Patent Application
20220256965
The present invention relates to footwear, and more particularly to footwear having waterproof features.
A variety of footwear are designed for specific applications. Many footwear are designed for outdoor activity. A subset of those, such as boots and hiking shoes, as well as work footwear, frequently are used in damp, wet or snowy conditions. These footwear can be designed and constructed from special waterproof materials, such as rubber or polymers, to keep a wearer's foot from becoming wet from the surrounding environment. Rubber or polymer footwear, however, typically do not provide much support, and tend to look rather industrial and/or plain.
Some manufacturers offer other types of boots and shoes having an upper, which is constructed from other materials, such as leather or fabric, and which can have a more aesthetic or stylish appearance, versus a conventional waterproof rubber boot. These aesthetic materials typically are not waterproof, so the footwear also includes a special waterproof bootie as an inner layer, stuffed inside the footwear. The bootie is constructed from a plastic membrane that usually includes multiple parts that are adhered with an adhesive, or taped together at respective edges with a waterproof tape. The edges are carefully joined and made waterproof via the adhesive and/or tape so that water cannot enter the interior of the bootie at the junction of the edges.
Frequently, waterproof booties can become loosened from the interior of the boot and can be pulled out from the boot upon removal of a user's foot. This can be cumbersome and require reinsertion of the bootie carefully inside the interior of the footwear so that the bootie is not bunched to cause the wearer discomfort. The booties also can stretch and can sometimes tear or rip apart at the junction of the membrane edges. With such a compromise in the bootie, it no longer is waterproof, so the wearer's foot can become wet via a leak. Further, such booties can be difficult to manufacture, because the tape and glue must be precisely placed at the edges of the membrane, typically in a manual fashion. Due to operator error, the placement can be imperfect, so the edges are not completely sealed during manufacture. Alternatively, the tape or glue forms a weakened or poor initial seal, which is quickly damaged or compromised with minimal use and/or wear on the footwear.
Accordingly, there remains room for improvement in the field of waterproof footwear and associated waterproofing features.
Footwear is provided including a waterproof gasket system disposed at an interface of different panels of an upper of the footwear.
In one embodiment, a thread that is disposed between and/or within an interface of adjacent waterproof panels, and melted to yield a waterproof gasket between the panels.
In another embodiment, the footwear can include an upper including a first layer, a waterproof functional second layer adjacent the first layer, and a waterproof functional insole including a perimeter. The perimeter can be disposed adjacent the first layer and/or the second layer. The thread can extend through the first layer, sewn through it multiple times, and can be located between the insole and the second layer, and adjacent the perimeter. The thread can be melted to form the waterproof gasket between the waterproof functional second layer and the waterproof functional insole, optionally along the perimeter, and optionally continuously around the entire perimeter.
In even another embodiment, the footwear can include a structural stitch extending through the first layer, the second layer and the insole. This structural stitch can be in addition to the thread that is melted and/or fused, and can be placed or sewn in place after the thread is placed or sewn in place. In some cases, the structural stitch extends transversely through the gasket. The melting of the thread can form a waterproof seal around the structural stitch.
In yet another embodiment, the first segment of the structural stitch can be parallel to a first segment of the thread extending through the first layer. A second segment of the structural stitch can be parallel to a second segment of the thread extending along the first layer. The first and second segment of the structural stitch can be transverse to one another. The first and second segment of the thread can be transverse to one another.
In still another embodiment, the thread can be melted to form a waterproof gasket around the perimeter of the insole such that liquids cannot penetrate or flow between the insole, which can be a waterproof functional insole or Strobel board, and the waterproof functional second layer.
In yet another embodiment, the thread can be sewn through the first layer so that some segments of the thread extend through a body of the first layer, some segments lay on an interior surface of the layer, and some segments lay on an exterior of the layer. The segments can be melted and can fuse or embed within the body, the interior surface and the exterior surface.
In even another embodiment, the thread can be a polymeric thread with a melting temperature that is less than the melting temperature of the structural stitch and/or the first layer, second layer and the insole. When heated, the thread can melt while the other components do not melt substantially.
In a further embodiment, the thread that forms the gasket can be a thermoplastic polyurethane thread. The thread can melt at a temperature optionally above 200 degrees Fahrenheit so that the thread melts and encapsulates or embeds within adjacent materials in the first layer, and adheres to or otherwise joins with a surface of the waterproof functional second layer and/or the insole.
In still a further embodiment, the waterproof functional insole can have a longitudinal axis and an insole width perpendicular to the longitudinal axis. The gasket can have a gasket width. A ratio of the gasket width to the insole width can be selected to provide waterproofing at the gasket but prevent the insole from becoming too rigid and/or leading to cracking of the gasket in stress regions. In some cases, the ratio of the gasket width to the insole width can be optionally less than 1:2, less than 1:4, less than 1:6, less than 1:8, less than 1:10 or less than 1:12.
In yet a further embodiment, the gasket can have a gasket width. This width can be the width of the gasket on one side of a longitudinal axis of the footwear and/or the layer to which the thread is attached. The gasket width can be optionally less than 30 mm, less than 20 mm, or less than 10 mm. The gasket width can be selected so that it does not become too wide and prone to cracking or splitting at its perimeters when the insole and/or layers are repeatedly bent or placed under load.
In even a further embodiment, a waterproof gasket system can be formed between an upper and a Strobel board or insole. The system can include an upper including a first layer having an upper layer perimeter or edge to which a hot melt flange is secured via first structural stitching. A waterproof functional second layer can be joined with and can overlap the hot melt flange, the first stitching and the first layer to form a composite upper panel.
In still a further embodiment, the composite upper panel can include a composite upper panel perimeter that is disposed adjacent and/or abutted against a perimeter of an insole which optionally is in the shape of a human foot. The insole and composite panels can be joined together, optionally with a second structural stitching along their respective perimeters.
In still yet a further embodiment, a waterproof panel can be secured over the insole, over the perimeters and over the second structural stitching to form a waterproof barrier over these elements. This waterproof barrier, plus the hot melt flange and waterproof functional second layer can cooperate to provide the waterproof gasket system.
In even a further embodiment, a method is provided. The method can include providing an upper having a U-shaped outer perimeter, sewing a thread repeatedly through the first layer around the outer perimeter; positioning a waterproof functional insole having an insole perimeter adjacent at least one of the first layer and the second layer; and melting the thread to form a waterproof gasket between the waterproof functional second layer and the waterproof functional insole.
In another, further embodiment, the method can include sewing a structural stitch through the first layer, the waterproof functional second layer and the waterproof functional insole. The structural stitch can extend transversely through the gasket. A first segment of the structural stitch can be parallel to a first segment of the thread extending through the first layer, a second segment of the structural stitch can be parallel to a second segment of the thread extending along the first layer.
In still another embodiment, the method can include heating the thread to at least 200 degrees Fahrenheit so that the thread melts and encapsulates adjacent strands in the first layer, and adheres to a surface of the waterproof functional second layer. This heating and fusing can form the gasket from the thread to produce a waterproof interface between the first layer and/or second layer and the insole.
The footwear of the current embodiments provides a waterproofing system that is simple to manufacture and provides a watertight gasket between joined panels of the footwear. Where the gasket is constructed from thread, the thread can be consistently and precisely sewn where a gasket is desired to be placed relative to other panels and components of the footwear. The sewn on thread also can maintain its position in subsequent processing, for example, when the different panels of the upper and insole are placed adjacent and secured to one another. The gasket can be continuous and can penetrate the layer in which the thread is sewn, as well as form a bond between that layer and other components that are placed adjacent that layer. The gasket can be flexible and less prone to cracking, breaking and damage where the thread is melted and impregnated in one or more layers. The thread can be compatible with any included structural stitching that secures the panels together. When melted, the thread also can encapsulate and bond to the optional structural stitching to waterproof around any holes in material formed around that stitching.
These and other objects, advantages, and features of the invention will be more fully understood and appreciated by reference to the description of the current embodiment and the drawings.
Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited to the details of operation or to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention may be implemented in various other embodiments and of being practiced or being carried out in alternative ways not expressly disclosed herein. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof. Further, enumeration may be used in the description of various embodiments. Unless otherwise expressly stated, the use of enumeration should not be construed as limiting the invention to any specific order or number of components. Nor should the use of enumeration be construed as excluding from the scope of the invention any additional steps or components that might be combined with or into the enumerated steps or components.
A current embodiment of the footwear is illustrated in
Although the current embodiments are illustrated in the context of a hiking boot or water resistant shoe, they may be incorporated into any type or style of footwear, including performance shoes, hiking shoes, trail shoes and boots, work boots, all-terrain shoes, barefoot running shoes, athletic shoes, running shoes, sneakers, conventional tennis shoes, walking shoes, multisport footwear, casual shoes, dress shoes or any other type of footwear or footwear components. It also should be noted that directional terms, such as “vertical,” “horizontal,” “top,” “bottom,” “upper,” “lower,” “inner,” “inwardly,” “outer” and “outwardly,” are used to assist in describing the invention based on the orientation of the embodiments shown in the illustrations.
Further, the terms “medial,” “lateral” and “longitudinal” are used in the manner commonly used in connection with footwear. For example, when used in referring to a side of the shoe, the term “medial” refers to the inward side (that is, the side facing the other shoe) and “lateral” refers to the outward side. When used in referring to a direction, the term “longitudinal direction” refers to a direction generally extending along the length of the shoe between toe and heel, and the term “lateral direction” refers to a direction generally extending across the width of the shoe between the medial and lateral sides of the shoe. The use of directional terms should not be interpreted to limit the invention to any specific orientation. Further, as used herein, the term “arch region” (or arch or midfoot) refers generally to the portion of the footwear or sole assembly corresponding to the arch or midfoot of the wearer's foot; the term “forefoot region” (or forefoot) refers generally to the portion of the footwear forward of the arch region corresponding to the forefoot (for example, including the ball and the toes) of a wearer's foot; and the term “heel region” (or heel) refers generally to that portion of the footwear rearward of the arch region corresponding to the heel of the wearer's foot.
In the embodiment illustrated herein, the vamp, lateral panel, medial panel, and heel panels are contiguous and form a unitary upper 20. This upper can include a first layer 21 that can include an interior surface 21I and an exterior surface 21E. The first layer optionally can be a unitary textile. Such a textile can be woven, knit, mesh, nonwoven, felt constructions, etc. Textiles can be produced from natural fibers such as cotton, or from synthetic fibers such as polyesters, polyamides, polypropylenes, polyolefins and/or blends thereof. As shown, the first layer can be knit from multiple individual strands that form interconnect loops that extend between or from the exterior to the interior in a predetermined manner. Between the individual strands and their loops, interstitial spaces or voids are formed in the first layer. The first layer can be formed by a knitting process, such as circular knitting, flat knitting, raschel knitting or any other knitting processes and the fusible monofilament strand can extend throughout the entire first layer. The textile upper layer 21 can be formed of unitary knit construction, for example, when formed as a one-piece element through a knitting process. That is, the knitting process substantially forms the, various shapes and structures of the textile upper and the layer without the need for significant additional manufacturing steps or processes. Although portions and edges of the upper and the first layer can be joined to each other (e.g., a seam joining the heel panels 20H) following the knitting process, the textile layer of the upper remains formed of unitary knit construction because it can be formed as a one-piece knit element.
The textile first layer 21 can be formed as a knit element produced via a mechanical knitting process performed on an automated knitting machine. Optionally, the knitting machine can be a circular knitting machine, such a.s a sock or tube knitting machine. Alternatively, the knitting machine can be a flat knitting machine or a jacquard raschel knitting machine. The knitting process can produce the knitted tube, and can incorporate a variety of different knit patterns in the knitted tube and/or the textile upper layer 21. With regard to knit patterns, the strands forming the textile upper layer 21 can have one type of knit pattern in one area and another type of knit pattern in another area. Depending upon the types and combinations of knit patterns utilized, areas of the textile upper layer 21 can have a plain knit structure, a mesh knit structure, a rib knit structure, and various combinations thereof, for example. Different types of knit patterns can be incorporated into specific locations of the textile upper layer 21 to modify the physical properties or aesthetics of the upper 20 in general, such as elasticity, air permeability, stiffness and abrasion-resistance.
In other embodiments, the upper 20 can be a multi-panel upper with the first layer formed as a vamp, lateral panel, medial panel, and heel panels sewn or otherwise joined together. The upper 20 can further include various trim, cushioning and reinforcing elements (not shown), such as, but not limited to, a toe bumper provided to reinforce the vamp, a pull tab provided to help pull the footwear 10 onto the wearer's foot, and/or a heel counter can be fitted into the heel region to reinforce the heel panels and seam, and to increase support.
Referring to
The upper 10 can be constructed in a laminate form, and can include the first layer 21 as mentioned above, and a second layer 22. This second layer can include an interior surface 22I and an exterior surface 22E as shown in
Waterproof functional layers or a waterproof functional insole described herein optionally can be and/or include a water vapor permeable functional layer comprising a polymeric membrane material. This membrane can be water vapor permeable or breathable. As used herein, water vapor permeable and breathable can be used interchangeably and mean that the functional layer has a water vapor coefficient RET of less than 200 m2Pa/W. Breathable polymeric membranes can be breathable via pores in the membrane or through a solution diffusion mechanism. Some examples of breathable polymeric membranes optionally can be polyurethane, polyester, polyether, polyamide, polyacrylate, copolyether ester and/or copolyether amides.
The footwear also can include an insole 40. The insole can be a waterproof functional insole. The insole 40 generally can be in the shape of the bottom of a human foot, and can extend from a forefoot region, through an arch region and to a heel region. Of course, the insole can be shorter than the full length of the footwear, and can instead extend only in one or two of these regions in some applications. The insole 40 can include a longitudinal axis LA and an insole width 1W taken perpendicular to the longitudinal axis. The insole optionally can be a knitted, woven or nonwoven material, or EVA or other polymer foam material. Optionally, the insole can be constructed from polyester, nylon, polyacrylic, polyolefin, polyurethane, polyvinyl, cotton, acetate, rayon, olefin, acrylic and/or wool. Further optionally, a waterproof film can be included as part of the insole. This film can be a polyvinyl chloride, rubber, neoprene and/or any other stretchable, flexible film.
Further optionally, as illustrated, the insole 40 can be in the form of a waterproof functional Strobel board, incorporated into a Strobel construction with the upper as described below. The insole 40 can include a perimeter 44 that is positioned adjacent and/or directly engaging the edge of the upper 20, or more particularly the first layer 21 and the second layer 22 where included. The perimeter 44 can terminate at a third edge 43. This third edge 43 can be configured to engage and/or can be abutted against the first edge 21R of the first layer and/or the second edge 22R of the second layer in the Strobel construction as described below.
As mentioned above and shown in
The thread 55 can include multiple second segments 52 that extend along and/or across a portion of the exterior surface 21E of the first layer. Multiple ones of these second segments can crisscross one another in a transverse manner on or over the interior of the layer. The thread can also include multiple third segments 53 that extend along and/or across a portion of the interior surface 21I of the first layer. Multiple ones of these third segments can crisscross one another in a transverse manner on or over the exterior of the layer. The second and third segments can lay against and/or directly engage the interior and exterior surfaces. The second and third segments also can be transverse, optionally perpendicular or angled relative to the first segments, depending on the orientation of the sewing machine and the thread as it is sewn to the upper first layer 21.
The thread 55, and the resulting gasket 50, can be disposed adjacent the first edge 21R and the second edge 22R. In this position, the thread can be inset a preselected distance D1 from the edge 21R of the first layer through which it is sewn. This distance can be optionally less than 10 mm, less than 5 mm, less than 2 mm, less than 1 mm, between 0.1 mm and 10 mm inclusive, between 0.1 mm and 5 mm inclusive, or between 0.1 and 2 mm inclusive. The distance can be selected so that the thread passes through the body of the layer, and optionally not over the edge 21R. Of course, in some cases, the thread and the first segment can be placed adjacent and contact that edge.
As shown in
Optionally, the upper 20 can include a liner 23 as shown in
As mentioned above, the waterproof gasket 50 can be implemented in a Strobel construction, which is illustrated in
This structural stitch 60 further can extend through the gasket 50. In particular, the gasket 50 can include an inner perimeter 50I and an outer perimeter 50O. The gasket can define a gasket width GW between these perimeters. This width can be slightly greater than a width of the thread 55 when sewn or applied to the first layer 21, as the thread material can melt and bleed or flow outward. In some cases, the thread can melt enough that it flows through the edge 21R of the first layer, and becomes visible and prominent beyond that edge. As explained below, this can assist the melted thread to fuse and bond with other components such as the insole. As shown, the outer perimeter 50O can be closer to the edge 21R of the first layer 21.
The structural stitch 60 shown in
The gasket 50 as mentioned above can be completed or formed when the threads 55 are melted and fused to various components of the footwear. For example, as shown in
As further shown in
As shown, the regions 28 and 29 can be optionally angled relative to one another, for example, generally perpendicular to one another. As will be appreciated, to form the region 29, the melted thread material can bleed or seep out the first edge and/or the interior surface 21I of the first layer, to contact the first edge, as well as in some cases the second edge 22R. In so doing, the melted thread can flow and then cure against the exterior surface 22E of the second layer and bond mechanically and chemically to that layer to form the region 28. As mentioned above, the first edge and the second edge can be aligned one above the other in this construction.
As mentioned above, the gasket can have a gasket width GW. This gasket width can be taken on one side of the longitudinal axis of the footwear as shown in
A method of manufacturing the footwear 10 herein is also provided. On a high level, the method can include: providing an upper having a U-shaped outer perimeter, the upper including a first layer and a waterproof functional second layer adjacent the first layer; sewing a thread repeatedly through the first layer around the outer perimeter; positioning a waterproof functional insole having an insole perimeter adjacent at least one of the first layer and the second layer; and melting the thread to form a waterproof gasket between the waterproof functional second layer and the waterproof functional insole. For example, the upper 20 can be formed with the first layer 21, second layer 22 and lining 23 joined with one another, optionally as a laminate as discussed above, or as separate components. The upper can be placed on a foot shaped last and formed. The insole can be joined with the upper lower allowance 27 at the edges 21R and 22R of the first and second layers via the structural stitch 60, which can pass through the region around the edge 21R including the thread 55. The structural stitch can be sewn through the first layer 21, the waterproof functional second layer 22 and the waterproof functional insole 40. The structural stitch 60 can extend transversely through the region with the thread 55, and thus the gasket 50 after the thread is melted and forms the gasket.
Optionally after the insole is joined with the upper, the region around the thread 55 can be heated, which can cause the thread to melt and fuse (which also can include bond) to the various components around the thread. This heating can include heating the thread to at least 200 degrees Fahrenheit, at least 250 degrees Fahrenheit, at least 300 degrees Fahrenheit, at least 350 degrees Fahrenheit, at least 400 degrees Fahrenheit, or between 250 to 425 degrees Fahrenheit, inclusive. Such heating can cause the thread to melt and encapsulates adjacent strands in the first layer, and adhere to a surface of the waterproof functional second layer. Some of the thread can remain intact as segments, but much of the thread can melt to form an amorphous flowing material that penetrates the interstitial spaces between the strands of the first layer and/or the insole or other layers, embedding in, encapsulating and/or bonding to those strands and structures. After the melted thread does this, it is effectively cured and fused to those strands and structures of the upper and the insole, forming the waterproof gasket as described above.
Optionally, the thread 55 forming the gasket 50 can be melted and fused to the various components of the upper 20 and the insole 40 before the sole assembly 30 is joined with the upper. Thereafter, the sole assembly 30 can be joined with the formed upper and insole. This securement can be achieved with cement and/or adhesives that secure the sole assembly to the upper. With the gasket already being formed when the sole assembly is joined, the thread that forms the gasket generally does not melt and fuse to the outsole.
A first alternative embodiment of the footwear and waterproof gasket thereof is shown in
In this construction, however, the waterproof functional insole 140 can include a waterproof functional film 141 joined with an insole body 142 that may or may not be waterproof. This film can be a waterproof functional fourth layer adjacent the insole interior surface 140I. The exterior 121E of the first layer can be placed on, atop and/or engaging the insole interior 140I, and the film and its interior surface 141I. The upper lower allowance 127 can be stitched and secured to the insole around a perimeter 144 via the structural stitch 160 that passes through the thickness of the upper and the insole, with the first and second layers stacked atop the insole 140, rather than butted edge to edge with the insole. This can generally form an overlap seam between the first layer and the insole.
The threads can be melted and fused to the second layer exterior surface 122E above the first layer 121. The threads 155 also can be melted and fused to the insole 140, and the interior surface 141I of the waterproof functional fourth layer, shown as a film 141, under the first layer to form the waterproof gasket 150. The respective surfaces are thus sealed and bonded to one another, rather than the edges of the layers and insole. Optionally, the gasket waterproof regions or seals 128 and 129 optionally can be noncontiguous. The region 128 can be above the first layer, while the second region 129 can be below the first layer. The regions also can be parallel to one another, located on opposite surfaces of the layer 121. These regions also both can be penetrated by the structural stitch 160, with the melted and fused gasket sealing around that stitch and the hole it creates in the layers and insole.
A second alternative embodiment of the footwear and waterproof gasket thereof is shown in
In this construction, however, the lower allowance 227 can be turned or bent outward from the longitudinal axis LA of the insole. The edges 221R and 222R can be aligned with and above the edge 243 of the waterproof functional insole 240, to form a plain seam. The insole can include an interior surface 240I. The interior surface 221I in this embodiment can engage and contact that interior surface 240I. When the gasket 250 is formed by melting and fusing the thread 255, the seal 229 forms between the interior surface 221I and the interior surface 240I. The seal 228 also forms between the first layer and the second layer as described in the other embodiments above. The melted threads also seal around the structural stitch 260 and the hole created when that stitch is sewn through the layers.
A third alternative embodiment of the footwear and waterproof gasket thereof is shown in
As shown in
With reference to
The perimeter stitching 350 can extend over the interior surfaces 370I and 321I of the flange and first layer. To seal apertures in the flange due to the stitching and to seal over the stitching section 353 external to the flange and first layer, a waterproof functional second layer 322 like that described in the embodiments above can be disposed over the interior surfaces 379I and 321I. This can form a waterproof barrier region 377 shown in
With reference to
The composite panel 378 that forms part of the upper 320 can be joined with an insole 340 as shown in
The insole stitching 360 can extend around the perimeter of the insole 340. Optionally, the insole stitching 360 can be distal from and not traverse the first perimeter 321P or the perimeter stitching 350. The insole stitching can be separated a distance D5 from the perimeter stitching. The distance D5 can be optionally about 5 mm to about 50 mm, about 10 mm to about 30 mm, about 10 mm to about 20 mm, or about 15 mm.
The insole stitching 360 also can include a section 363 that extends over the insole exterior or outer surface 340O and the first layer exterior or outer surface 370O. This section can form apertures as it re-enters the respective insole and flange. To address these apertures, and/or to form a waterproof barrier over the exterior 340O of the insole where it is not itself waterproof, a gasket panel 380 can be secured or joined with the insole 340 and part of the panel 378. This gasket panel 378 can be bonded, fused, glued, cemented or otherwise joined with these elements in an optionally waterproof manner. The gasket panel can extend over and can be bonded to the insole exterior surface 340O, the first layer exterior surface and the insole stitching 360 or Strobel stitch where included to form a waterproof barrier 379 over apertures formed by the insole stitching, and optionally over the remainder of the exterior surface 340O of the insole. Further optionally, the gasket panel, the hot melt flange and the waterproof functional second layer form a continuous waterproof barrier so water or other liquids cannot enter the footwear.
The gasket panel 380 can include an outer gasket perimeter or edge 380E. This edge 380E can be located outward from the insole stitching 360 so it can cover and waterproof that stitching as well as the abutment of the panel 378 and the perimeter 340P of the insole 340. The gasket panel edge also can be located between the insole stitching 360 and the perimeter stitching 350, optionally without extending over the perimeter stitching 350 because that is already waterproofed with barrier 377 on the interior of the layer 321 and by the hot melt flange 370. The gasket panel can be made from a film, membrane or sheet of polyurethane, rubber, polymer silicone or other waterproof material described herein.
A method of making an article of footwear of the third alternative embodiment shown in
Optionally, the hot melt flange can be heated to at least partially melt the hot melt flange and bond it to the first layer, the waterproof functional second layer and/or the insole. In turn, this can enhance the rigidity of the hot melt flange. In some cases, the hot melt flange can be selectively heated and cooled in different regions or areas around the perimeter to provide controlled stiffened or softened regions around the footwear. The various components and features of the embodiments herein can take on a variety of aesthetic forms, shapes and sizes. Although a particular component or feature can have a function, that feature can be expressed in different aesthetic manners to form an artistic design and/or purely ornamental design.
The following additional Statements illustrate further embodiments, the numbering of which is not to be construed as designating levels of importance. Moreover, it is to be understood that the Statements of embodiments recited below are provided in conjunction with and in addition to the embodiments described above, as well as those claimed even farther below. Alternative embodiments that result from combining, integrating, and/or omitting features of the embodiments of the Statements below or any other embodiment described herein may also be within the scope of the present invention.
Statement A: An article of footwear comprising: an upper including a first layer having a first perimeter; a hot melt flange secured around the first perimeter to the first layer; a waterproof functional second layer laying over and joined with the first layer, the hot melt flange and the first perimeter; an insole having a second perimeter, the second perimeter being positioned adjacent at least one of the first layer, the hot melt flange and the second layer; an insole stitching extending through and joining the insole and the hot melt flange; and a gasket panel extending over and joined with the insole, the insole stitching and the hot melt flange, wherein the gasket panel, the hot melt flange and the waterproof functional second layer form a waterproof barrier so liquid cannot enter the footwear.
Statement B: The article of footwear of Statement A, wherein the insole stitching is distal from and does not traverse the first perimeter.
Statement C: The article of footwear of any preceding Statement comprising: a perimeter stitching extending through the first layer and the hot melt flange to join the first layer and the hot melt flange.
Statement D: The article of footwear of any preceding Statement comprising: wherein the insole stitching does not traverse the perimeter stitching and is distal from the perimeter stitching.
Statement E: The article of footwear of any preceding Statement, wherein the first layer includes a first layer edge and a first layer inner surface, wherein the hot melt flange includes a flange edge and a flange inner surface, wherein the waterproof functional second layer is bonded to and coextensive with the first layer inner surface and the flange inner surface.
Statement F: The article of footwear of any preceding Statement, wherein the first layer edge and the flange edge are abutted against one another, wherein a perimeter stitching crisscrosses the first layer edge and the flange edge to join the first layer edge and the flange edge distal from the insole stitching.
Statement G: The article of footwear of any preceding Statement, comprising: a perimeter stitching cross crossing the first perimeter and joining the first layer and the hot melt flange, wherein the perimeter stitching lays above an inner surface of the first layer and above an inner surface of the hot melt flange, wherein the waterproof functional second layer covers and is bonded over the perimeter stitching, the inner surface of the first layer and the inner surface of the hot melt flange to form a waterproof barrier over a plurality of apertures formed by the perimeter stitching.
Statement H: The article of footwear of any preceding Statement, wherein the insole includes an insole exterior surface, wherein the hot melt flange includes a hot melt flange exterior surface, wherein the insole stitching extends over the insole outer surface and the hot melt flange exterior surface, wherein the gasket panel extends over and is bonded to the insole exterior surface, the hot melt flange exterior surface and the insole stitching to form a waterproof barrier over a plurality of apertures formed by the insole stitching.
Statement I: A method of making an article of footwear, the method comprising: providing an upper having a U-shaped outer perimeter, the upper including a first layer having a first layer perimeter, a hot melt flange joined around the first layer perimeter, and a waterproof functional second layer overlapping and adjacent the first layer and the hot melt flange; positioning an insole having an insole perimeter adjacent to at least one of the first layer and the second layer; sewing an insole stitching through the hot melt flange and the insole to join the hot melt flange and the insole; and placing a gasket panel over the insole stitching, hot melt flange and the insole to form a waterproof barrier there.
Statement J: The article of footwear of any preceding Statement, comprising: heating the hot melt flange to at least partially melt the hot melt flange and bond to at least one of the first layer, the waterproof functional second layer and the insole.
Statement K: The article of footwear of any preceding Statement comprising: stitching the hot melt flange to the first layer perimeter with a perimeter stitching before said sewing the insole stitching step.
Statement L: The article of footwear of any preceding Statement, wherein the perimeter stitching is distal from the insole stitching, wherein the insole stitching does not traverse the first layer perimeter.
Directional terms, such as “vertical,” “horizontal,” “top,” “bottom,” “upper,” “lower,” “inner,” “inwardly,” “outer” and “outwardly,” are used to assist in describing the invention based on the orientation of the embodiments shown in the illustrations. The use of directional terms should not be interpreted to limit the invention to any specific orientation(s).
The above description is that of current embodiments of the invention. Various alterations and changes can be made without departing from the broader aspects of the invention as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. This disclosure is presented for illustrative purposes and should not be interpreted as an exhaustive description of all embodiments of the invention or to limit the scope of the claims to the specific elements illustrated or described in connection with these embodiments. For example, and without limitation, any individual element(s) of the described invention may be replaced by alternative elements that provide substantially similar functionality or otherwise provide adequate operation. This includes, for example, presently known alternative elements, such as those that might be currently known to one skilled in the art, and alternative elements that may be developed in the future, such as those that one skilled in the art might, upon development, recognize as an alternative. Further, the disclosed embodiments include a plurality of features that are described in concert and that might cooperatively provide a collection of benefits. The present invention is not limited to only those embodiments that include all of these features or that provide all of the stated benefits, except to the extent otherwise expressly set forth in the issued claims. Any reference to claim elements in the singular, for example, using the articles “a,” “an,” “the” or “said,” is not to be construed as limiting the element to the singular. Any reference to claim elements as “at least one of X, Y and Z” is meant to include any one of X, Y or Z individually, any combination of X, Y and Z, for example, X, Y, Z; X, Y; X, Z; Y, Z, and/or any other possible combination together or alone of those elements, noting that the same is open ended and can include other elements.
| Number | Date | Country | |
|---|---|---|---|
| 63225231 | Jul 2021 | US | |
| 63148813 | Feb 2021 | US |
