PROTECTIVE FOOTWEAR
The disclosed technology includes a multi-layered protective footwear device, and methods of manufacturing and using the protective footwear device. In one implementation, the protective footwear device includes a substrate layer comprising waterproof antimicrobial microfiber material or antibacterial microfiber material sized to the shape of a user's foot with a void space between a big toe region and an index toe region. In one implementation, an adhesive layer comprises a sine wave multi-sectioned design configured to adhere to a user's foot. The protective footwear device can further include a perforated backing layer for sectional removal. The backing layer is configured to cover the adhesive layer until user application. Some implementations of the protective footwear device include extendable adhesive layers, easy removal tabs, traction grips, padding, rubber, or ointment.
The present application claims priority to pending U.S. Provisional Patent Application Ser. No. 62/102,167, entitled “Foot Protective Device, Method of Making, and Method of Using the Same,” filed on Jan. 12, 2014, which is specifically incorporated by reference herein for all that it discloses and teaches.
BACKGROUND OF THE INVENTIONTraditional foot coverings protect human feet from exposure to microbes and/or bacteria and promote daily healing of minor foot conditions in dry or wet conditions. In the absence of traditional foot coverings, the health of a person's foot may be at risk. For example, in certain airport security areas, a passenger may be required to take off their footwear. As a result, there is no foot protection from a highly exposed floor area unless the passenger is wearing socks. In other examples, a person's feet may be exposed to microbes and/or bacteria in health club locker rooms and showers, academic institution locker rooms and showers, yoga studios, fitness shows, spas, salons, and hotels.
SUMMARY OF THE INVENTIONThe disclosed technology includes a protective footwear device comprising a substrate layer including, wherein the substrate layer is shaped and sized to cover an entire bottom surface of a user's foot, an adhesive layer affixed to a first side of the substrate layer configured to attach the substrate layer to the user's foot, and a backing layer affixed to the adhesive layer, the backing layer configured to be removed from the adhesive layer prior to user application.
In another implementation of the disclosed technology, a method of manufacturing a protective footwear device comprises attaching a first side of an adhesive layer to a first side of a substrate layer, attaching a backing layer to a second side of the adhesive layer, and cutting the backing layer, the adhesive layer, and the substrate layer in a shape of a human foot. In yet another implementation, a method of using a protective footwear device comprises removing a backing layer from an adhesive layer in the protective footwear device, applying the protective footwear device to a bottom surface of a user's foot, wherein applying the protective footwear device includes affixing a portion of the adhesive layer to a first region of the bottom surface of the user's foot, stretching the adhesive layer to conform to the bottom surface dimensions of the user's foot, and pressing the adhesive layer firmly against remaining exposed regions of the bottom surface of the user's foot, thereby affixing the remaining adhesive layer to the user's foot.
This Summary of the Invention section is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Descriptions. This Summary is not intended to identify key features or essential characteristics of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter. This Summary of the Invention section is neither intended to be, nor should be, construed as being representative of the full extent and scope of the present disclosure. Additional benefits, features and implementations of the present disclosure are set forth in the attached figures and in the description herein below, and as described by the claims. Accordingly, it should be understood that this Summary section may not contain all of the aspects and implementations claimed herein. Additionally, the disclosure herein is not meant to be limiting or restrictive in any manner. Moreover, the present disclosure is intended to provide an understanding to those of ordinary skill in the art of one or more representative implementations supporting the claims. Thus, it is important that the claims be regarded as having a scope including constructions of various features of the present disclosure insofar as they do not depart from the scope of the methods and apparatuses consistent with the present disclosure (including the originally filed claims). Moreover, the present disclosure is intended to encompass and include obvious improvements and modifications of the present disclosure.
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate implementations of the invention and together with the description serve to explain the principles of the invention. Note: Each figure represented hereinafter is interchangeable between a right and left human foot.
For the purposes of promoting an understanding of the principles of the present disclosure, reference will now be made to the exemplary implementations illustrated in the drawing(s), and specific language will be used to describe the same.
Appearances of the phrases an “implementation,” an “example,” or similar language in this specification may, but do not necessarily, refer to the same implementation, to different implementations, or to one or more of the figures. The features, functions, and the like described herein are considered to be able to be combined in whole or in part one with another as the claims and/or art may direct, either directly or indirectly, implicitly or explicitly.
As used herein, “comprising,” “including,” “containing,” “is,” “are,” “characterized by,” and grammatical equivalents thereof are inclusive or open-ended terms that do not exclude additional un-recited elements or method steps unless explicitly stated otherwise.
The disclosed technology relates to a protective footwear device. In other implementations, the disclosed technology includes methods of manufacturing and using a protective footwear device. The protective footwear device can include a substrate layer, an adhesive layer and a backing layer. In other implementations, the protective footwear device may include at least one of a substrate layer, an adhesive layer and a backing layer. In other implementations, the protective footwear device can include a protective layer, traction grips, ointment, padding, or other layers or components in various combinations and shapes. The disclosed technology provides protection to feet from microbes and/or bacteria in dry or wet conditions, and provides daily healing of minor foot conditions in dry or wet conditions.
The protective footwear device conforms to the shape of a user's foot, attaching via the adhesive layer. The backing layer can be perforated or unperforated, and configured to cover the adhesive layer to protect the adhesive layer from drying prior to user application. One implementation includes an extended adhesive layer that wraps on the sides of a user's foot. One implementation of the protective footwear device includes at least one removal pull tab.
In another implementation, the substrate layer may include any number of traction grips aligned in various configurations for additional traction during use. One implementation of the protective footwear device includes padding. In yet another implementation, there may be rubber grips aligned on the substrate layer to help the user when running on hard surfaces as well as help provide additional traction. One implementation of the protective footwear device can include ointment.
In one implementation, the adhesive layer can comprise a waterproof, breathable, high-elasticity material. In some implementations, the protective footwear device includes approximately 35-45% acrylic polymer, approximately 50-60% ethyl acetate, and approximately 1-10% tackifying resin. Other compositions of the protective footwear device in varying amounts and materials are contemplated.
For example, the substrate layer can comprise of a variety of materials. For example, the substrate layer can include at least one of fabric, synthetic fabric, woven fabric, non-woven fabric, rayon woven fabric, rayon non-woven fabric, yarn, weft yarn, wool fibers, linen, string, filaments, twine, cord, thermoplastic, thermoplastic polyurethanes, polyurethane, viscose fiber, plastic, natural fibers, synthetic fibers, woven fibers, non-woven fibers, microfibers, antimicrobial agents, antibacterial agents, elastic strand, elastic core, elastic sheathes, synthetic elastic sheathes, non-elastic sheathes, non-elastic synthetic sheathes, thread, rubber thread, elastomeric filament, lycra, vinyl, ethylene vinyl acetate (EVA), animal fibers, alpaca, angora, bison down, camel hair, cashmere, catgut, chiengora, guanaco, llama, mohair, pashmina, qiviut, rabbit, silk, sinew, spider silk, wool, vicuna, yak, vegetable fibers, aback bamboo, coir, flax, hemp, jute, kapok, kenaf, pina, raffia palm, ramie, sisal, wood, mineral fibers, asbestos, basalt, mineral wool, glass wool, cellulose fibers, acetate, art silk, bamboo, lyocell (tencel), modal, rayon (viscose silk), acrylic, aramid (twaron, kevlar, technora, and nomex), carbon (tenax), derclon, modacrylic, nylon, olefin, polyester, polyethylene (dyneema, spectra), spandex, vinalon, zylon, acetate, polyurethane, liquid silicone, foam, foam pellets, polyurethane foam, rubber, solid rubber, gum rubber, carbon rubber, blown rubber, synthetic elastomers, silicone elastomer, silicone rubber, neoprene rubber, Butyl rubber Buna-n (nitrile), styrene block copolymers, EPDM rubber, SBR rubber, SBR/EPDM blended rubber, synthetic mesh, artificial suede, nylon yarn, canvas, leather, synthetic leather, polyether, cloth, cotton, cotton sheathes, cotton yarn, cotton fiber, polyester yarn, paper, paper facestock, foil, polytetrafluoroethylene (PTFE), polypropylene, polypropylene yarn, polyimide, polycarbonate, urethane, sponge rubber, neoprene, silicone, silver nanoparticles, gauze, foam, foam rubber, felt, adhesive felt, orthopedic felt, moleskin, hydrocolloid, plastazote, evazote, lunasoft, lunairflex, lunairmed, lunalastik, dinoform, dino foam, superform, PPT, biflex padding material, dyatec, dyasoft padding material, cellular unvulcanized rubber, rubber padding, relax foam, bedding foam, foam sheeting, terry cloth padding fabric, sportolon, PS velour, d3o, viscoelastic polymer dough (VPD), and poron.
The backing layer can comprise a variety of materials in a variety of compositions and shapes. For example, the backing layer can include at least one of material non-breathable to the adhesive layer, paper, waxed paper, crepe paper, flatback paper, kraft paper, tissue paper, paper facestock, polymeric film, foam, fabric, cotton, cloth, glass cloth, polyethylene coated cloth, non-woven fiber, laminates, aluminum, lead, neoprene, foil, plastic, acrylic, polyester, polypropylene, polyethylene, polypropylene co-polymer, polyethylene co-polymer, UHMW-polyethylene, polyvinyl chloride (vinyl), polyimide, polyamide (nylon), PTFE, PVA, polyurethane, polyvinyl fluoride, adhesive primer, silicone release agent, paper liner, polyester liner, poly-coated paper, siliconized paper, siliconized film, and polyvinyl carbamate.
In one implementation, the protective footwear device is sized and dimensioned to outline a human foot and/or approximate the shape. The protective footwear device may include adhesive protective tape, e.g., kinesiology tapes as described with reference to U.S. Patent Application Publication Nos. 2011/0056621, 2011/0271854, and 2014/0102362, each of which are hereby incorporated by reference
In some implementations, additives may be added to the protective footwear device (e.g., additives configured for protecting human feet from microbes and/or bacteria and promoting daily healing of minor foot conditions in dry or wet conditions when traditional foot coverings are not worn).
In one implementation, the substrate layer includes adhesive protective tape for other applications. For example, the adhesive protective tape in the shape of a hand to be adhered to or around a hand, shaped to be adhered to or around a knee, shaped to be adhered to or around an elbow, shaped to be adhered to or around an inner thigh to help prevent chafing, shaped to be adhered to or around a shoulder, shaped to be adhered to or around a shin, shaped to be adhered to or around recently applied tattoos, shaped to be adhered to or around a neck (e.g., for weightlifters to help prevent irritation when performing squats with a bar on their back, shaped to be adhered to or around a forearm, shaped to be adhered to or around paws, hooves or feet of animals).
Reference will now be made to the figures wherein like structures will be provided with like reference designations. It is understood that the figures are diagrammatic and schematic representations of some implementations of the invention, and are not limiting of the present invention, nor are they necessarily drawn to scale. Each individual figure of either a right or left foot depicted and described hereinafter are to be understood that the opposite foot (not shown) with an exact mirrored image of the figure are included in the invention.
Referring to
Referring to
In this implementation, three perforated sections of the backing layer 300 are shown, section 301, section 302, and section 303. The sections are separated by perforated lines 304 and 305 as described herein (see dashed lines). In one implementation, section 301 can be peeled starting from a heel region 312 in a direction of the arrows shown in
Referring to
In one implementation, the pattern designs of the adhesive layer can include a series of adhesive lines interrupted by gaps (e.g., air gaps). The adhesive lines are non-permeable to fluids such as sweat and in one implementation non-permeable to air. The gaps are permeable to both air and fluid, thereby allowing a user's foot to breathe while the protective footwear device is attached to the foot. For example, the gaps can allow air to reach the skin of the user. Additionally or alternatively, the gaps can be permeable to fluids such as sweat. The gaps can allow sweat from the user's skin to be wicked away from the skin by the substrate layer. Removing sweat from the user's skin can prevent the sweat from adversely affecting the adhesion of the adhesive layer to the user's skin.
In one implementation, the adhesive layer 500 can include dyes or pigments to make the adhesive layer any variation of color or colors and applied in any form, fashion, or design.
In one implementation, the pattern designs of
Referring to
The simple continuous design of the adhesive layer 500 can allow for the adhesive layer to better adhere to the contour of a human foot as opposed to a solid and/or continuous adhesive layer without any air gaps, which does not allow breathability or horizontal or vertical adhesive lines 520 which can cause lifting at the edges of the substrate layer.
The adhesive layer 500 is configured to permit moderate vertical stretching of the adhesive layer and minimal horizontal stretching of the adhesive layer with improved adhesion of the substrate layer to the foot. This design allows the substrate layer to stretch vertically along the foot to fit the length of the user's foot for optimal fit and also keeps the substrate layer from peeling with vertical movement. The spacing between adhesive sine waves is normal throughout which provides optimal adherence to the entire foot. The normal spacing which provides normal size air gaps is essential for the breathability of the entire foot, prevention of sweat buildup and functionality of the adhesive layer. The width of the adhesive 520 can vary from about 0.1 mm to about 50 mm or greater. In one implementation, the width is in a range from about 2 mm to about 4 mm. Moreover, the width of the air gap 522 can vary from about 0.1 mm to about 50 mm or greater. In one implementation, the width is in a range from about 1 mm to about 1.5 mm. In addition, the width of the air gap 522 and width of adhesive 520 can be constant or vary.
The adhesive layer 500 can include any adhesive which will allow the substrate layer to adhere to the skin of a user without irritating the user's skin. For example, the adhesive layer 500 can include pressure-sensitive adhesive. A pressure sensitive adhesive is an adhesive which forms a bond when pressure is applied and no solvent, water, activator chemicals, heat or other activating agent is needed to activate the adhesive. In at least one implementation, the degree of bonding is influenced by the amount of pressure which is used to apply the adhesive layer to the surface of the backing layer. In one implementation, the adhesive layer 500 can be latex free for sensitive skin using an acrylic based, medical grade adhesive. The main ingredient of the adhesive layer 500 can include a single compound or a mixture of compounds. For example, the adhesive layer 500 can include a polyacrylate material as a main ingredient. Additionally, or alternatively, the adhesive layer 500 can include a solvent which is configured to evaporate or break down after application of the adhesive layer, leaving the main ingredient behind. For example, the adhesive layer 500 can include approximately 50% of a main ingredient and approximately 50% solvent. In one implementation, the solvent can include ethyl acetate.
In one implementation, the adhesive layer 500 can include a reusable washable adhesive. One example of a reusable washable adhesive can include a body side adhesive preferably being a hypoallergenic, pressure-sensitive, acrylate adhesive that is non-toxic and reduces irritation of the skin of a user. The reusable adhesive can have a pressure-sensitive silicone gel adhesive. The reusable adhesive may be reused multiple times, even after washing. The washability of the adhesive layer 500 can be significantly improved by forming a layer of pressure-sensitive adhesive silicone gel directly on the surface of a material. One implementation of the reusable adhesive layer 500 can be formed by applying a layer of unsaturated silicone containing a thermally activated catalyst, such as platinum, to the sheet or material, and heating it to an elevated temperature to cure the layer of gel. The final product can be washed numerous times without loss of adhesive.
In at least one implementation, the adhesive layer 600 can provide greater adhesion for the substrate layer in one area relative to another area of the substrate layer. For example, the adhesive layer 600 can provide adhesion even with vertical movement of the substrate layer relative to the user's skin. In particular, the adhesive layer 600 can provide resistance to movement of the substrate layer in any direction on the user's skin. In at least one implementation, such resistance can allow the substrate layer to better provide benefits to the user during use of the protective footwear device, as described above.
The adhesive layer 600 includes adhesive lines 620 and air gaps 622 in both sections 601 and 602. The two sections 601 and 602 allow for the adhesive layer to better adhere to the contour of a human foot as opposed to a solid and/or continuous adhesive without any air gaps, which does not allow breathability or horizontal or vertical adhesive lines 620 which can cause lifting at the edges of the substrate layer.
The pattern design section 601 is configured to permit moderate horizontal stretching of the adhesive layer and minimal vertical stretching of the adhesive layer over the heel and lower half of the midsole. The pattern design section 601 allows the substrate layer to stretch horizontally to fit the width of the lower half of the user's foot for optimal fit. The spacing between adhesive sine waves is normal throughout which provides optimal adherence to the heel and lower half of the midsole which do not flex or bend as much as other areas of the foot. The normal spacing which provides normal size air gaps is essential for the breathability of the lower half of the foot, prevention of sweat buildup and functionality of the adhesive layer.
The pattern design section 602 is configured to permit moderate vertical stretching of the adhesive layer and minimal horizontal stretching of the adhesive layer over the upper midsole, ball and toes. The pattern design section 602 allows the substrate layer to stretch vertically to fit the length of the user's upper half of the foot for optimal fit and also keeps the substrate layer from peeling with vertical movement. The spacing between the adhesive sine waves is decreased throughout which provides more adhesion to the upper midsole, ball and toes which have the most movement out of the foot. The decreased spacing across the upper half of the foot exchanges breathability for added adhesion in an area which requires the substrate layer to stay perfectly adhered to the skin during movement.
The pattern design section 709 is configured to permit moderate vertical stretching of the adhesive layer and minimal horizontal stretching of the adhesive layer over the heel and midsole. The pattern design section 709 allows the substrate layer to stretch vertically to fit the length of the heel and midsole of the user's foot for optimal fit. The spacing between adhesive sine waves is normal throughout which provides optimal adherence to the heel and midsole. The normal spacing which provides normal size air gaps is essential for the breathability of the heel and midsole of the foot, prevention of sweat buildup and functionality of the adhesive layer.
The pattern design section 710 is configured to permit moderate horizontal stretching of the adhesive layer and minimal vertical stretching of the adhesive layer over the ball. The pattern design section 710 allows the substrate layer to stretch horizontally to fit the width of the ball of the user's foot for optimal fit. The spacing between adhesive sine waves is normal throughout which provides optimal adherence to the ball. The normal spacing which provides normal size air gaps is essential for the breathability of the ball of the foot, prevention of sweat buildup and functionality of the adhesive layer.
The pattern design section 711 is configured to permit moderate vertical stretching of the adhesive layer and minimal horizontal stretching of the adhesive layer over the toes. The pattern design section 711 allows the substrate layer to stretch vertically to fit the length of the toes of the user's foot for optimal fit. The spacing between adhesive sine waves is normal throughout which provides optimal adherence to the toes. The normal spacing which provides normal size air gaps is essential for the breathability of the toes of the foot, prevention of sweat buildup and functionality of the adhesive layer.
The six pattern design sections allow for the adhesive layer 800 to better adhere to the contour of a human foot as opposed to a solid and/or continuous adhesive layer without any air gaps, which does not allow breathability or horizontal or vertical adhesive lines 820 which can cause lifting at the edges of the substrate layer.
The pattern design section 815 is configured to permit moderate horizontal stretching of the adhesive layer and minimal vertical stretching of the adhesive layer over the heel. The pattern design section 815 allows the substrate layer to stretch horizontally to fit the width of the user's heel for optimal fit and also keeps the substrate layer from peeling with vertical movement. The spacing between adhesive sine waves is normal throughout which provides optimal adherence to the heel which does not flex or bend. The normal spacing which provides normal size air gaps is essential for the breathability of the heel, prevention of sweat buildup and functionality of the adhesive layer.
The pattern design section 816 is configured to permit moderate vertical stretching of the adhesive layer and minimal horizontal stretching of the adhesive layer over the inner midsole. The pattern design section 816 allows for the substrate layer to stretch and move as the user flexes and bends the inner midsole of the foot. The spacing between adhesive sine waves is normal throughout which provides optimal adherence to the inner midsole. The normal spacing which provides normal size air gaps is essential for the breathability of the inner midsole, prevention of sweat buildup and functionality of the adhesive layer.
The pattern design section 817 is configured to permit moderate horizontal stretching of the adhesive layer and minimal vertical stretching of the adhesive layer over the outer midsole. The pattern design section 817 allows for the substrate layer to stretch horizontally to the outer edge of the foot for optimal fit and also keeps the substrate layer from peeling with vertical movement. The spacing between the adhesive sine waves is normal throughout which maintains optimal adherence to the outer midsole which does not flex or bend as much as the inner midsole. The normal spacing across the outer midsole which provides normal size air gaps is essential for the breathability of the outer midsole, prevention of sweat buildup and functionality of the adhesive layer.
The pattern design section 818 is configured to permit moderate vertical stretching of the adhesive layer and minimal horizontal stretching of the adhesive layer over the ball. The pattern design section 818 allows for the substrate layer to stretch vertically with the ball of the foot for optimal fit and also keeps the substrate layer from peeling with vertical movement. The spacing between adhesive sine waves is normal throughout which provides optimal adherence to the ball. The normal spacing across the ball which provides normal size air gaps is essential for the breathability of the ball, prevention of sweat buildup and functionality of the adhesive layer.
The pattern design section 819 is configured to permit moderate horizontal stretching of the adhesive layer and minimal vertical stretching of the adhesive layer over the base of the toes. The pattern design section 819 allows for the substrate layer to stretch horizontally to fit the width of the user's toes for optimal fit. The spacing between adhesive sine waves is normal throughout which provides optimal adherence to the base of toes. The normal spacing across the base of the toes which provides normal size air gaps is essential for the breathability of the base of the toes, prevention of sweat buildup and functionality of the adhesive layer.
The pattern design section 824 can allow for moderate vertical stretching of the adhesive layer and minimal horizontal stretching of the adhesive layer over the tips of the toes. The pattern design section 824 allows for the substrate layer to stretch vertically to fit the length of the user's toes for optimal fit and also keeps the substrate layer from peeling with vertical movement. The spacing between the adhesive sine waves is decreased throughout which provides more adhesion to the tips of the toes which have the most movement out of the foot. The decreased spacing across the tips of the toes exchanges breathability for added adhesion in an area which requires the substrate layer to stay perfectly adhered to the skin during movement.
Referring to
The pattern design sections allow for the adhesive layer 900 to better adhere to the contour of a human foot as opposed to a solid and/or continuous adhesive layer without any air gaps, 922 which does not allow breathability or horizontal or vertical adhesive lines 920 which can cause lifting at the edges of the substrate layer.
The pattern design section 924 is configured to permit moderate vertical stretching of the adhesive layer and minimal horizontal stretching of the adhesive layer over the heel. The pattern design section 924 allows the substrate layer to stretch vertically to fit the length of the heel of the user's foot for optimal fit. The spacing between the adhesive sine waves is decreased throughout which provides more adhesion to the heel. The decreased spacing across the heel of the foot exchanges breathability for added adhesion in an area which requires the substrate layer to stay perfectly adhered to the skin during movement.
The pattern design section 925 is configured to permit moderate vertical stretching of the adhesive layer and minimal horizontal stretching of the adhesive layer over the lower half of the inner midsole. The pattern design section 925 allows for the substrate layer to stretch vertically for optimal fit and also keeps the substrate layer from peeling with vertical movement. The spacing between the adhesive sine waves is normal throughout which maintains optimal adherence to the lower half of the inner midsole. The normal spacing across the lower half of the inner midsole which provides normal size air gaps is essential for the breathability, prevention of sweat buildup and functionality of the adhesive layer.
The pattern design section 926 is configured to permit moderate vertical stretching of the adhesive layer and minimal horizontal stretching of the adhesive layer over the lower half of the outer midsole. The pattern design section 926 allows for the substrate layer to stretch vertically for optimal fit and also keeps the substrate layer from peeling with vertical movement. The spacing between the adhesive sine waves is decreased throughout which provides more adhesion to the lower half of the outer midsole. The decreased spacing across the lower half of the outer midsole exchanges breathability for added adhesion in an area which requires the substrate layer to stay perfectly adhered to the skin during movement.
The pattern design section 928 is configured to permit moderate vertical stretching of the adhesive layer and minimal horizontal stretching of the adhesive layer over the upper half of the outer midsole and the outer half of the ball. The pattern design section 928 allows for the substrate layer to stretch vertically for optimal fit and also keeps the substrate layer from peeling with vertical movement. The spacing between the adhesive sine waves is decreased throughout which provides more adhesion to the upper half of the outer midsole and the outer half of the ball. The decreased spacing across the upper half of the outer midsole and the outer half of the ball exchanges breathability for added adhesion in an area which requires the substrate layer to stay perfectly adhered to the skin during movement.
The pattern design section 929 is configured to permit moderate vertical stretching of the adhesive layer and minimal horizontal stretching of the adhesive layer over the toes. The pattern design section 929 allows for the substrate layer to stretch vertically for optimal fit and also keeps the substrate layer from peeling with vertical movement. The spacing between the adhesive sine waves is normal throughout which maintains optimal adherence to the toes. The normal spacing across the toes which provides normal size air gaps is essential for the breathability, prevention of sweat buildup and functionality of the adhesive layer.
In one implementation, the protective footwear device can have a total thickness in a range from about 0.01 mm to about 1 mm. In another implementation, the total thickness of the substrate layer is in a range from about 0.1 mm to about 0.4 mm, including an adhesive layer, of about 0.15 mm to about 0.5 mm. The small thickness of the adhesive layer can allow for the protective footwear device to be worn in socks, shoes, sandals, and other footwear without snagging or obstructing natural movement by conforming perfectly to the human foot without any protruding edges.
The protective footwear device is cut out in the shape of a human foot with a slit in between the big toe and the index toe. The slit in between the big toe and the index toe allows for natural movement of the toes when wearing the protective footwear device which can also help prevent the substrate layer from peeling around the toes. One implementation of the substrate layer 1000 can include lettering, designs and/or logos printed onto the sheet.
In one implementation, the protective footwear device includes microfiber material wrapped around synthetic elastic sheathes, the microfiber material layer a strip of elastic and non-elastic fibers, each fiber is covered in a material which can include synthetic antimicrobial microfiber material or synthetic antibacterial microfiber material. Both the synthetic antimicrobial microfiber material or synthetic antibacterial microfiber material materials can be waterproof. The fibers can be microfibers having a median diameter of 10 micrometers or less. In one implementation, the protective footwear device includes ultra-light microfibers made up of reinforced 100% synthetic elastic sheathes designed to provide durability and increased strength.
Synthetic microfibers are fast drying and provide superior weight-to-strength ratios. The synthetic elastic sheathes retain their elasticity far better over time than cotton. These synthetic elastic sheathes can be embedded into weft yarn to provide unidirectional elasticity allowing for bilinear elasticity along the length of the substrate layer and no elasticity in the substrate layer's width. These fibers ensure the substrate layer 1000 will provide stable support without restricting motion. The stretch-ability of the substrate layer 1000 allows it to flex and move comfortably with the body's tissue, releasing and recoiling like a rubber-band. In one implementation, the substrate layer 1000 is also 100% waterproof and 100% sweat proof which allows for moisture release which is critical for comfort and wear-ability. The more porous the substrate layer's weave, the better it releases moisture caused by sweating or being worn in the water.
The protective footwear device with application of adhesive layer can provide up to 50% breathability over the entire layer. In this configuration, enhanced breathability and release of moisture so that it is comfortable to wear for numerous days at a time without itching, irritation or reactions with the skin is achieved. The protective footwear device can also cover the entire bottom of a human foot, which prevents any contact between the ground and the bottom of the foot.
In one implementation, the protective footwear device can include a synthetic antimicrobial microfiber material. Antimicrobial is defined as a substance that kills microorganisms or inhibits their growth or replication; an antimicrobial agent also called antimicrobic.
In one implementation, the protective footwear device can include added antimicrobial agents. An antimicrobial agent is configured to kill microorganisms or suppresses their multiplication or growth. Antimicrobial agents are classified functionally according to the manner in which they adversely affect a microorganism.
In one implementation, the protective footwear device can also include an antibacterial agent. An antibacterial agent is classified as an antibiotic which is a substance derived from a mold or bacterium, or produced synthetically, that destroys (bactericidal) or inhibits the growth (bacteriostatic) of other microorganisms and is thus used to treat infections. Antibiotics can be classified into several groups according to their mode of action on or within bacteria.
In one implementation, the protective footwear device can include an antibacterial agent preventing bacterial growth, which can include but is not limited to topical antibacterial agents for the treatment of bacterial skin infections, e.g. 2% fusidic acid, 2% mupirocin (Bactroban), 0.25% neomycin (e.g. Cicatrin, Graneodin), 10,000 units polymyxin (Polyfax), 1% silver sulfadiazine (Flamazine).
In one implementation, the protective footwear device can include an antibacterial coated fabric. For example, the antibacterial fabric can include embedding sets of nanowires or nanothreads loaded with silver-TCNQ into a textile material. The fabric can be built into most materials, including but not limited to cotton and nylon. The coating of the silver-TCNQ onto the substrate layer is configured to kill off the bacteria within 10 minutes of being exposed to the organisms. The fast-acting nature of the silver TCNQ-coated fabric gives it an advantage over other antibacterial fabrics.
The protective footwear device can help prevent the skin of the bottom of a human left and right foot from touching a surface, which can help protect human feet from microbes and/or bacteria and help promote daily healing of minor foot conditions in dry or wet conditions when traditional foot coverings are not worn.
The protective footwear device can include a substrate layer made into any color or variations of colors, e.g., red, green, blue or combinations of the same. Also, the protective footwear device can be glow in the dark or have portions that are glow in the dark. One implementation of the substrate layer 1000 can include the substrate layer 1000 with reflectors, e.g., exposed retroreflective lenses (WO2011147079 A1).
In one implementation, the protective footwear device can be dimensioned into dimensions approximating a human foot. The protective footwear device extends in a longitudinal direction from a first end to a second end. The width and length of the protective footwear device are dimensioned to accommodate every foot size (e.g., U.S. sizes for Men (3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9, 9.5, 10, 10.5, 11, 11.5, 12, 12.5, 14), U.S. sizes for Women (5, 5.5, 6, 6.5, 7, 7.5, 8, 85, 9, 9.5, 10, 10.5, 12, 13, 14, 15.5), U.S. sizes for Boys (11.5, 12, 12.5, 13, 13.5, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5), and U.S. sizes for Girls (9.5, 10, 10.5, 11, 11.5, 12, 12.5, 13, 13.5, 1, 1.5, 2, 2.5, 3, 3.5, 4)). Alternatively, different sizing standards can be used, e.g., Extra Small (XS), Small (S), Medium (M), Large (L), and Extra Large (XL). The thickness of the protective footwear device can range from about 0.01 mm to about 1.0 mm or greater. Again, in one implementation, the protective footwear device can be configured to have an open space between the big toe and the index toe. Leaving a big toe region disconnected from a region comprising the other toes can allow for better movement when the protective footwear device is worn on a foot.
Referring to
The traction dot grips with connectors 1524 allow for additional grip for users after having been adhered to the skin of a human foot. Alternatively, the protective footwear device can include other materials considered to improve traction. Acceptable traction grips are considered to be within the knowledge of persons skilled in the art of footwear manufacturing and are not discussed here in detail. In one implementation, the traction grips are a grip-dot forming emulsion and can be selected from a number of well-known prior art curable emulsions, including polymer emulsions, polyvinyl chloride emulsions and the like. The traction dot grips with connectors 1524 and the traction waves 1520, 1523 and 1526 may be high performance platinum cure liquid silicone compounds and the like. The traction dot grips with connectors 1524 and the traction waves 1520, 1523 and 1526 may be a rigid, malleable or combination of same material, e.g., thermoplastic material.
In this implementation, the padding 1626 is located on the ball of the protective footwear device. The added padding can be used to help prevent blisters or abrasion as well as help provide additional comfort when worn. Acceptable paddings are considered to be within the knowledge of persons skilled in the art of bandage, shoe, and mole skin manufacturing and are not discussed here in detail.
The padding 1728 is located on the heel of the protective footwear device. The padding 1726 is located on the ball of the protective footwear device. The added padding can be used to help prevent blisters or abrasion as well as help provide additional comfort when worn. Acceptable paddings are considered to be within the knowledge of persons skilled in the art of bandage, shoe, and mole skin manufacturing and are not discussed here in detail.
In this implementation, the rubber is covering the ball and toes of the substrate layer. The protective layer portion can be configured to help the user when running on hard surfaces as well as help provide additional traction. Acceptable rubber is considered to be within the knowledge of persons skilled in the art of footwear manufacturing and is not discussed here in detail.
An operation 2402 applies an adhesive layer to a substrate layer. For example, in at least one implementation, an adhesive applicator can be used to apply adhesive in an adhesive layer, or applying an adhesive layer to a substrate layer, as a strip of adhesive layer. In one implementation, the adhesive layer can include a dye and/or pigment in any form, fashion, or design. The adhesive layer allows a user to easily apply the protective footwear device as need requires, without additional materials.
An operation 2404 applies a pattern to the adhesive layer. In one implementation, the pattern can include a single color dye and/or pigment used across the entire adhesive design in any form, fashion, or design. An adhesive applying device can include a comb, wherein the comb is configured to produce a pattern in the adhesive as the backing layer moves past the comb, wherein the comb includes a spine and multiple teeth protruding from the spine, wherein the teeth remove adhesive from the backing layer. The adhesive applying device can further include a shaft attached to the spine and an erratic cam, wherein the erratic cam is configured to move the shaft on the comb to produce motion in the comb and a motor for rotating the erratic cam. Additionally or alternatively, the teeth need not all be the same size depending on the desired pattern. In at least one implementation, the width of the comb can indicate the width of the area on the surface of the backing layer which can receive adhesive.
For example, the width of the comb may be greater than the width of the backing layer to which adhesive may be applied, e.g., if the width of the comb is 950 millimeters, the width of the surface to which adhesive may be applied can be 900 millimeters. Further, lateral movement of the teeth can allow a periodic or non-periodic pattern to be created in the adhesive. For example, regular reciprocating motion of the teeth can create a sine wave pattern in the adhesive. Additionally or alternatively, lateral motion of the teeth can create a pattern, such as a step frequency pattern. Patterns in the adhesive may provide for better adhesion between the protective footwear device and the user's skin. For example, patterns can allow some of the tracks in the adhesive to point horizontally and others to point vertically. Patterns can allow the protective footwear device to resist forces caused by a user's movement in any direction. In one implementation, the comb can have varying sizes of teeth. For example, the comb can have alternating sections of small and large teeth width along the length of the comb. The alternating teeth width along the comb can be specially aligned so that when applying patterns to the adhesive on the adhesive layer the sections of small teeth width can run across the area of the adhesive layer where the outer edges of the protective footwear device will be located, and the sections of large teeth width can run across the area of the adhesive layer where the inner area of the protective footwear device will be located. Alternating the sections of teeth width of the comb as described can allow for better adhesion of the outer edges of the protective footwear device and increased breathability for the inner area of the protective footwear device when applied to a human foot. In other implementations, the teeth of the comb can be arranged in any form, fashion, design, size, or width to apply a pattern to the adhesive on the adhesive layer. Additionally or alternatively, the adhesive pattern can be applied with deposition techniques including printing, depositing, and others as known in the art.
In other implementations, more than one pattern may be applied to the adhesive on the adhesive layer. In one implementation, the protective footwear device can include any number of sections in the adhesive on the adhesive layer which contain different adhesive designs such as described in
In some implementations, a pattern is not applied to an adhesive layer and operation 2404 is omitted. For example, the adhesive layer may not have a pattern and may be one uniform sheet of adhesive. Or in another implementation, the adhesive layer may be applied in a pattern, thereby negating the operation of later applying a pattern on the adhesive layer.
In an operation 2406, a backing layer is applied to the adhesive layer. The backing layer can be used to protect the adhesive on the adhesive layer and prevent drying of a solvent until a user is ready to apply the protective footwear device. For example, the adhesive can be pressure-sensitive adhesive. Pressure sensitive adhesive is adhesive which forms a bond when pressure is applied, e.g., no solvent, water, activator chemicals, heat or other activating agent is needed to activate the adhesive. In at least one implementation, the degree of bonding is influenced by the amount of pressure which is used to apply the adhesive to the surface of the substrate layer. In at least one implementation, attaching the backing layer to the adhesive layer can include applying pressure to the adhesive layer and the backing layer to activate or administer pressure sensitive adhesive.
The backing layer, the adhesive layer, and the substrate layer attached together make up an assembled protective footwear device. An operation 2408 cuts the assembled protective footwear device with laser cutting techniques, heat cutting techniques, mechanical cutting techniques, combinations of the same and the like. In at least one implementation, the protective footwear device can include using a die cut. For example, in at least one implementation, the die can cut, shape and form protective footwear devices sized and dimensioned to perfectly outline a human foot or approximate the shape, and the backing layer attached to the adhesive layer, during the manufacture thereof. In particular, dies in varying sizes and shapes can be used to cut, shape, and form perfectly dimensioned and outlined shapes of a human left and right foot into different foot sizes.
An operation 2410 cuts perforations or perforates the backing layer. Cutting or perforating the backing layer of the protective footwear device allows a user to separate individual strips or sections of the protective footwear device from one another as needed. In addition, varying designs for multiple patterns of perforations in any form, fashion, or design can be die cut or perforated onto the backing layer. In one implementation, a perforation design, which can include a single perforation design, can be cut into the backing layer running horizontally across the midsection of the foot such as described in
The examples operations 2400 can also include cutting one or more removal pull tabs on the protective footwear device, or cutting the protective footwear device into the shape of a human foot, or into the shape of a human foot with extended portions for stretching the protective footwear device to extend around the sides of a user's foot.
In other implementations, examples operations 2400 can also include printing a logo on the protective footwear device. The printing can be accomplished using a printing device, such as described in US 2011/0056621. In at least one implementation, the printing device can print on the protective footwear device using a screen, or silk-screen, printing method or combinations of the same. Screen printing includes a printing technique that uses a woven mesh to support an ink-blocking stencil. The attached stencil forms open areas of mesh that transfer ink as a sharp-edged image onto a substrate layer. Also, the logo or design can be glow in the dark or have portions that are glow in the dark. One implementation can include reflectors, e.g., exposed retroreflective lenses (WO2011147079 A1). In addition, the protective footwear device can include a logo or design made into any color or variations of colors, e.g., red, green, blue, neon green, black or tan.
An operation 2502 removes a pair of the protective footwear devices, which includes a left and right footwear device. For example, in one implementation, the pair of protective footwear devices can be unwound from and torn off a roll of protective footwear devices. In one implementation, the pair of the protective footwear devices can be removed from a package in which the protective footwear devices are stacked upon one another. Nevertheless, one of skill in the art can appreciate that the operation 2502 can be accomplished using other apparatus for removal than those described.
The following operations 2504-2512 involve applying the protective footwear devices to the bottom of a user's feet. In one implementation, each protective footwear device can be applied individually in order to make use of the user's two hands to best handle and apply the protective footwear device one at a time.
An operation 2504 removes a first section of a backing layer of one of the left or right protective footwear devices starting at a heel region and peeling towards a toe region. In one implementation, the protective footwear device can include a single sheet of backing layer, which when removed peels off in one piece, revealing the entire underlying adhesive layer. However, other implementations can include multiple perforated sections of the backing layer allowing for the backing layer to be removed in sections.
An operation 2506 applies an exposed adhesive layer to the bottom of the user's foot starting at a heel region and applying towards a toe region by stretching the adhesive layer to fit the desired dimensions of the bottom of the user's foot. In one implementation, numerous adhesive design sections of the adhesive layer can be applied to corresponding sections of the user's foot in order for the adhesive layer to provide optimal breathability and adhesion when worn. For example, different adhesive design sections as described in
An operation 2508 peels off remaining sections of the backing layer from the bottom of each perforation towards the toe region. Operation 2508 occurs if there are one or more perforations or perforated sections in the backing layer. In one implementation, the backing layer can have a single perforation running horizontally across the protective footwear device corresponding to the midsection of a user's foot as described in
An operation 2510 applies the exposed adhesive layer to the remaining area of the bottom of the user's foot by stretching the adhesive layer to fit the desired dimensions of the bottom of the foot. Operation 2510 occurs if there are one or more perforations in the backing layer. In one implementation, numerous adhesive design sections of the adhesive layer can be applied to their corresponding sections of the human foot in order for the adhesive design to provide optimal breathability and adhesion when worn. For example, different adhesive design sections as described in
If there are no perforations or perforated sections in the backing layer, operations 2508 and 2510 do not occur. In such implementations, one uniform section of backing layer is peeled off the adhesive layer from the heel region toward the toe region.
An operation 2512 presses the protective footwear device after application to the bottom of the user's foot to affix the adhesive of the adhesive layer onto the user's skin. In one implementation, the adhesive in the adhesive layer can be pressure sensitive adhesive, which can be heat activated and ensure optimal adhesion to the skin of the user's foot and prevent peeling on the edges of the substrate layer.
In implementations using a pair of protective footwear devices, the operations 2504-2512 can be performed for the foot of the protective footwear device. After applying the second protective footwear device, the bottom of both feet can then be protected when the protective footwear device is worn.
The described implementations are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the purpose of the protective footwear device as discussed in the Background, Brief Summary and Detailed Description. All changes which come within the meaning and range of equivalency of the purpose are to be embraced within their scope.
EXAMPLESBy way of example, and not by way of limitation, examples will be provided for use of the protective footwear device to help protect feet, prevent infection, and enhance healing of wounds.
The protective footwear device can be utilized for taping to the bottoms of feet, without the need for any additional cutting to form to the feet. Each individual strip of the protective footwear device can be applied as a single sheet (if unperforated), or the uncut portion could be applied as an “anchor” portion followed by separation of the perforated portions of the backing layer. The various versions of perforations of the backing layer can facilitate such placement by allowing removal of only some of the backing layer to expose only a portion of adhesive during application.
The inventions and methods described herein can be viewed as a whole, or as a number of separate inventions, that can be used independently or mixed and matched as desired. All inventions, steps, processes, devices, and methods described herein can be mixed and matched as desired. All previously described features, functions, or inventions described herein or by reference may be mixed and matched as desired.
It will be apparent to those skilled in the art that various modifications and variation can be made in the present invention without departing from the spirit or scope of the invention. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
Claims
1. A protective footwear device comprising:
- a substrate layer including, wherein the substrate layer is shaped and sized to cover an entire bottom surface of a user's foot;
- an adhesive layer affixed to a first side of the substrate layer configured to attach the substrate layer to the user's foot; and
- a backing layer affixed to the adhesive layer, the backing layer configured to be removed from the adhesive layer prior to user application.
2. The protective footwear device of claim 1, wherein the substrate layer includes a void space between a big toe region and an index toe region.
3. The protective footwear device of claim 1, wherein the backing layer is perforated to facilitate sectional removal of the backing layer from the adhesive layer.
4. The protective footwear device of claim 1, wherein the substrate layer includes a weave of at least one elastic fiber.
5. The protective footwear device of claim 1, wherein the adhesive layer comprises two or more layers of adhesive material separated by an air permeable gap, the air permeable gap configured to provide breathability to the user's foot.
6. The protective footwear device of claim 1, wherein the adhesive layer comprises a step-frequency wave pattern.
7. The protective footwear device of claim 1, wherein the substrate layer comprises at least one of synthetic antimicrobial microfiber material and synthetic antibacterial microfiber material.
8. The protective footwear device of claim 1, wherein the substrate layer comprises one or more removal pull tabs.
9. The protective footwear device of claim 1, wherein the substrate layer is configured to extend around sides of a user's foot.
10. The protective footwear device of claim 1, wherein the substrate layer comprises one or more padding material regions.
11. The protective footwear device of claim 1, wherein the substrate layer comprises one or more traction dot grips arranged on the substrate layer.
12. The protective footwear device of claim 1, further comprising a protective layer covering at least a portion of the substrate layer.
13. A method of manufacturing a protective footwear device, comprising:
- attaching a first side of an adhesive layer to a first side of a substrate layer;
- attaching a backing layer to a second side of the adhesive layer; and
- cutting the backing layer, the adhesive layer, and the substrate layer in a shape of a human foot.
14. The method of claim 13, wherein cutting the backing layer, the adhesive layer, and the substrate layer in the shape of a human foot includes cutting a void space in between a big toe region and an index toe region.
15. The method of claim 14, wherein cutting the backing layer, the adhesive layer, and the substrate layer further comprises cutting one or more removal pull tabs on the protective footwear device.
16. A method of using a protective footwear device comprising:
- removing a backing layer from an adhesive layer in the protective footwear device;
- applying the protective footwear device to a bottom surface of a user's foot, wherein applying the protective footwear device includes: affixing a portion of the adhesive layer to a first region of the bottom surface of the user's foot; stretching the adhesive layer to conform to the bottom surface dimensions of the user's foot; and pressing the adhesive layer firmly against remaining exposed regions of the bottom surface of the user's foot, thereby affixing a remaining adhesive layer to the user's foot.
17. The method of claim 16, wherein affixing the portion of the adhesive layer to a first region of the bottom surface of the user's foot includes affixing the portion of the adhesive layer to a heel region of the user's foot, and affixing the remaining adhesive layer to the user's foot includes affixing the adhesive layer to a toe region with a void space between a big toe region and an index toe region.
18. The method of claim 16, wherein removing the backing layer from the adhesive layer further comprises removing sections of perforated portions of the backing layer.
19. The method of claim 16, further comprising removing the protective footwear device from the user's foot with one or more removal pull tabs.
20. The method of claim 16, further comprising stretching the protective footwear device to extend around sides of a user's foot.
Type: Application
Filed: Jan 12, 2016
Publication Date: Jul 14, 2016
Inventors: Brittany Ishmael (Castle Rock, CO), Thomas Blake Ishmael (Castle Rock, CO)
Application Number: 14/993,608