable article of footwear including a protective toe cap, a protective heel cap, spacer tape, and a window cling board.

[0023] [Figure 7] FIG. 7 shows the toe area of a waterproof, moisture vapor permeable article of footwear including a window cling board, spacer material, and a liner.

[0024] [Figure 8] Figure 8 shows the frame board.

[0025] [Figure 9] FIG. 9 shows the adhesive board.

[0026] [Figure 10] FIG. 10 shows a top view of the spacer tape. DETAILED DESCRIPTION OF THE INVENTION

[0027] While the making and using of various embodiments of the invention are described in detail below, it should be understood that the invention provides many applicable inventive concepts that can be embodied in a variety of specific contexts. The specific embodiments described herein are merely illustrative of specific ways to make and use the invention and do not limit the scope of the invention.

[0028] To facilitate understanding of the present invention, several terms are defined below. Terms defined herein have meanings commonly understood by one of ordinary skill in the art relevant to the present invention. Terms such as "a," "an," and "the" are not intended to refer to only a single entity, but include general classes of which specific examples may be used for illustration. While the terms herein are used to describe particular embodiments of the present invention, their use does not limit the present invention except as outlined in the claims.

[0029] The term waterproof and moisture vapor permeable footwear article refers to an outer covering for the foot, such as a shoe, boot, sandal, trainer, sneaker, or the like.

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

[0031] The upper includes a laminated outer material and a waterproof, water-vapor-permeable membrane. The upper can further include at least one textile layer between the outer material and the waterproof, water-vapor-permeable membrane. A backing layer can be laminated to the side of the waterproof, water-vapor-permeable membrane facing the interior of the footwear article. The backing layer can be an open mesh material or a textile layer. Textile layer and open mesh material with respect to the backing layer refer to any material that allows the injected polymeric sole material to completely penetrate the textile layer or open mesh material. The textile layer is preferably knitted or woven. The openings between the fibers, filaments, or yarns provide sufficient openings for the injected polymeric sole material to penetrate and reach the waterproof, water-vapor-permeable membrane. The outer material and the waterproof, water-vapor-permeable membrane are laminated together so that the outer material and the waterproof, water-vapor-permeable membrane are attached over the majority of the surface. The upper can include a laminate (including a waterproof, water-vapor-permeable laminate) having two, three, or four layers.

[0032] The outer material can be made from any material typically used for this purpose. Examples include leather, synthetic leather, textile fabrics, etc. Typically, textile fabrics include polyester, polypropylene, polyamide (e.g., nylon), or cotton. The outer material can be a laminate including two or more layers of the above materials.

[0033] The textile fabric may comprise filaments, such as monofilaments, or fibers, or any mixture thereof. Fibers include natural fibers, synthetic fibers, and any mixture thereof. Natural fibers include cellulosic fibers, such as cotton, hemp, and linen, and animal fibers, such as silk, angora, wool, alpaca, cashmere, and 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 can be knitted, woven, or nonwoven. The fabric can be stretchable. The stretchability can be due to the use of stretchable yarns or fibers, for example, made from elastomers. The stretchability can be due to the knitting or weaving of the yarns or fibers.

[0035] As used herein, the term "knitted fabric" refers to any fabric or textile having at least one yarn, thread, or monofilament configured into a continuous row of loops called loop stitches. As each row progresses, a new loop is pulled through an existing loop. The active loop stitch is held on the needle until another loop can be threaded.

[0036] In the knitting process, fabric is formed by intertwining loops of a yarn, multiple yarns, threads, or monofilament. Each thread of yarn or monofilament follows a serpentine path, called a course, forming loops symmetrical to the serpentine path of the thread. When one loop is pulled through another, a loop stitch is formed. Loop stitches can be formed horizontally (flat knitting) or vertically (warp knitting). A sequence of loop stitches, with each stitch suspended from the next, is called a wale.

[0037] Weft knitting is a method of fabric formation in which loops are made horizontally from a single yarn or monofilament and the interlacing of the loops is transverse, i.e., the wales are perpendicular to the course of the yarn or monofilament. Weft knitting can be done using only one yarn or monofilament, or multiple yarns or monofilaments.

[0038] Warp knitting is a fabric-forming method in which loops are made from each warp yarn or monofilament vertically along the length of the fabric, with the loops interlocking longitudinally. In warp knitting, the wales and courses run parallel. Because each wale requires one yarn or monofilament, the ends of many yarns or monofilaments are fed simultaneously onto individual crosswise needles.

[0039] Preferred knit materials include fibers made from polyamides such as nylon (PA6 or PA6.6) or polyesters.

[0040] "Woven fabric" refers to a fabric or textile formed by weaving. Weaving is a process of forming fabric by the interlacing of warp and weft threads. Both warp and weft threads run essentially straight and parallel to each other, either lengthwise (warp) or widthwise (weft).

[0041] A "nonwoven" is typically defined as a sheet or web structure in which fibers or filaments are mechanically, thermally, or chemically entangled. The fibers are typically arranged in a random configuration in the form of a sheet or web and then bonded either mechanically, such as by needlepunching or hydroentangling, or chemically, by applying a binder onto the sheet or web, or thermally, by at least partially melting and bonding the fibers or filaments, with or without a binder.

[0042] In an embodiment, the upper can be a laminate including four layers. The outermost layer of this laminate can be made from microfiber. This outermost layer can be laminated to a nonwoven layer. On the surface opposite the microfiber layer, the nonwoven layer can be laminated to a waterproof, water vapor permeable membrane. As a fourth layer, a textile layer can be laminated to the surface of the waterproof, water vapor permeable membrane opposite the nonwoven layer. This layer faces the interior side of the upper footwear. This layer can be an open mesh material, such as a knit. The open mesh structure allows the sole material to penetrate the textile layer and reach the waterproof, water vapor permeable membrane. Preferably, the microfiber is made from polyamide or polyurethane. Preferably, the nonwoven layer is made from polyester or polyamide, such as nylon.

[0043] In embodiments, the outer layer can be treated with a durable water repellent (DWR) treatment. DWR is a treatment in which a fabric is coated, soaked, or sprayed with a hydrophobic agent to make the fabric water-resistant or hydrophobic. By preventing the fabric from becoming saturated with water, a decrease in the breathability of the functional layer is avoided.

[0044] The waterproofness of footwear can be determined using the centrifuge test described in U.S. Patent 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 observed after 30 minutes, the footwear article is considered waterproof.

[0045] The moisture vapor permeability of the footwear can be evaluated as determined by the Whole Boot Moisture Vapor Transmission Rate Test in accordance with the Department of Defense Army Combat Boot Temperate Climate Specification. specification The specifications are as follows: Water vapor permeability throughout the boot The vapor permeability test for boots should be designed to indicate the moisture vapor transmission rate (MVTR) through the test sample, depending on the difference in water vapor concentration between the internal and external environments. Device a) The external test environmental control system should be capable of maintaining 23 (±1)°C and 50% ±2% relative humidity throughout the test period. b) The weighing scale should be capable of measuring the weight of the water-filled test sample to an accuracy of (±0.01) grams. c) The water-retention bag should be flexible so that it can be inserted into the test sample and conforms to the internal contours; it should be thin enough to prevent air gaps from being created by folds; it should have a much higher MVTR than the footwear article being tested; and it should be waterproof so that only water vapor, and not liquid water, contacts the interior of the footwear article. d) The internal heater of the test sample should be able to control the temperature of the liquid water in the test sample uniformly at 35(±1)°C. e) The sealing method around the collar of the test sample should be impermeable to both liquid water and water vapor. procedure a) Place the sample in the test environment and conditions for at least 12 hours. b) Insert the heating device into the water retention bag and place the complete assembly into the opening of the test sample and fill with water to a height of 5 cm measured from the inner sole. c) Wrap plastic wrap around the top of the footwear to seal the opening around the collar and tape it over using packing tape. d) Heat the water in the test sample to 35°C. e) Weigh the test sample and record as Wi. f) After weighing, the temperature inside the test sample shall be maintained for a minimum of 4 hours. g) After a minimum of 4 hours, reweigh the test sample. Record the weight as Wf and the test time as Td. h) Calculate the MVTR of the test sample in grams / hour from the following formula: i)MVTR=(Wi-Wf) / Td This test is in accordance with ASTM D8041 (2016). For example, for a low ankle shoe with a European shoe size of 42, if the calculated value exceeds 1.5 grams per hour, the shoe can be considered breathable. For larger or smaller shoe sizes, the above limit can be extrapolated depending on the increase or decrease in the shoe surface area.

[0046] A waterproof, water-vapor-permeable membrane is considered to have waterproof properties when it meets the requirements set out in DIN EN 343 (2010), i.e., when the test for liquid water resistance against hydrostatic pressure according to EN 20 811 (1992) gives a liquid water resistance Wp of 8000 Pa or more. The water vapor permeability of a waterproof, water-vapor-permeable membrane is tested and specified in EN ISO 15496 (also known as the "cup test"). A 20 cm x 20 cm or circular 100 mm diameter sample of a waterproof, water-vapor-permeable membrane is placed over a container filled with water and covered with a water-vapor-permeable, waterproof membrane. A cup filled with potassium acetate and covered with the same membrane is then placed over the sample. Water vapor passes through the waterproof, water-vapor-permeable membrane into the cup, and the weight gain of the cup is measured. A waterproof, water-vapor-permeable membrane has a water vapor permeability of 0.01 g / (Pa m 2 h) or greater, it is considered to be water vapor permeable or breathable. If the required sample size is not available, a smaller sample can be measured using a small cup containing half the amount of potassium acetate specified in the standard, i.e., 50 g instead of 100 g, and mixed with 15.6 g of water. Here, the terms water vapor permeable and breathable are used interchangeably.

[0047] Non-limiting examples of suitable waterproof, water vapor permeable synthetic polymeric membranes include polyurethane, polytetrafluoroethylene (PTFE), expanded polytetrafluoroethylene (ePTFE), polyvinylidene fluoride (PVDF), fluorinated ethylene propylene (FEP), perfluoroalkoxyalkanes (PFA), modified polytetrafluoroethylene polymers, tetrafluoroethylene (TFE) copolymers, polyalkylenes such as polypropylene and polyethylene, polyethersulfone (PES), polyesters, poly(p-xylylene) (ePPX) as taught in U.S. Patent Publication No. 2016 / 0032069, porous ultra-high molecular weight polyethylene (eUHMWPE) as taught in U.S. Patent No. 9,926,416 to Sbriglia, U.S. Patent Application No. 2021 / 0317276 to Bell, and PCT Patent Application No. 2020 / 28331 to Bell, and the like. No. 9,932,429 to Sbriglia et al., porous polylactic acid (ePLLA) as taught in U.S. Pat. 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. Pat. No. 9,441,088 to Sbriglia, and copolymers and combinations thereof.

[0048] The waterproof and water vapor permeable membrane can comprise 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 can be made from a fluoropolymer, in particular microporous expanded polytetrafluoroethylene (ePTFE).

[0049] The microporous polytetrafluoroethylene waterproof and water vapor permeable membrane can be an expanded polytetrafluoroethylene membrane as taught in U.S. Patent Nos. 3,953,566 and 4,187,390. Such expanded polytetrafluoroethylene membranes are included in fabrics sold by WL Gore and Associates under the trade name GORE-TEX® fabric. The water vapor permeable and waterproof membrane can be composed of a polyurethane-coated expanded microporous polytetrafluoroethylene membrane manufactured substantially according to the teachings of U.S. Patent Nos. 4,194,041 and 4,942,214, assigned to WL Gore and Associates, Inc., Elkton, Maryland. At least one additional support material, such as a knitted textile, can 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 support layer, or a membrane sandwiched between two support layers. The support layer can be a textile layer as described above. The support layer on the surface of the waterproof and water vapor permeable membrane facing the spacer can be an open mesh material or an open textile layer alone. In this regard, the open textile layer and open mesh material refer to any material that allows the injected polymer material of the sole to completely penetrate the open textile layer or open mesh material. The open textile layer is preferably a knitted or woven fabric.

[0051] The waterproof and moisture vapor permeable membrane can be present along the entire length of the upper, or it can be present in the area of the upper that surrounds the wearer's foot, for example, from the bottom of the foot to the area that surrounds the wearer's ankle, but no further.

[0052] The spacer comprises a plurality of channels. The spacer may be selected from spacer tape, frame board, adhesive board, window board with spacer material, or window adhesive board with spacer material. The waterproof, moisture vapor permeable article of footwear may include different spacers in different regions of the waterproof, moisture vapor permeable article of footwear.

[0053] The channels in the spacer are adapted to allow the injected sole polymer to flow from the injection location, for example, toward the periphery of the upper. The channels in the spacer can allow the injectable polymer of the sole to flow toward the waterproof, moisture vapor permeable membrane of the upper during injection of the sole, and optionally toward the waterproof, moisture vapor permeable membrane of the liner, thereby sealing the waterproof, moisture vapor permeable footwear article against water intrusion.

[0054] In the context of the present invention, the term "channel" is used to describe a passage or duct through which the injection-moldable polymer of the sole assembly can flow. The channel has an inlet and an outlet for the injection-moldable polymer. The channel provides a lumen through which the injection-moldable polymer flows during injection. There are openings around the periphery of the channel that allow the injection-moldable polymer to flow toward the waterproof, water vapor permeable membrane of the upper and / or liner.

[0055] The channels in the spacer can extend horizontally in the finished footwear article. The channels in the spacer can extend vertically in the finished footwear article. Because the injected sole polymer is waterproof, the waterproof, water vapor permeable footwear article is sealed against water intrusion. In particular, the area between the waterproof, water vapor permeable membrane of the upper and the waterproof sole is durably sealed to make the footwear article waterproof.

[0056] Additionally, the channel can include openings around its periphery to improve the flow of the injection-moldable polymer during injection. In these embodiments, the channel can be in the form of a groove. Alternatively, the channel can be formed between raised portions of the spacer material. The raised portions can have a thickness of at least 1.5 mm, preferably at least 3 mm. The channel diameter is at least 1.5 mm, preferably at least 3 mm.

[0057] The channels can be grooves or spaces between raised portions of the spacer material and can have any suitable shape, for example, square, rectangular, triangular, oval or circular diameter.

[0058] Alternatively, the channels are formed from a three-dimensional wave pattern, the channels being formed by valleys along the length of the spacer material and spaces between two peaks on either side.

[0059] In a further embodiment, the channels can be formed in a spacer material used in combination with window boards or window cling boards. The spacer material includes a fabric of interwoven fibers to provide channels through which injected polymer can enter and flow between the fibers of the fabric. The channels can be at least 1.5 mm in diameter, preferably at least 3 mm.

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

[0061] The spacer material can be a spacer tape. The spacer tape can be provided as a ribbon including a plurality of channels perpendicular to the length of the ribbon. The spacer tape can be a tape including said channels across the entire width or a portion of the width of the tape. The spacer tape can include a channel-free portion that can extend longitudinally of the tape. This portion can be used for mounting the spacer tape within the footwear article. This portion of the spacer tape that does not include channels can be thinner than the remainder of the spacer tape to facilitate mounting, for example, by a Strobel seam. The spacer tape can be made from a material that is sufficiently flexible to conform to the contours of the footwear article.

[0062] The spacer tape can be cut to an appropriate length to fit around a portion or the entire circumference of the footwear article. The spacer tape can be used on at least a portion of the waterproof, water vapor permeable footwear article, for example, in the midfoot and / or heel portion of the footwear article. Spacer tape can be used in the midfoot and heel portions of the waterproof, water vapor permeable footwear article, while a different spacer can be used in the toe portion of the waterproof, water vapor permeable footwear article. The waterproof, water vapor permeable footwear article can include spacer tape in the midfoot and heel portions of the waterproof, water vapor permeable footwear article, and adhesive boards or window adhesive boards can be used as spacers in the toe region of the waterproof, water vapor permeable footwear article.

[0063] The waterproof and moisture-vapor-permeable footwear article may include a frame board as a spacer. The frame board may include a footprint shape. The frame board may be a footprint-shaped frame with a large opening in the center of the frame board. The sole polymer may be injected through this opening. The frame board may include channels oriented on the frame such that the lumen of the channel traverses the frame from the inside to the outside, for example, across the width of the frame. When injected through the central opening of the frame board, the sole polymer enters the channels and flows across the frame toward the waterproof and moisture-vapor-permeable membrane of the upper and / or liner. Furthermore, the frame board may further include flat and / or raised portions for attachment to the upper. In a further embodiment, the frame board may include openings in the frame in addition to the channels to optimize the flow of the injected sole polymer. The openings may have different sizes and / or shapes, such as round, square, triangular, or oval.

[0064] The spacer can further be a backing board. The backing board can be the toe portion of the frame board. The arrangement of channels and / or additional openings in the frame board also applies to the backing board. The backing board may not include a central opening. The backing board can be shaped as the front of the footprint cut out in the midfoot region. The channel can be arranged so that its lumen extends from the cut line towards the outer edge of the backing board. The backing board can include a raised portion around the outer edge for attachment to the insole, liner and / or upper. The backing board can be glued to the insole, liner and / or upper. The insole can be a net board.

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

[0066] The spacer can be a window cladding with a spacer material. The window cladding has the same profile as the cladding. The window cladding can be free of raised portions. The window cladding can have at least one opening.

[0067] On an interior-facing surface of the waterproof, water vapor permeable article of footwear, the window cladding includes a spacer material as described above. The spacer material can be attached to the window cladding. The spacer material can be sewn to the window cladding. The spacer material can be attached to the window cladding with an adhesive. The spacer material can cover at least one opening. The spacer material can cover only the window cladding and not cover the at least one opening.

[0068] The spacer can be attached to the upper at a lower edge of the upper's interior-facing surface. The spacer can be attached to the upper with an adhesive. The spacer can be sewn to the upper. The spacer can be disposed between the upper and the lower edge of the waterproof, moisture vapor permeable membrane of the liner.

[0069] The waterproof, moisture-vapor-permeable article of footwear may include a spacer in the toe region of the waterproof, moisture-vapor-permeable footwear article that is different from other portions of the waterproof, moisture-vapor-permeable footwear article, such as the midfoot portion and / or heel portion.

[0070] The waterproof and moisture-vapor-permeable footwear article may further include a liner. The liner may be disposed inside the upper. The liner may include at least one textile layer or mesh material. The liner may include at least one textile layer and a waterproof and moisture-vapor-permeable membrane. The liner may be a laminate including a waterproof and moisture-vapor-permeable membrane sandwiched between two textile layers. The liner may be in the shape of a bootie. The liner may form the bootie only in the toe area. The bottom of the bootie may include a different material than the sides of the bootie. At the bottom of the bootie, the liner may be reinforced with a different material. When the material of the bottom of the bootie is different from the material of the sides of the bootie, the different materials may be sewn together. The bottom of the bootie may be made from a nonwoven board.

[0071] When the liner is open at the bottom and includes 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 liner, the textile layer located between the waterproof and water vapor permeable membrane and the spacer must have an open textile or open mesh structure, as described for the upper.

[0072] The lower end of the liner can extend beyond the lower end of the upper.

[0073] The insole can be made of any suitable material, such as, for example, bonded leather, synthetic fabric, thermoplastic polymer, fiberboard, or rubber. The insole can be a lasting board, a strobel board, a net board, or a toe lasting board. A lasting board can have greater stiffness and hardness than a strobel board. A strobel board is typically a textile material to which a spacer and / or liner can be sewn. A toe lasting board is a lasting board with smaller dimensions to allow for sealing of the bootie between the toe lasting board and the seam that sews the strobel board to the bootie.

[0074] Common lasting adhesives such as hot melt adhesives or pressure sensitive adhesives can be used, for example copolyester or polyamide hot melt adhesives or polyurethanes.

[0075] When the protective toe cap is used as a safety toe cap, the safety toe cap extends to the edge of the lasting board, and the injected polymer material may not penetrate the spacer enough to reach the waterproof, vapor-permeable membrane of the upper to seal the footwear. To increase the amount of injected sole material reaching the waterproof, vapor-permeable membrane, the lasting board including the window and spacer material can be used as an insole. The spacer material can be attached around the window to the upper surface of the insole 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 toward the waterproof, vapor-permeable membrane. Alternatively, it can be mesh. The mesh can be glued onto the window. The spacer material preferably has a thickness of at least 2 mm.

[0076] The sole can be made from a polymeric material such as polyurethane, thermoplastic polyurethane (TPU) or ethylene vinyl acetate (EVA) and injected onto the bottom of the footwear structure assembled onto a last.

[0077] At the end of the manufacturing process, the waterproof, moisture vapor permeable article of footwear can be provided with a footbed, which can be made from a material that cushions the wearer's foot, providing a better fit and additional insulation.

[0078] In embodiments, the footbed can include two layers of material. The lower layer, which faces the sole, can be made from, for example, polyurethane (PU) foam, ethylene vinyl acetate (EVA), or polyethylene (PE) foam. The upper layer, which faces the wearer's foot, can be made from any of the materials disclosed for the liner. The footbed can be removable and not attached to the insole and / or liner.

[0079] 1 shows a waterproof, moisture-vapor-permeable footwear article 10 including an upper 40, an insole 50, and a sole 90. A frame board 60 is adhered to the underside of the insole 50 by adhesive 80. The frame board 60 may also be manufactured integrally with the insole 50. The upper 40 includes at least an outer material 20 and a waterproof, moisture-vapor-permeable membrane 30. A further open textile or open mesh layer (not shown) is laminated onto the surface of the waterproof, moisture-vapor-permeable membrane 30 facing the interior of the footwear article 10.

[0080] The lower end of the upper 40 is adhered to the frame board 60 by a lasting adhesive 70. When the sole polymer is injected to form the sole 90, the sole polymer flows through a central opening in the frame board 60. On the surface facing the sole 90, the frame board 60 includes channels that direct the sole polymer from the central opening in the frame board 60 to the outside of the footwear article. The polymer that enters these channels contacts the waterproof, water vapor permeable membrane 30 of the upper 40, forming a waterproof bond. The channels are located in a raised portion around the central opening of the frame board 60, and when the sole polymer is injected, a sealing ring is formed around the bottom of the footwear article 10, making the footwear article 10 durably waterproof.

[0081] An alternative embodiment is shown in Figure 2. In contrast to the embodiment of Figure 1, the embodiment of Figure 2 is dual-lasting, allowing two waterproof and moisture vapor permeable membranes to be sealed at once. Upper 40 includes outer material 20 and waterproof and moisture vapor permeable membrane 30. An additional textile or mesh layer may be laminated to the surface of waterproof and moisture vapor permeable membrane 30 facing the interior of footwear article 10 (not shown).

[0082] The waterproof and moisture-vapor-permeable footwear article 10 further includes a liner 110. The liner 110 is a laminate of at least a lining textile 100 and a waterproof and moisture-vapor-permeable membrane 30. Alternatively, the liner 110 can be a laminate including a waterproof and moisture-vapor-permeable membrane 30 sandwiched between two lining textiles 100 (not shown).

[0083] In the first step, the lining 110 is attached to the back of the insole 50 with a lasting adhesive 70. The lasting adhesive can be applied discontinuously to allow the injected sole material to penetrate between the lining and the insole. Next, the frame board 60 is attached to the outer surface of the liner 110 with adhesive 80. The adhesive must be compatible with the sole material; that is, it must fuse with the sole material. Alternatively, the adhesive can be applied in dots, allowing the sole material to flow around the glue dots toward the liner's waterproof, water vapor permeable membrane. The frame board includes a raised portion around its inner periphery where the channels intersect. Finally, the upper 40 is lasted to the frame board 60 and attached with a lasting adhesive 70. The periphery of the liner 110 can extend beyond the frame board 60 and the upper 40. If desired, a protective toe cap can be inserted between the liner 110 and the upper 40 (not shown).

[0084] When the sole polymer is injected to form the sole 90, it seals the periphery of the liner 110, providing a seal with the waterproof, moisture vapor permeable membrane 30 of the liner 110, particularly as the liner 110 extends beyond the upper 40 and frame board 60. Additionally, the sole polymer passes through a central opening in the frame board 60 and then through channels toward the waterproof, moisture vapor permeable membrane 30 of the upper 40. A seal ring is created around the bottom of the article of footwear 10, making the connection between the upper 40 and the sole 90 waterproof.

[0085] Figure 3 shows an embodiment of a waterproof, water vapor permeable footwear article 10 including a liner 110, an upper 40, an insole 50, and a sole 90. In contrast to the dual-lasting waterproof, water vapor permeable footwear article 10 of Figure 1, the waterproof, water vapor permeable footwear article 10 of Figure 3 includes a strobel board as the insole 50, and the lower edge of the liner 110 is sewn to the strobel board 50 to form a bootie.

[0086] The frame board 60 is adhered to the bottom of the boot with adhesive 80. The frame board 60 in this embodiment has a narrower frame than the frame board 60 of Figure 1, allowing the injected sole polymer to reach the waterproof, moisture vapor permeable membrane 30 of the upper 40 on both the inner and outer peripheries of the frame board 60. In addition, the injected sole polymer also reaches the waterproof, moisture vapor permeable membrane of the liner, thereby forming a seal between the sole and both waterproof, moisture vapor permeable membranes.

[0087] Once the frame board 60 is attached to the bootie, the upper 40 is lasted to the frame board 60 with a lasting adhesive 70, and the sole 90 is injection molded. This structure does not require a lasting board for the lasting process due to the presence of the frame board 60.

[0088] The waterproof, moisture-vapor-permeable footwear article 10 of Figure 4 differs from the embodiment of Figure 3 in that a window board 150 and spacer material 140 are used as spacers instead of a frame board containing channels in the frame. When the sole polymer is injected to form the sole, it enters through the openings in the window board 150 and flows through the spacer material 140. The three-dimensional structure of the spacer 140 allows the injected sole polymer to come into contact with the waterproof, moisture-vapor-permeable membrane 30 of both the upper 40 and the liner 110. A waterproof seal is provided under the wearer's foot where the upper 40 is lasted to the bootie.

[0089] 1-4, the upper 40 is lasted on a spacer to provide channels through which the injected sole polymer can flow to the waterproof, moisture vapor permeable membrane 30 of the upper 40 and, if present, the liner 110. The flow of the injected sole polymer can also be directed in other directions by the spacer.

[0090] 5 shows such an embodiment in which a spacer tape 160 is sewn to the bottom of the upper 40 as a spacer. The spacer tape 160 includes channels that direct the injected sole polymer through vertical channels to the waterproof, water vapor permeable membrane 30 of the upper membrane. The upper 40 is closed by a net board 170 that is attached to the upper 40 and the spacer tape 160 with another seam.

[0091] However, it is not always possible to apply spacer tape along the entire circumference of the waterproof, moisture-vapor-permeable footwear article 10. For example, heavy-duty work boots often require the presence of steel toe caps and / or heel protection caps to protect the wearer's feet from mechanical impact. To accommodate these applications, different spacers can then be used in different areas of the waterproof, moisture-vapor-permeable footwear article. Figure 6 illustrates such an embodiment.

[0092] In the toe area, a protective toe cap 200 is positioned between the upper 40 and the liner 110, and in the heel area, a protective heel cap or standard heel cap (typically made of polyester nonwoven fabric) 210 is positioned between the liner 110 and the upper 40. The liner 110 includes a liner textile 100 and a waterproof and moisture-vapor-permeable membrane 30. The lower edge of the liner 110 is sewn to a nonwoven fabric 220 to form a bootie. The upper 40 includes an outer material 20 and a waterproof and moisture-vapor-permeable membrane 30. In the heel area, the lower edge of the upper 40 is sewn to a net board 170. In the midfoot area, a spacer tape 160 is sewn to the lower edge of the upper 40, after which the net board 170 is attached by another seam 120. In the toe area, the net board 170 is glued to the liner 110. The adhesive board 190 is then attached to the net board 170 by the lasting adhesive 70. The adhesive board 190 includes a channel on the underside facing the sole 90. The upper 40 is then lasted to the adhesive board 190.

[0093] As the sole polymer is injected onto the net board 170, the spacer tape 160 directs the injected sole polymer in the heel and midfoot regions through vertical channels in the spacer tape 160 and toward the waterproof, moisture vapor permeable membrane 30 of both the upper 40 and the liner 110. In the toe region, the injected sole polymer is guided by channels in the adhesive board 190 toward the waterproof, moisture vapor permeable membrane 30 of both the liner 110 and the upper 40.

[0094] Alternatively, a window adhesive board 230 and spacer material 140 can be used in combination in place of adhesive board 190 of Figure 6. Such an embodiment is shown in Figure 7. Spacer material 140 is attached to window adhesive board 230 on the bootie-facing surface formed by liner 110 and nonwoven 220. The lower edge of upper 40 is then attached to window adhesive board 230 with adhesive 70. Upon injection, sole polymer flows through openings 230 in the window adhesive board and is then distributed through spacer material 140 toward the waterproof, moisture vapor permeable membrane 30 of upper 40 and liner 110, providing a durable, waterproof seal.

[0095] 8 shows a frame board 60 with an opening in the center of the frame board 60 and a footprint-shaped frame around the opening. The frame has raised portions 270 with channels 240 positioned between them. In the top half of the frame board 60, the raised portions are positioned toward the center of the frame's width, providing space along the outer edge for attachment of the upper's waterproof, vapor-permeable membrane. In the bottom half of the frame board 60, the raised portions 270 are moved toward the inner edge of the frame, and additional openings 250 are added to the frame to increase the flow of sole polymer during injection.

[0096] 9 shows an embodiment of a pasteboard 190. The contour of the pasteboard 190 is shaped like the contour of the toe area of the insole. Channels 240 are located between raised portions 270 that direct the flow of the sole polymer during injection. In the case of the window pasteboard 230, there is an opening in the center, leaving only the frame. The window pasteboard 230 can be the toe portion of the frame board 60. To improve the flow of the injected sole polymer, the window pasteboard can include openings around the edges.

[0097] Spacer tape 160 is shown in Figure 10. The tape includes extended edges 260 that provide attachment areas to the upper. These extended edges are in the same plane as the stitching that secures spacer tape 160 in the waterproof, moisture vapor permeable article of footwear. Channels 240 are located between raised portions 270.

Claims

1. upper, insole, a spacer, and Including the sole, the upper includes at least an outer material and a waterproof, water vapor permeable membrane laminated to an interior-facing surface of the outer material; the spacer includes a channel structure; the spacer is attached to an interior-facing surface of the upper; and The waterproof and water vapor permeable article of footwear, wherein the sole is an injection molded sole.

2. 10. The waterproof, water vapor permeable article of footwear of claim 1, wherein the spacer is selected from spacer tape, frame board, or adhesive board.

3. 10. The waterproof, water vapor permeable article of footwear of claim 1, wherein the spacer is selected from a window board having a spacer material or a window cling board having a spacer material.

4. The waterproof and water vapor permeable footwear article of any one of claims 1 to 3, wherein the spacer is attached to a lower edge of the waterproof and water vapor permeable membrane of the upper.

5. The waterproof and water vapor permeable article of footwear according to any one of claims 1 to 4, wherein the spacer is attached to the upper by adhesive or a seam.

6. The waterproof and water vapor permeable footwear article of any one of claims 1 to 5, further comprising a liner.

7. 7. The waterproof and moisture-vapor-permeable article of footwear of claim 6, wherein the liner comprises at least a liner textile or at least a liner textile and a waterproof and moisture-vapor-permeable membrane.

8. 8. The waterproof and water vapor permeable footwear article of claim 6 or claim 7, wherein the liner together with a nonwoven fabric forms a bootie.

9. The waterproof, water vapor permeable article of footwear according to any one of claims 6 to 8, wherein the lower end of the liner extends beyond the lower end of the upper.

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

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

12. The waterproof and water vapor permeable article of footwear according to any one of claims 1 to 11, wherein the channel comprises a wall around at least 60% of its perimeter.

13. 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 an insole and an interior-facing surface of the waterproof, water vapor permeable membrane of the upper, wherein the spacer includes a channel structure and the spacer is attached to the interior-facing surface of the upper; and injection molding the sole polymer; A method for producing a waterproof and water vapor permeable footwear article, comprising:

14. 14. The method of claim 13, further comprising providing a liner, and optionally the liner comprising at least a liner textile or at least a liner textile and a waterproof, moisture vapor permeable membrane.

15. The method of claim 14 further comprising attaching the liner to the insole.

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