Optimised footwear inner made of multi-layered fabric

Abstract

This Invention describes a breathable, waterproof footwear inner in multi-layered material - with a closed design - that can be inserted in footwear and has structural characteristics that make it easy to use. The footwear inner in this Invention is produced to optimise its comfort and protection, and to make it easy to produce on an industrial scale.

Description

DescriptionTitle of Invention: Optimised footwear inner made of multilayered fabric.Technical Field

[0001] This Invention comes under the category of equipment to improve foot comfort and safety when wearing footwear. These footwear inners may also be worn for sport and exercise where there is a high level of physical stress, such as climbing, running and hiking, where footwear must adapt and deliver suitable technical performance. The Invention is also suitable for any footwear with a view to improving overall comfort.Background Art

[0002] Modern footwear is designed to meet high specification objectives in terms of protection, performance and comfort. In recent years the manufacturers of these items have been able to offer the market a wide range of products thanks to improvements in the technologies and materials in construction processes.

[0003] A special footwear inner is currently available in the Prior Art, which is inserted in the upper of footwear to make it waterproof but sufficiently breathable to ensure a high level of comfort for the foot.

[0004] The footwear inner available in the Prior Art is made of two sheets of multi-layered fabric suitably cut in the shape of a foot and joined together (10, 11). The two sheets of multi-layered fabric are joined to create the three-dimensional shape (12) of the footwear inner. Each sheet of multi-layered fabric has two layers, one representing an internal lining in contact with the foot (13) and one representing an external membrane, preferably breathable and waterproof (14). The two combined sheets of multi-layered fabric are sewn together at the perimeter edges (15,16), except for the upper section where the foot is inserted (18) and the underside (17), which both remain open.

[0005] Once the footwear inner with the open underside is made, it is positioned and joined to the footwear between its upper and sole.

[0006] In the Prior Art the perimeter seam is heat-sealed to make the footwear inner waterproof, whereby the seam is covered appropriately with a strip of waterproof material attached to the seam using a heat-activated glue or adhesive. In practice the seam results in the footwear inner material having perforations and the heat-sealing restores the necessary waterproofing.

[0007] The presence of the heat seal is an issue in the footwear inner production phase due to reprocessing steps that result in additional costs. Moreover, heat-sealing can impact comfort when wearing footwear due to the obvious addition of material on the surface of the footwear inner.

[0008] Optimisation solutions are currently available in the Prior Art to overcome the footwear inner reprocessing issue due to the heat-sealing, as specified in patents IT2018000020647 and IT2019000001973,

[0009] In IT2018000020647 the two sheets of multi-layered material that form the open footwear inner are joined via ultrasonic welding, which can be implemented advantageously on the constituent materials. Ultrasonic welding is already used on synthetic materials in the Prior Art, and ensures a high level of waterproofing while avoiding the need for heat-seal reprocessing.

[0010] Likewise in IT2019000001973, the two sheets of multi-layered material that form the open footwear inner are joined with a hot-melt adhesive, which is already known in footwear manufacturing techniques, and this joins the perimeter of the two sheets ensuring the necessary waterproofing.

[0011] The material and process instructions provided in Application IT2019000001973 are too generic however, and the result obtained from these patents is a footwear inner that deteriorates easily when used, and does not have technical characteristics that are especially better than anything in the Prior Art.

[0012] There are numerous materials currently available for making the open footwear inner, as stated above. The internal lining i.e. one of the two sheets of multi-layered material in contact with the foot, can be made of synthetic material such as polyamide (PA) or polyester, or natural materials widely available in the range of textiles on the market. The processing techniques used on these yarns can create different looks and textures when making the aforementioned lining, such that it has a smooth, fur or nap effect i.e. features that can be obtained by using different loom setups.

[0013] The second layer of the multi-layered material forming the open footwear inner i.e. the external layer which is waterproof and breathable and is also called the membrane, is generally processed starting with materials such as polyurethane, polyester, polyamide (PA), polypropylene (PP) or polytetrafluoroethylene (PTFE), and is also made breathable as a result of hydrophilic construction (ability to bond with water molecules) or a microporous structure. In this case too the production processes can create membranes with various physical characteristics, making them strong, light and elastic, thereby enabling them to be classed according to weight, colour, thickness etc.

[0014] Also available in the Prior Art are open footwear inners with a multi-layered material made up of three layers, namely an internal lining, external membrane and a fabric attached to the membrane, constructed from a choice of synthetic materials.

[0015] This is usually a fabric with a thick weave and it is glued entirely to the membrane. It can also be treated with a process that gives it hydrophobic characteristics to prevent moisture.

[0016] The patent literature includes other applications that include the implementation of an internal waterproofing system for footwear using a footwear inner.

[0017] Application EP3332661 A1 describes a footwear inner assembled in a format and using methods similar to those used for specific footwear. However this application does not demonstrate adaptability characteristics that would enable its successful application in other footwear.

[0018] The application in GB2408190A describes a waterproof, breathable footwear inner for footwear made to incorporate other elements designed to improve the comfort and protection of the foot, but this patent describes general solutions in terms of materials and layout that do not aim to produce a high standard of performance and fit.

[0019] Application US5253434A describes a breathable, waterproof item for inserting in footwear and a process for making it. In this case too no details are provided on how to achieve improved features such that the item is lightweight and offers improved comfort and protection. Furthermore, the construction process is extremely complex and expensive in US5253434A.

[0020] Application WO0211571A1 describes a process for making footwear uppers waterproof. However, even though this patent aims to create waterproofing, it is not appropriate in this Invention because it involves steps carried out directly on the inside of the upper during the footwear assembly process.

[0021] Therefore an analysis of the Prior Art has demonstrated some practical areas of optimisation: a. the footwear inner should be made with a mix of materials and construction processes to enable an overall reorganisation, for example to achieve the required technical performance without making it uncomfortable, facilitating perfect stability and sealing the materials when multi-layered, and ensuring durability etc.b. even though the footwear inner in the Prior Art is made of fabric, it cannot be positioned easily in footwear as it is not stiff enough to prevent the material from collapsing and folding when it is being inserted, c. the footwear inner should be able to adapt to footwear with a side or rear zip fastener, a common technical solution which the footwear inner already known in the Prior Art could not adapt to, d. generally the use of several layers of material with different characteristics to create the multi-layered material results in poor stability after being cut when the layers are joined together, causing unwanted gathering and deformation, e. the footwear inner production process should be mindful of the need to use materials and production techniques that are as environmentally-friendly as possible and not too energy-intensive.

[0022] Further to the information above, the aim of this Invention is to create a waterproof, breathable footwear inner with suitably moderate structural rigidity, and an innovative layout that improves on the Prior Art with regards to comfort and protection.Summary of Invention

[0023] This Invention describes a breathable, waterproof footwear inner in multi-layered material - with a closed design - that can be inserted in footwear and has structural characteristics that make it easy to use. The footwear inner in this Invention is produced to optimise its comfort and protection, and to make it easy to produce on an industrial scale.Advantageous Effects of Invention

[0024] The benefits of this Invention can be summarised as follows: a. the footwear inner is extremely comfortable despite it being made with multiple layers of different material, b. the overall structure is fairly rigid to facilitate its positioning inside footwear, c. the optimised comfort features also include moderate structural stiffness, d. the chosen materials joined to form the multi-layered design, as per the idea of the Invention, do not ruffle when being cut or become unstable, e. in another Invention implementation method the footwear inner can be created with an optimised layout for footwear with a side or rear zip fastener,f. the use of the footwear inner in this Invention does not require footwear manufacturers to use additional processes to make it waterproof (e.g. heatsealing), making it suitable for all product types, such as footwear made using the Strobel method, assembly or injection methods etc.Brief Description of Drawings

[0025] The table with diagrams is included with the documentation for this application to illustrate the characteristics of the Invention, with application variations highlighted where described. More specifically it includes:Fig.1

[0026] [fig.1] showing a waterproof, breathable footwear inner currently available in the Prior Art,Fig.2

[0027] [fig.2] showing the shape of the internal lining of the Invention and the shape of the external cover of the internal lining, as per the idea of the Invention,Fig.3

[0028] [fig.3] showing the folding of the internal lining and the external cover of the internal lining of the innovation, as per the idea of the Invention,Fig.3A

[0029] [fig.3A] showing the seam along the perimeter edges of two linings consisting of the internal lining of the footwear inner and the external cover of the internal lining, profiled appropriately as per the idea of the Invention,Fig.3B

[0030] [fig.3B] showing a possible implementation of the external cover of the internal lining as per the idea of the Invention,Fig.3C

[0031] [fig.3C] showing a gusset joined to the inside section of the footwear inner as per the idea of the Invention,Fig.3D

[0032] [fig.3D] showing an axonometric view of the internal structure of the footwear inner and the gusset before it is sewn onto it, as per the idea of the Invention,

[0033] [fig.4] showing an initial layout of the Invention's structural layer, as per the idea of the Invention,Fig.5

[0034] [fig.5] showing a second layout of the Invention's structural layer, as per the idea of the Invention,Fig.6

[0035] [fig.6] showing the shape of the breathable, waterproof membrane, as per the idea of the Invention,Fig.6A

[0036] [fig.6A] showing detail of the glue between the membrane and the fabric, as per the idea of the Invention,Fig.6B

[0037] [fig.6B] showing the distribution of glue applications on the membrane, as per the idea of the Invention,Fig.6C

[0038] [fig.6C] showing an implementation variation for the footwear inner, whereby the area of the internal lining and its external cover go beyond the area of the membrane in the opening section for fitting to the foot, as per the idea of the Invention,Fig.7

[0039] [fig.7] showing a cross-section of the Invention with the layers of material, as per the idea of the Invention,Fig.7A

[0040] [fig.7A] showing detail of the joint on the perimeter edges of the symmetrical membranes when joined to the internal section of the footwear inner, as per the idea of the Invention,Fig.8

[0041] [fig.8] showing protective padding on the Invention in natural or synthetic material, as per the idea of the Invention,Fig.8A

[0042] [fig.8A] showing another implementation of the footwear inner where the elastic gusset is placed in a lateral position on the Invention, as per the idea of the Invention,Fig.9

[0043] [fig.9] showing footwear in the Prior Art with side zip opening,Fig.10

[0044] [fig.10] showing footwear in the Prior Art with side zip opening in which the footwear inner is inserted as per the idea of the Invention,Fig.11

[0045] [fig.11] showing the footwear inner ensemble once assembly is complete as per the idea of the Invention,Fig.12

[0046] [fig.12] showing the footwear inner ensemble with an elastic gusset at the back as per the idea of the Invention,Description of the Invention

[0047] The description of the various methods for implementing this Invention is outlined for illustration purposes, therefore all possible modifications of an obvious nature in its field of application, when carried out by industry operators, will not limit the terms for protecting the licence itself.

[0048] The technique and equipment described in this Invention relate to additional solutions already known in the Prior Art which are referred to for correct implementation in the chosen technical environment.

[0049] In the wording of this Invention, reference to an individual technical element may also apply to multiple instances of it in the Invention, unless stated otherwise.

[0050] In the wording in this Invention the term 'complex' has the same meaning as 'multilayered'.

[0051] As per the Invention implementation method, and in general terms, the footwear inner is made by starting with two symmetrical sheets of multi-layered material joined together and partially at their perimeter in order to create a three-dimensional shape, excluding the upper opening for inserting the foot and the area known as the instep, where an appropriate elastic gusset will be placed.

[0052] As per the Invention implementation method, the multi-layered material - or complex - forming the footwear inner has five layers of material joined together with different technical specifications and formats, more specifically:a. an internal lining in contact with the foot, b. an external cover on the internal lining in the same shape, in a soft, compressible material attached to the internal lining, both sewn together at their edges and with an elastic gusset incorporated, c. a suitably profiled structural layer, d. a microporous or hydrophilic waterproof membrane, e. an external fabric attached to the membrane.

[0053] As per the Invention implementation method, each layer has its own specific function. Furthermore, as described in the Prior Art above, each layer always has two symmetrical sections, except for the gusset, and they are joined together to create the three- dimensional shape of the Invention i.e. the footwear inner.

[0054] As per the idea of the Invention, the footwear inner is 'closed' whereby the sole of the foot is not in contact with the inside of the footwear as it is contained within the space of the footwear inner, unlike the descriptions in the Prior Art in IT2018000020647 and IT2019000001973. This means that the only opening on the footwear inner is where the foot enters to put it on.

[0055] As per the Invention implementation method, the sole of the footwear inner is not closed with more multi-layered material, as illustrated in GB2408190A, it is closed by joining the two sections of the symmetrical multi-layered material that form the Invention, as detailed below.

[0056] As per the Invention implementation method, the internal lining of the footwear inner is made of polyamide (PA) and / or polyester and / or natural textiles, and may even be a mix. The materials already known in the Prior Art are chosen for this Invention on the basis of their resistance and cost. All textile and finishing processes available in the Prior Art can be used for the lining to determine its appearance, texture, colour, feel and comfort.

[0057] As per the Invention implementation method, the variability of the internal lining's physical / chemical characteristics also depends on aesthetic factors, as the lining is visible within the inner through the instep opening once its implementation process is complete. Polyamide and / or polyester and / or natural textiles, even as a mix, at weights of between 60g / m2and 800 g / m2, preferably between 90g / m2and 180g / m2, can be used for this application.

[0058] As per the Invention implementation method, another aim of the internal lining is to create a point of contact with the foot that is as compatible as possible with the skin.

[0059] As per the Invention implementation method, the internal lining is cut out in the shape shown in Fig. 2, which will enable the creation of a three-dimensional footwear inner in the shape of a foot that is closed at the sole. To obtain the three-dimensional shape two symmetrical linings are joined together by sewing part of the perimeter edge. In the heel area of the lining a specific process is also visible that produces another feature of the aforementioned lining.

[0060] As per the Invention implementation method, this process involves the partial removal of material in the shape of a V from the internal lining in the heel area, for the purpose of creating a flap (20) that can be folded over the area relating to the sole of the foot (30) to create the surface of the sole of the footwear inner (31 , 32), thereby creating a three- dimensional shape from a flat portion of the lining surface. Obviously the process is carried out on the two symmetrical sections of the internal lining of the footwear inner, and enables the creation of a complete seam along the cut edges (30a) to form a portion of the internal section of the footwear inner. This seam will not be created in the upper section of the Invention, in order to retain the opening for the foot to be inserted into the footwear inner.

[0061] As per the Invention implementation method and the information below, the seam on the internal lining to establish its final shape will only be created when the lining is already attached to another layer i.e. the external cover.

[0062] As per the Invention implementation method, at this point the external cover of the internal lining is created, and is also produced in the same shape as the aforementioned lining and in two symmetrical sections, using a range of materials that are soft, elastic and breathable. For this purpose soft natural and / or synthetic materials are used which are already known in the Prior Art related to the footwear industry. The aim of the external cover on the internal lining is to stabilise it, as on its own it would not hold stitches properly, thereby compromising its resistance and integrity. The details specified above in Fig. 2, Fig. 3 and Fig. 3A relating to the shape of the internal lining are used in the wording in the table of diagrams to also describe the shape of the external cover for this interior lining, as it features the same structural layout.

[0063] As per the Invention implementation method, the external cover for the internal lining is also processed whereby the V-shaped material is partially removed and the flap created in the heel area is folded over, as shown in (20, 30, 31 , 32). The dimensions of this flap are identical to those of the internal lining.

[0064] As per the Invention implementation method, the aim of the external cover on the internal lining is also to make the footwear inner more comfortable during use and to strengthen its structure in the presence of seams.

[0065] As per the Invention implementation method, before the internal lining and the corresponding external cover sections are sewn together to form the internal profile of the footwear inner, they are joined together using techniques already known in the Prior Art, for example: a. spot gluing using hot-melt glues, b. spot gluing using water-based hot-melt adhesives c. hot-melt adhesive web i.e. a lightweight mesh fabric with adhesive that is activated with heat and pressure (https: / / www.protechnic.fr / 2021 / 02 / 19 / what-is- hotmelt-adhesive-web / ) d. distributing and melting hot-melt elements, using the flame method for example, with a layer of hot-melt gel.

[0066] As per the Invention implementation method, the internal lining and its external cover constitute an initial semi-finished product, which may also be prepared alongside the final assembly of the footwear inner.

[0067] As per the Invention implementation method and as stated above, once the two internal linings joined to their external covers are cut (30, 31 , 32) and sewn at their perimeter edges (30a), they create the inside section of the footwear inner, namely an initial semi-finished version of the footwear inner. Obviously the section where the foot is inserted (30c) is not stitched.

[0068] As per another Invention implementation method, the external cover of the lining may have a different layout, namely a shape consigned solely to the area next to the seams required to create the three-dimensional shape of the footwear inner. As mentioned previously, the presence of a smaller external cover for the internal lining means the same seams will not unravel the weave of the internal lining in the footwear inner. Fig.3B shows seams on the internal lining that create the three-dimensional shape of the Invention when joined to the corresponding external cover, (30b) which is restricted to an area defined by the perimeter of the footwear inner and along the edges joined by the same seam.

[0069] As per the Invention implementation method, the external cover / internal lining pair is attached to a front gusset at the instep, as shown in Fig.3C and Fig.3D, to enable a better fit on the foot inside the shoe where the inner is positioned.

[0070] As per the Invention implementation method, the gusset is made of elastic material and pre-shaped appropriately (30c) so it can be stitched (31c) to the inside section of the footwear inner (formed from the internal lining and the corresponding external cover i.e. the first semi-finished product) at the front with respect to the opening for inserting the foot.

[0071] As per the Invention implementation method, all seams on the inside section of the footwear inner i.e. the initial semi-finished product, are sealed appropriately and made waterproof by attaching the breathable, waterproof membrane using glue or another method, as outlined below in the Description. This membrane will cover the entire outside of the initial semi-finished product, including the front gusset.

[0072] As per another Invention implementation method, the gusset at the front and the membrane can be attached with a higher amount of adhesive i.e. by distributing the glue, or using a gluing method already described in section 0062, on the surface of the gusset section and the existing section on the surface of the membrane, thereby increasing the coefficient of adhesion between the elastic gusset and the membrane.

[0073] Fig. 3D shows an axonometric view of the inside section of the footwear inner in this Invention with the gusset (30d) before it is sewn onto the lining and the corresponding external cover attached to it.

[0074] As per the Invention implementation method, at this point a structural layer is created to obtain two important features: a. a layer of synthetic and / or natural material is inserted to further increase foot comfort in specific areas, b. the footwear inner is made semi-rigid to ease insertion in the upper of the footwear and prevent it from collapsing.

[0075] It is known that footwear inners in the Prior Art are difficult to insert in the space defined by the upper and sole of footwear because they are made of soft textiles and tend to collapse or fold when handled.

[0076] As per the Invention implementation method, the structural layer is therefore suitably profiled to create the right amount of stiffness in the footwear inner, making it manageable for inserting in the footwear without this stiffness making it uncomfortable.

[0077] Moreover, as per the Invention implementation method, the particular shape of the structural layer does not affect the breathability of the footwear inner, as the overall surface of this layer is smaller than the total surface of the Invention.

[0078] As per the Invention implementation method, the structural layer is made of soft synthetic and / or natural materials, which may also be a mix, and are already known in the footwear industry in the Prior Art.

[0079] As per the Invention implementation method, a possible format of the structural layer is shown in Fig. 4 and creates a cover on the sole of the footwear inner (40) similar to the sole of footwear, but it extends vertically (41) for approximately a third of its height.

[0080] As per another Invention implementation method shown in Fig.5, it is possible to establish an increase in the area of the structural layer in the forefoot area and the heel area (51 , 52), with this increase extending vertically while maintaining cover in the area of the sole of the foot (50). Varied formats for the structural layer are possible, and may even differ from those illustrated in Fig. 4 and Fig. 5.

[0081] As per the Invention implementation method, the structural layer should always cover at least one part of the sole area of the footwear inner.

[0082] As per another Invention implementation method, this increase in the area of the structural layer enables the stiffness of the footwear inner to be improved moderately, facilitating its insertion in footwear.

[0083] As per another Invention implementation method, the structural layer can also be made solely by spreading natural and / or synthetic resins in the areas of the footwear inner already described above. The use of these resins will stiffen the aforementioned areas moderately in the same way as a structural layer obtained by using textiles, as already described above.

[0084] Therefore as per the Invention implementation method, the structural layer is positioned between the external cover of the internal lining and the membrane, which will be described further on in this Description.

[0085] As per the Invention implementation method and contrary to the Prior Art, it can be noted how the basic requirement for comfort in the footwear inner is created by three of the five layers in the complex, namely: a. an internal lining, b. an external cover on the internal lining with a gusset attached, c. a structural layer, each of which is designed with materials and technical characteristics, including their particular format, that work together in synergy.

[0086] As per the Invention implementation method, at this point a waterproof membrane is used which is microporous, therefore breathable or with hydrophilic characteristics (62), and this is also made of two symmetrical sections. The material chosen to make the membrane, even as a mix, may be:a. polyurethane, b. polyester, c. polyethylene, d. polyamide (PA), e. polytetrafluoroethylene (PTFE).

[0087] As per the Invention implementation method, the use of these materials can also include the respective bio-based versions which have plant-based products added during processing.

[0088] As per the Invention implementation method, the membrane used is created with an elasticity factor as per standard UNI EN ISO 14704-1 :2005 that varies between 220% and 250% transversally and longitudinally i.e. with identical values in the elastic required for the correct use in this field of application. When the footwear inner is walked on it has to withstand forces and compression in all directions, and provide the correct fit and comfort for the foot through its elasticity.

[0089] As per the Invention implementation method, the membrane weighs between 8g / m2and 75g / m2. Both surfaces of the membrane also have spots of glue distributed so they can be attached to the other layers of material in the complex described previously. The gluing process is applied according to the following possible techniques in the Prior Art: a. spot gluing using hot-melt glues, b. spot gluing using water-based hot-melt adhesives, c. hot-melt adhesive web, d. distributing and melting hot-melt elements, using the flame method for example, with a layer of hot-melt gel.

[0090] As per the Invention implementation method, the waterproof microporous or hydrophilic membrane is cut into a shape to make a three-dimensional footwear inner, therefore it is in the shape of a foot and made of two symmetrical sections that are joined together, covering the internal structure of the footwear inner and creating the initial semifinished product (see section 0082).

[0091] As per the Invention implementation method, and unlike the internal lining and its external cover, the membrane has the following characteristics: a. has not undergone the partial removal of V-shaped material in the heel area, which is common to the internal lining and its external cover,b. the shape of the membrane is similar to that of the internal lining of the footwear inner, but the overall area of the waterproof membrane is greater than that of the aforementioned lining when attached to its external cover with the front gusset sewn on, excluding the area for inserting the foot in the internal lining (61). This particular shape is perfected so that the larger proportion enables a perimeter edge with surplus (60) with respect to the initial semi-finished product, with this edge being joined to create the final appearance of the footwear inner.

[0092] Therefore as per the Invention implementation method, the perimeter join (60) of the two symmetrical membrane surfaces creates the total volume of the footwear inner and encapsulates its internal structure and the structural layer i.e. the initial semi-finished product.

[0093] As per the Invention implementation method and as illustrated in Fig. 6, the perimeter edge of the membrane in the foot insertion section of the footwear inner (61) i.e. that of the instep, is not included in the joint of the two membrane sheets, as the area of the membrane does not exceed that of the internal structure of the footwear inner, thereby retaining the opening for inserting the foot into the internal lining of the Invention.

[0094] As per the Invention implementation method, the internal lining, corresponding external cover, structural layer and the gusset forming the internal structure of the footwear inner are therefore all contained by the joint of the perimeter edges of the two membranes, which are closed and so there is no further stitching on the aforementioned edges, which would require a subsequent waterproofing step with a heat-sealing process. In practice the stitching would create perforation in the membrane with the resulting consequences described in the background to the Invention.

[0095] As per another Invention implementation method, and for reasons relating to the nature of the footwear in which the footwear inner should be used, it is possible for the internal lining with its external cover to have an area larger than the membrane in the section of the footwear inner where the foot is inserted, as illustrated in Fig. 6C (60c), extending towards the ankle.

[0096] As per the Invention implementation method, the membrane is glued firmly to a fabric made of polyester and / or polyamide, or even with a mix of these materials, and cut into two symmetrical sections and weighing between 20g / m2and 100g / m2and having an elasticity factor as per standard UNI EN ISO 14704-1 :2005 of between 20% and 60% transversally and longitudinally. The area and shape of the fabric sections follow those of the membrane entirely.

[0097] As per the Invention implementation method, the membrane and fabric combination create a symmetrical pair of a second semi-finished product, also prepared alongside the footwear inner production process, in which a total elasticity factor in accordance with standard UNI EN ISO 14704-1 :2005 will be determined by the value for the fabric, therefore between 20% and 60% transversally and longitudinally.

[0098] As per a preferable implementation method, the fabric is produced in circular knit polyester weighing between 20g / m2and 100 g / m2.

[0099] As per the Invention implementation method, the adhesion technique between the membrane and the fabric uses individual spots of glue with a distribution of between 8g / m2and 15g / m2, preferably 12 g / m2of adhesive, with a hot-melt adhesive for example, or a water-based hot melt.

[0100] As per another Invention implementation method, the membrane and the fabric can be joined using an adhesive web or melt process as detailed in this Invention.

[0101] As per the Invention implementation method, this technique is required due to the overall layout of the complex in this Invention: a. the use of individual spots of the adhesive web or melt technique enables the membrane / fabric pair to expand and return to its original size without compromising the aforementioned elasticity, which would be limited or compromised by gluing with a uniform distribution of adhesive. As per the Invention implementation method, the fabric and the membrane ensure comparable elasticity transversally and longitudinally, and this is facilitated by the spot gluing, adhesive web or melt techniques, which only partially oppose the forces applied during normal stresses applied due to walking, which produces continuous, repetitive extension and contraction motions on the Invention. b. The aforementioned gluing methods enable a suitable level of breathability in the materials used to create the Invention.

[0102] Fig. 6A shows a cross-section of the membrane and fabric combination i.e. the second semi-finished product. As per the Invention implementation method, the two layers of joined materials consisting of the membrane (62a) and the fabric (63a) preferably have a thickness of between 0.20mm and 0.50mm.

[0103] As per the Invention implementation method, the inside surface of the membrane that is not attached to the fabric is prepared, for example, with spots of hot-melt adhesive, or a water-based hot melt, or an adhesive web or adhesive melt process. The aim of the glueis to attach the membrane to the inside section of the footwear inner i.e. to the initial semifinished product.

[0104] As per an Invention implementation method and as detailed in this Description, the membrane / fabric pair can represent a second semi-finished product prepared alongside the final assembly process for the footwear inner, and is obtained via the following process: a. one of the gluing techniques from those already described (61a) is applied to a surface of the membrane, b. the fabric (63a) is attached to the membrane (62a), c. the other surface of the membrane which is not attached to the fabric undergoes one of the gluing techniques already described (60a).

[0105] As per the Invention implementation method, the perimeter edges of the membrane, creating the join that forms the final shape of the footwear inner, are glued using a flat press on all layers in the complex that have been described and assembled in this Invention. The flat press is heated appropriately and activates the glue on the surface of the membrane which is in contact with the inside structure of the footwear inner, as the two symmetrical surfaces of the second semi-finished membrane / fabric pair are closed to encapsulate the aforementioned section. As the area of the membrane and the attached fabric is greater than that of the inside section of the footwear inner, on the outer edge of the aforementioned inner, as shown in detail in the cross-section in Fig. 7a, a perimeter edge (70a) is created from the contact between the two membranes, which will form a shell around the inside section constituting the Invention (71a), thereby avoiding the need for any type of seam that could compromise the necessary waterproof characteristics.

[0106] As per the Invention implementation method, once its assembly has been completed, the Invention is in the A-A' partial cross-section as shown in Fig. 7, whereby the layers of material are illustrated unattached and spaced out to show their position clearly: a. an initial ensemble of materials consisting of the internal lining (70) and its external cover (71) with the gusset joined, which is designed to accommodate the foot and create an environment that surrounds it adequately; the aforementioned materials are joined together using one of the gluing techniques already described, and sewn at their perimeter edges, except for the section where the foot is inserted, b. a structural layer (72) which aims to make the footwear inner semi-rigid and increase its comfort, with this layer joined to the external cover of the internal lining,c. an outer structure consisting of the breathable membrane (73) and an attached fabric (74), whereby this outer structure is thin and breathable and forms a soft outer shell containing the inside structure of the footwear inner, making the Invention cohesive and stable, d. glue on the perimeter edges of the membrane attached to the fabric (75) that defines the overall shape of the Invention.

[0107] As per another Invention implementation method, it is possible to reduce wear and tear on the membrane and the fabric of the footwear inner, especially between its mid-section and the forefoot area, where the bones of the toes bend and come into contact with the metatarsals.

[0108] As per another Invention implementation method, soft, elastic protective pads in natural or synthetic material are positioned external to the fabric.

[0109] As per another Invention implementation method, the protective pads are situated between the mid-section of the footwear inner, known as the mid-foot, and the forefoot area, preferably on the internal and external sides of the footwear inner (80, 81), external to it, given that these sides always rub against the inside of the footwear upper due to the toes bending.

[0110] As per the Invention implementation method, the protection pads are made as a pair, one for inside and one for outside the footwear upper. The protection pads are attached using a glue in the Prior Art. Depending on requirements, more than two protection pads can be added to the footwear inner in this Invention.

[0111] As per another Invention implementation method, a different layout can be used with the gusset attached to the footwear inner when the footwear in which it is being used has a side zip opening, as illustrated in Fig. 9 (90). In practice a side zip is a common solution in footwear manufacture and is used for technical reasons, such as in sports footwear as in motor cycle sports for example, and for non-technical reasons, such as aesthetic purposes.

[0112] As per another Invention implementation method, the gusset on the footwear inner is arranged laterally in the hindfoot area above the heel (80a) i.e. in the same area where the aforementioned footwear is usually equipped with the zip fastener. This step is carried out when the inside section of the footwear inner is complete i.e. when the lining and its external cover are attached and stitched together to create a three-dimensional shape.

[0113] As per the Invention implementation method, a cut is made in the selected area and stitches (81a) are used to attach the gusset (82a). Once the Invention is complete with theinclusion of the waterproof membrane attached to its fabric (83a) i.e. the second semifinished product, a cut will be made on it following the vertical midline of the gusset (84a).

[0114] When putting on the item, the wearer will use the zip of the footwear (90) already on the inside with the footwear inner in this Invention, such that the upper can open up (91) for the foot to be inserted into the footwear. As the gusset on the footwear inner (100) is in the area of the zip fastener, its constituent elastic material can expand freely as it is not obstructed by the upper, making fit easier.

[0115] As per another Invention implementation method, when the gusset material is positioned laterally on the footwear inner it can be suitably attached, using one of the gluing techniques already described, to an additional section of the membrane to ensure it is completely waterproof.

[0116] As per another Invention implementation method, the gusset can also be suitably positioned to the back of the footwear inner (120) for footwear that has a zip fastener in that area.

[0117] As per the Invention implementation method, obviously the format of the footwear inner is decided and produced in relation to the shape of the footwear, adapting its proportions so it can be inserted into it correctly. For example, the partially visible footwear inner in Fig. 10 (100) has a very high instep to suit the shape of the footwear in which it is inserted.

[0118] A construction process for the Invention is described below, which includes all five layers as specified previously in this document, in an implementation format with the gusset positioned laterally in the hindfoot area and the structural layer is made of a textile: a. two symmetrical internal linings are cut from the chosen material from which partial V-shapes of material (20) are removed in the heel area, b. two symmetrical external covers for the internal linings are cut from the chosen material from which partial V-shapes of material (20) are removed in the heel area, c. the internal linings and their external covers are attached using a gluing technique, d. the internal linings and their external covers are pre-shaped (30, 31 , 32) and sewn together (30a) along their perimeter edges, including those of the flap (20) to create the inside of the footwear inner while leaving the upper area open for inserting the foot, e. a cut is made in the heel area and a gusset is sewn on,f. a structural layer is cut from a chosen material, g. two symmetrical breathable membranes are cut from a chosen material, h. two symmetrical pieces of fabric are cut from a chosen material, i. each membrane is attached to its respective piece of fabric using a gluing technique, j. the remaining unattached surfaces of the membranes are treated with a gluing technique (60a, 60b), k. the structural layer is attached on top of the external cover of the internal lining, l. the membranes and their attached fabrics are placed over the internal lining, its external cover, the gusset and the structural layer such that the surfaces of the membrane with the glue are in contact with the inside of the footwear inner mentioned previously, m. a hot pressing process is carried out to activate the glue on the surface of the membranes to form a common perimeter join on the membranes (70,75,121) going beyond the inside area of the footwear inner, n. two protection pads are cut from a chosen material, o. the protection pads are attached to the inside and outside area of the fabric, including the midfoot and forefoot (123).

[0119] Fig. 11 shows the footwear inner in this Invention once the production process has been completed. Illustrated are a. the expansion created by the structural layer (110), b. the adhesion of the perimeter sections of the membrane (111) attached to the fabric, c. the gusset at the front (112) covered by the membrane and its attached fabric, with the membrane sealing the underlying seams (114) of the gusset entirely, d. the protection pads positioned between the midfoot and the forefoot section (113).Examples

[0120] None.Industrial Applicability

[0121] The industrial field of application of this invention is the production process for footwear and related accessories.Citation List

[0122] Citation List follows: none. Patent Literature

[0123] PTL1 : IT2018000020647

[0124] PTL2: IT2019000001973

[0125] PTL3: EP3332661A1

[0126] PTL4: GB2408190A

[0127] PTL5: US5253434A

[0128] PTL6: WO0211571A1Non-Patent Literature

[0129] NPL1 : https: / / www.protechnic.fr / 2021 / 02 / 19 / what-is-hotmelt-adhesive-web /

Claims

AMENDED CLAIMS received by the International Bureau on 27 March 2026 (27.03.2026)

1. Waterproof and breathable sock closed on the sole insertable inside a footwear and realized in synthetic and / or natural materials, realized from two mirrored sections of foot-shaped multilayer materials joined together on part of their respective perimeter edges (111) to realize a three-dimensional aspect, said sock characterized by an opening for fitting the foot in its upper section in communication with the inner lining (61) and equipped with an elastic bellows (30c, 30d), said mirrored multilayer sections composed of the union of: a. two foot-shaped inner linings (Fig.2) attached to two respective outer coverings of said linings and sewn around the perimeter (30a) excluding the foot insertion area (31 b, 61), said sewing forming a first semi-finished product, b. a structural layer (40,41) placed upon the outer covering of the inner lining, preferably in the sole area of the sock, c. two waterproof and breathable foot-shaped membranes (62) glued respectively to two knits, said membranes and knits with a larger area than that of the internal lining and the respective external covering, said membranes and knits forming a second semi-finished product, said second semi-finished product closed above the first semi-finished product and to the structural layer by gluing the perimeter edges (60) excluding the foot insertion area (61), d. the inner lining is made up of a polyester and / or polyamide and / or natural textile materials, also in a mixture, characterized by a weight between 60gr / m2and 800gr / m2, preferably between 90gr / m2and 180gr / m2, said lining characterized by a partial removal of a “V”-shaped material in the heel area, forming a flap (20), e. the outer covering of the inner lining is realized in natural and / or synthetic material and is characterized by a shape and an area of the alternative type: i. a shape and an area equal to that of the inner lining, or ii. a shape and an area limited to the areas bordering the seams (30b) joining the inner lining with the said outer covering. f. the surface of the outer covering attached to the inner lining is treated with one of the following bonding techniques: i. spot gluing with hot-melt type glue, ii. spot gluing with water-based heat-adhesive glue,iii. Web- based bonding, iv. coupling by interposition and fusion of heat-fusing elements, g. the structural layer (Fig.4) is realized with a synthetic and / or natural textile material and it extends at least partially to the bottom area of the sock (40), h. the membrane (62) is made using the following materials, even mixed each other and / or with bio-based bases: i. Polyurethane, ii. Polyester, iii. Polyethylene, iv. Polyamide, v. Polytetrafluoroethylene (PTFE), i. the membrane has a weight between 8 gr / m2and 75 gr / m2, j. the membrane is characterized by a total surface area greater than the area delimited by the inner lining attached to its own outer covering, excepted the area prepared for the insertion of the foot in the inner lining (61) in such a way as to generate a perimeter edge (60), k. the membrane has an elasticity factor according to UNI EN ISO 14704-1 :2005 standard, varying from 220% to 250% in both transverse and longitudinal direction, l. the surface of the membrane attached to the outer covering of the inner lining alternately presents one of the following bonding methods: i. a deposit by means of a single glue spot engraved cylinder (60a, 60b) in a quantity between 8 gr / m2and 15gr / m2, preferably 12gr / m2, of hot- melt type or water heat-adhesive type, ii. an adhesive element via Web-based bonding, iii. coupling by interposition and fusion of heath-fusing elements, m. the surface of the membrane attached to the knit has one of the following bonding techniques: i. spot gluing with hot-melt type glue, ii. spot gluing with water-based heat-adhesive glue,iii. Web-based bonding, iv. coupling by interposition and fusion of heat-fusing elements, n. the knit is realized in Polyester and / or Polyamide, even mixed each other, with a weight between 20gr / m2and 100gr / m2, said knit with a shape and a total surface equal to that of the membrane, said knit realized preferably from circular knitted Polyester fabric with a weight between 20gr / m2and 100gr / m2, o. the knit has an elasticity factor according to UNU EN ISO 14704-1 :2005 between 20% and 60% in both transverse and longitudinal direction, p. the overall thickness of the knit attached to the membrane is between 0,20mm and 0,50mm.

2. Sock of Claim 1 in which the flaps (20) resulting from the removal of the “V” shaped linings material in the heel area are folded down (30) in order to determine a three- dimensional shape of the two inner linings in the area of the sock sole (30,31).

3. Sock of Claim 1 in which the two inner linings attached to the respective outer covering are sewn together in the respective perimeter edges (30a) including flaps (20) - except for the foot insertion area (61) - to form a three-dimensional shape.

4. Sock of Claim 1 in which an elastic bellows (30c) (30d) realized with an elastic textile material is sewn on the two foot-shaped inner linings (30c) (31c), said elastic bellow alternately arranged: a. in a frontal position (30d) with respect to the opening for the foot insertion area, or b. in a lateral position (82a) with respect to the opening for the foot insertion area, or c. in a back position with respect to the opening for the foot insertion area (120).

5. Sock of Claim 1 in which the surface of the structural layer extends vertically towards the heel and forefoot area (51,52).

6. Sock of Claim 1 in which the structural layer is realized by coating natural or synthetic resins.

7. Sock of Claim 1 in which two or more protective pads in natural or synthetic material (80,81) are applied on the knits in the area between the mid-foot and the forefoot.

8. Sock of Claim 1 in which, limited to the portion of the sock used for inserting the foot, the area of the inner lining and its outer covering exceeds the area of the membrane (60c).

9. Sock of Claim 4 in which the elastic bellows arranged in lateral position (82a) or in back position (120) on the sock, is attached by means of a bonding technique to an additional portion of waterproof and breathable membrane.

10. Sock of Claim 4 in which the surface of the elastic bellows in frontal position (30d) is prepared with a bonding technique before joining with the membrane.

11. Process of realization of the sock of Claim 1 equipped with a frontal bellows in which: a. two symmetrical-shaped inner linings are cut out from a chosen material on which, on the heel area, the “V”-shaped material partial removals are performed to create the flap (20), b. two symmetrical-shaped outer coverings of the respective inner linings are cut out from a chosen material, on which the “V”-shaped partial material removals are performed in the heel area to create the flap, c. the inner linings are attached with their respective outer covering by means of a glue, d. the inner linings and the respective outer coverings are pre-formed (30,31 ,32) and sewn together (30a) along their respective perimeter edges, including those of the flap (20), with exception of the section for inserting the foot (31b) to form an inner section of the sock, e. in the instep area, at the front, a bellows (30c, 30d) is sewn onto the inner lining attached to its own outer covering, f. a structural layer is cut out from a chosen material, g. two symmetrical-shaped breathable membranes are cut out from a chosen material, h. two symmetrical-shaped knits are cut out from a chosen material, i. each membrane is glued to each respective knit, j. the structural layer is externally applied to the inner section of the sock,k. the knits and the waterproof and breathable membranes attached to them are placed upon the inner section of the sock so that the surface of the membranes treated with the glue adheres with the surface of the inner section of the sock, l. the knits and the waterproof and breathable membranes attached to them, including inside them the inner section of the sock, are subjected to a pressure treatment at a temperature that activates the glue on the surface of the membranes, said pressure treatment form a perimeter joint of the membrane edges (111) exceeding the area of the inner structure of the sock, m. two symmetrical-shaped protective pads are cut out from a chosen material, n. the two protective pads are externally applied to the sock, in the section between the mid-foot and the forefoot (80,81 ,113).

12. Process of realization of the sock of Claim 1 equipped with a lateral bellows in which: a. two symmetrical-shaped inner linings are cut out from a chosen material on which, on the heel area, the “V”-shaped material partial removals are performed to create the flap (20), b. two symmetrical-shaped outer coverings of the respective inner linings are cut out from a chosen material, on which the “V”-shaped partial material removals are performed in the heel area to create the flap, c. the inner linings are attached with their respective outer covering by means of a glue, d. the inner linings and the respective outer coverings are pre-formed (30,31,32) and sewn together (30a) along their respective perimeter edges, including those of the flap (20), with exception of the section for inserting the foot (31b) to form an inner section of the sock, e. in the heel area, near the opening of the sock for the foot fit (80a) and in a lateral position, a bellows (82a) is sewn (81) by cutting the inner lining and the respective outer covering, f. a structural layer is cut out from a chosen material, g. two symmetrical-shaped breathable membranes are cut out from a chosen material, h. two symmetrical-shaped knits are cut out from a chosen material,i. each membrane is glued to each respective knit, j. the structural layer is externally applied to the inner section of the sock, k. the knits and the waterproof and breathable membranes attached to them are placed upon the inner section of the sock so that the surface of the membranes treated with the glue adheres with the surface of the inner section of the sock, l. the knits and the waterproof and breathable membranes attached to them, including inside them the inner section of the sock, are subjected to a pressure treatment at a temperature that activates the glue on the surface of the membranes, said pressure treatment form a perimeter joint of the membrane edges (111) exceeding the area of the inner structure of the sock, m. two symmetrical-shaped protective pads are cut out from a chosen material, n. the two protective pads are externally applied to the sock, in the section between the mid-foot and the forefoot (80,81 ,113). o. a cut is made in the membrane and knit at the position of the vertical centerline of the bellows (84a) such that the bellows can extend and retract.

13. Process of Claim 11 and 12 in which the structural layer is realized by coating synthetic or natural resins.

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