Upper Assembly For Footwear and Footwear Including the Same

Abstract

The invention relates to an upper assembly (10) for footwear (100), comprising an upper (14) having a sole-sided upper end region, and an upper bottom (16). The sole-sided upper end region is joined to the upper bottom (16). The upper (14) includes an outer material layer (18) having a sole-sided outer material end region (18a), and an upper liner (20). The upper bottom (16) comprises a first water vapor permeable assembly sole (30) and an upper bottom laminate (32) including a first water vapor permeable and waterproof functional layer (34). The outer material layer (18) in the sole-sided outer material end region (18a) is joined to the first water vapor permeable assembly sole (30). The first assembly sole (30) and/or the sole-sided outer material end region (18a) of the upper (14) comprises at least one moisture transporting structure (54) adapted to transport moisture away from a first region (A) between the outer material layer (18) and the upper liner (20) of the upper (14) and/or between an outer peripheral part of the first outer assembly sole (30) and the upper liner (20) of the upper (14), to a second region (B) underneath the upper bottom functional layer (34).

Description

The present invention relates to an upper assembly for footwear and also to footwear comprising such an upper assembly.

Waterproof and water vapor permeable prior art footwear typically has a waterproof and water vapor permeable upper which allows perspiration of moisture to the outside, but still is waterproof with respect to penetration of liquid water. Since the human foot produces most perspiration at the sole, it has been suggested to provide footwear with perforated soles, in order to allow perspiration moisture to escape to the outside in the sole region. The regions below the foot of such footwear have been equipped with waterproof and water vapor permeable functional layers.

DE 10 2008 029 296 A1 discloses an example of a fully waterproof, yet water vapor permeable footwear. Such footwear has an upper which is closed to the sole side by an upper bottom separate from the upper, and both the upper and the upper bottom are equipped with water vapor permeable but waterproof functional layers making the upper assembly as a whole waterproof.

Footwear as shown in DE 10 2008 029 296 A1 can give rise to the problem that moisture accumulates in the foot sole region, where the human foot produces most perspiration. This particularly applies to the outer peripheral regions of the foot sole, where perspiration cannot be transported away efficiently because stability requires the sole to be relatively massive in such region. As a result, moisture may accumulate and may even condense in cold weather conditions. A further problem with moisture accumulation is caused by liquid moisture moving down on the inside of the outer material of the upper under wet conditions. Such moisture tends to add to the moisture accumulation at the lower ends of the upper where the upper is joined to the upper bottom.

As a consequence of such accumulation and possible condensation of moisture, the foot may develop an unpleasant feeling of coldness in cold weather. Unless specifically adapted outer materials are used, even stains may appear on the outer material of the upper.

An approach to overcome such problems has been suggested in the applicant's co-pending, unpublished patent application PCT/EP2011/051014, filed on 29 Jan. 2011. Such approach suggests to provide at least one wicking tape which extends from a region between the outer material and the liner of the upper into a region underneath the upper bottom functional layer laminate, in order to form a candlewick-like suction element which transports moisture away from the region between the outer material and the liner of the upper into the region underneath the upper bottom functional layer laminate. From the region underneath the upper bottom functional layer laminate, such moisture can be transported downwardly and out of the footwear via through holes or porosities formed in the sole unit. Several embodiments of such wicking tape in the form of one or a plurality of band-shaped wicking elements made of a water absorbent material are disclosed. Disclosure of this application in full is incorporated into the present application by reference.

In practice it has turned out that provision of separate wicking tapes, while being useful with respect to locally suppressing accumulation of moisture, complicates the manufacturing process of the upper assembly as such, as well as the process of attaching a sole unit to the upper assembly. To achieve improved moisture transport capabilities, the wicking tape needs to be positioned at the underside of the upper bottom rather precisely at those regions where moisture accumulation occurs, and the position of the wicking tape needs to be controlled stably and precisely during attachment of the sole unit. Further, there is a risk that the wicking tape detaches and changes its position in use of the footwear.

Therefore, it is the object of the present invention to provide an upper assembly for footwear, and also footwear comprising same, suppressing unpleasant feeling of coldness in the sole-sided end regions of the upper and/or in the outer peripheral region of the upper bottom. Preferably, also stain formation on the outer material of the upper is to be avoided for any typical outer material. Particularly, the present invention aims in providing an alternative to the wicking tape suggestion of the above mentioned PCT/EP2011/051014, allowing an easier and better controllable manufacturing process.

This object is solved according to the invention by an upper assembly for footwear, comprising an upper having a sole-sided upper end region, and an upper bottom. The sole-sided upper end region is joined to the upper bottom. The upper includes an outer material layer having a sole-sided outer material end region, and an upper liner. The upper bottom comprises a first water vapor permeable assembly sole and an upper bottom laminate including a first water vapor permeable and waterproof functional layer. The outer material layer at the sole-sided outer material end region is joined to the first water vapor permeable assembly sole. The first assembly sole and/or the sole-sided outer material end region comprises at least one moisture transporting structure adapted to transport moisture, away from a first region between the outer material layer and the upper liner and/or between an outer peripheral part of the first outer assembly sole and said upper liner, to a second region underneath the upper bottom functional layer.

The upper bottom, in particular the first assembly sole, closes the upper during manufacture, before a sole unit is attached to the upper assembly. In the upper assembly, a number of possibilities exist to join the upper to the upper bottom, as will be outlined below. In this respect, the first assembly sole has a function similar to the function of insoles as known for various types of footwear constructions, e.g. for lasted shoes. To allow permeation of water vapor across the upper bottom, the first assembly sole may be provided with openings or perforations or can be made at least in part of a water vapor permeable material. The first assembly sole typically will not be waterproof. Waterproofness of the upper bottom is achieved by a separate upper bottom laminate including a first water vapor permeable and waterproof functional layer.

According to the present invention, the first assembly sole and/or the sole-sided outer material end region provides the functionality of a suction element in the sense of the applicant's above mentioned co-pending application PCT/EP2011/051014. For this reason, the first assembly sole and/or the sole-sided outer material end region comprises at least one moisture transporting structure. Such moisture transporting structure provides for a moisture communication connecting a first region between the outer material layer and the upper liner of the upper and/or between an outer peripheral part of the first assembly sole and the upper liner of the upper with a second region underneath the upper bottom laminate. The moisture transporting structure has a configuration which allows transport of moisture or water, in some cases even in liquid form (i.e. not necessarily requiring a phase transition from the liquid phase into the vapor phase), between the first region and the second region. Therefore, in case of accumulation of moisture in the first region, such moisture can be transported away from the first region into the second region. From there, the moisture can further be transported outside, more particularly in the case of footwear having a sole unit attached to the upper assembly, via through holes or porosities formed in the sole unit.

The inventors have found that it is specifically in the region of the sole-sided end of the upper, which is usually connected in a waterproof way to the perimetric edges of the upper bottom, where moisture frequently collects and also frequently condenses to form liquid water. The result is that the foot in contact with the liner in this region experiences a feeling of coldness. Further, it has turned out that, in case the upper liner includes a water vapor permeable and waterproof functional layer, often no sufficiently steep water vapor pressure gradient develops across the inner and outer sides of the functional layer at this place. Such effect reduces breathability distinctly. Under very cold and wet conditions, even moisture stains have been observed in this region on the outer side of the footwear, impairing the appeal and appearance of the footwear. All this may finally ruin the footwear because of mold formation or deterioration of the bonding between different parts of the footwear.

A moisture transporting structure, as provided according to the invention, has turned out to efficiently suppress accumulation of moisture, and thereby prevents an unpleasant feeling of cold in such region, and helps in maintaining breathability, preventing staining and also suppressing the attacking of bonds in such region.

In contrast to the wicking tape solution suggested in the applicant's above mentioned co-pending application PCT/EP2011/051014, the present invention provides the first assembly sole and/or the sole-sided outer material end region with a moisture transporting structure. Hence, according to the present invention the function of the suction element is provided by the first assembly sole of the upper assembly, i.e. by a layer being part of the upper bottom and being used to close the upper assembly towards the sole unit during manufacture of footwear, and/or by the sole-sided outer material end region. Therefore, no separate item, like the wicking tape of PCT/EP2011/051014, needs to be arranged somewhere in between upper and the upper bottom. Rather, the suction element function is added to the upper assembly already when closing the upper assembly towards the sole unit by way of the first assembly sole, which is a usual step to be done during manufacture.

Providing the first assembly sole and/or the sole-sided outer material end region with a moisture transporting structure has the additional advantage of being able to control relatively precisely the position of the moisture transporting structure in the footwear, as the first assembly sole is joined to the outer material layer of the upper in a well defined geometric relationship, and the sole unit is firmly attached to the upper assembly, typically even to the first assembly sole and/or the sole-sided outer material end region. Therefore, the moisture transporting structure can be positioned relatively precisely in such regions where in use of the footwear most moisture accumulation is to be expected. Once assembled, the moisture transporting structure will no longer change its position significantly, e.g. during use, as it is formed by the first assembly sole and/or the sole-sided outer material end region. This is another advantage over providing a separate suction element like a wicking tape.

The moisture transporting structure is capable of transporting moisture between the first region and the second region. As the first and second regions are separated from each other in direction of the extension of the first assembly sole and/or the sole-sided outer material end region, the moisture transporting structure is capable of transporting moisture along the extensions of the first assembly sole and/or of the sole-sided outer material end region. Within the moisture transporting structure, such transport of moisture may occur along the upper and/or lower surfaces of the first assembly sole and/or of the sole-sided outer material end region, but preferably occurs within the thicknesses of the first assembly sole and/or of the sole-sided outer material end region. For this reason, the first assembly sole and/or the sole-sided outer material end region, in regions where a moisture transporting structure is provided, preferably include materials capable of transporting moisture, e.g. materials having wicking characteristics, and/or may be provided with a moisture conduit structure capable of allowing or even promoting transport of moisture, e.g. channel structures or wicking filaments. As used herein, transport of moisture refers to transport of water molecules in general, not being restricted to any form of water in liquid or gaseous form. Further, transport of moisture may be induced by any mechanism, in particular by sorption processes, capillarity, diffusion processes, gravity, pressure gradients and the like. In preferred embodiments, the first assembly sole in the water transporting structure is capable of transporting water from the first region, where moisture, often to a substantial part in form of liquid, accumulates, to the second region without the need of a phase transition from the liquid phase into the vapor phase occurring in the first region.

The moisture transporting structure typically will include the lower end or the lower ends of the upper and the more peripheral regions of the upper bottom. As outlined above, transport of moisture along the extension of the first assembly sole is required in such region, but is not necessarily required in other regions of the first assembly sole, e.g. the more central regions, of the upper bottom. In such regions, it may be sufficient if the first assembly sole is water vapor permeable, i.e. allows permeation of water vapor across its extension. In some embodiments, the first assembly sole may even allow water permeation of liquid water vapor across its extension. In some embodiments, the moisture transporting structure may extend over the whole first assembly sole.

Different mechanisms may be used to achieve transport of moisture along the extensions of the first assembly sole and/or of the sole-sided outer material end region in the moisture transport structure: A first possibility is to use a material having “wicking characteristics”. A material is referred to as having “wicking characteristics” in case it is able to take off liquid or gaseous moisture from a first reservoir and transport such moisture along its extension to a sec- and reservoir, as a consequence of its intermolecular or “micro” structure. Wicking characteristics refers to transport moisture based on processes like sorption, diffusion and/or capillarity processes. Materials having wicking characteristics include materials having an intermolecular or “micro” structure allowing such sorption, diffusion or capillarity processes. In wicking materials, typically moisture will be able to flow against gravity, such that moisture spontaneously rises. Typical wicking materials include narrow spaces, such as thin tubes, or are porous materials, such as paper or absorbent textiles. Even some non-porous materials are known to have wicking characteristics, e.g. some types of carbon fibers or nano-materials. Particular wicking materials include naturally hydrophilic materials or materials having been subject to a hydrophilic treatment. Examples for such materials are cellulose, leather, any materials having a porous structure, natural fibers, synthetic fibers and surfaces based on these fibers.

As a further possibility, the first assembly sole and/or the sole-sided outer material end region may be provided with a moisture conduit structure, e.g. with an arrangement of wicking filaments, with a channel like structure, and/or with suitable perforations, slits and/or recesses. In this case, the first assembly sole and/or the sole-sided outer material end region, in principle, need not be made of a material having wicking characteristics as a consequence of its intermolecular or “micro” structure, since the water transporting effect is achieved by the “macroscopic” moisture conduit structure. In such case, the first assembly sole and/or the sole-sided outer material end region may be made of an even water impermeable material.

It is noted that all possibilities mentioned before may be combined in the sense that a material having wicking characteristics due to its intermolecular or “micro” structure is used which is additionally provided with a macroscopic moisture conduit structure, in order to provide good moisture transport efficiency.

In all embodiments, the upper liner can be suitably connected to the outer material layer, for example stitched on an upper side or spot glued thereto. In a number of embodiments the upper as a whole will be provided on its inner side with an upper liner, such that the foot is enclosed on its lateral sides as well as on its upper side by the upper liner. In some embodiments, it may be conceivable that the upper liner is provided only on the lateral sides of the upper, extending from the upper bottom to some height above. When used with footwear where the upper liner includes a waterproof and water vapor permeable functional layer, such configuration of the upper liner still provides for waterproofness of the footwear with respect to moisture or water coming from the ground. In such embodiments it may be conceivable to extend the upper bottom functional layer or upper bottom functional layer laminate laterally such as to form the upper liner in the lower lateral regions of the upper.

In an embodiment, the second region underneath the upper bottom laminate may positioned such as to be, in a state in which a sole unit is attached to the lower surface of the upper assembly, in moisture permeable communication with at least one moisture permeable passage, or with a region exhibiting moisture permeable porosities, formed in the sole unit. This allows efficient transport of moisture from the second region underneath the bottom laminate to the outside via the passages or porosities formed in the sole unit. It is preferred that such moisture permeable communication even allows the transport of moisture in liquid form.

Similarly, in an embodiment, the first region between the outer material layer and the upper liner of the upper and/or between an outer peripheral part of the first outer assembly sole and the upper liner of the upper may positioned such as to be, in a state in which a sole unit is attached to the lower surface of the upper assembly, covered by sole material and/or sole adhesive. Because of the sole material and/or the sole adhesive, transport of water vapor from the inside of the footwear to the outside is hindered or even blocked. Hence, such moisture will accumulate typically at such locations.

The moisture transporting structure may comprise at least one material having wicking characteristics as discussed above, thereby forming a wicking element. Examples for such materials having wicking characteristics are hydrophilic natural fibers like cotton, and hydrophilic synthetic fibers like hydrophilic polyethylene, polyester and copolyester, or any fibers subject to a hydrophilic treatment, and mixtures thereof.

Alternatively, or additionally, the moisture transporting structure may be provided with at least one moisture conduit structure, thereby forming a moisture conduit element. E.g., the first assembly sole may be provided with grooves or slits which extend between the first region and the second regions mentioned above. Other forms of recesses and/or perforations are conceivable as well. It is also conceivable to provide the first assembly sole with an arrangement of wicking filaments.

To ensure permeation of perspiration moisture in the sole regions, the first assembly sole may be made of a water vapor permeable and/or perforated material with respect to a direction across the first assembly sole. Such water vapor permeability may be provided at least in the region laterally inside the moisture transporting structure(s), but in some embodiments may also be provided in the moisture transporting structure(s).

In some embodiments, the moisture transporting structure may extend over the first assembly sole as a whole, i.e. the first assembly sole as a whole may be made of a material having wicking characteristics and/or may be provided with one or a plurality of moisture conduit structures.

Preferably, the moisture transporting structure provides for a moisture transport rate of at least 1 cm per two 2 hours, measured after DIN 53924 (1997). In particular embodiments moisture transport rates, measured after DIN 53924 (1997), of at least 2 cm per 2 hours, or of at least 3 cm per 2 hours, or of at least 4 cm per 2 hours, or of at least 5 cm per 2 hours, or of even at least 6 cm per 2 hours may be achieved. Maximum moisture transport rates, measured after DIN 53924 (1997), up to 5 cm per 2 hours, or of even up to 8 cm per 2 hours, or of even 10 cm per 2 hours can be realized.

While the outer material layer of the upper is joined to the first assembly sole, preferably the outer material layer is not joined, or at least not joined directly, to the upper bottom functional laminate. In case an upper functional laminate is used, the upper bottom laminate will typically be connected in a waterproof way with such upper functional laminate. As the upper bottom laminate is not connected directly with the outer layer, a moisture transportation path may extend in between the inner side of the outer material layer and the upper bottom functional layer and the outer side of the upper functional layer.

In embodiments, the upper liner may be configured as an upper liner laminate having a second water vapor permeable and waterproof functional layer. Using such upper liner, fully waterproof yet breathable footwear may be constructed.

In some embodiments, the outer material layer may be shorter than the upper liner. In such configuration, the upper liner has a sole-sided upper liner end region which overlaps or extends beyond the corresponding sole-sided outer material end region. When closing the upper by way of the first assembly sole, the sole-sided end regions of the upper are connected, e.g. stitched, to the outer peripheral end regions of the first assembly sole thus forming at least one bonding region. In a configuration with shorter upper, the first assembly sole extends relatively far up on the lateral sides of the footwear, and reaches far into the first region where most accumulation of moisture will occur. Hence, the first assembly sole is able to effectively take up moisture in its outer peripheral regions, given such outer peripheral regions are provided with at least one suitable moisture transporting structure. Transport of moisture from the first region to the second region can be very efficient, as the first assembly sole rather effectively sucks in moisture in the first region, leading to a large gradient in concentration of moisture from the first region to the second region.

In some embodiments, the first assembly sole may be arranged underneath the upper bottom laminate. The first assemble sole thus forms the lowermost layer of the upper bottom. In footwear having the upper assembly, the first assembly sole will be the lowermost layer arranged immediately above the sole unit. Typically, in such configuration the sole unit will be attached in some way to the first assembly sole.

When joining the sole-sided end region of the outer material layer to the first assembly sole, a connection region may be formed which includes the areas where bonding takes place, e.g. seams covered by stitches, adhesive or the like, and/or seams where welding takes place. Further, the connection region typically will also include regions of the outer material layer and the first assembly sole being adjacent to such seams. In most embodiments the connection region can be considered to extend as far upwards as the sole-sided end region of the outer material layer comes into contact with the sole unit. In footwear having a sole provided with through holes and/or perforations, the connection region may be considered to reach as far inwards as an outer peripheral region of the first assembly sole encloses an inner peripheral region of the assembly sole overlying the through holes/perforations.

It is generally advantageous to join the outer material layer and the first assembly sole by stitching, e.g. using known types of stitches like Strobel stitches or zig-zag stitches. Stitching provides for a seam which does not impair transport of moisture from the sole-sided end region of the upper to the outer peripheral regions of the first assembly sole, and is relatively easy to carry out with typical materials to be used for the moisture transporting structure. In contrast, other bonding techniques, like gluing or welding, tend to adversely affect such moisture transport at least in the connection region. In a number of embodiments, neither the first assembly sole nor the outer material of the upper include a functional layer and hence providing a stitched seam to join the first assembly sole and the outer material does not affect waterproofness of the upper assembly. The moisture transporting capability may even be improved when using hydrophilic yarns or filaments for stitching together the outer material layer and the first assembly.

Bonding material or liquid polymeric material are used to attach or form a sole unit to the upper assembly by molding or injecting. Such material, if applied to the sole-sided end region of the outer material layer and/or to the first assembly sole, may affect moisture transport efficiency. To ensure efficient moisture transport, in particular embodiments the sole-sided end region of the outer material layer may be joined to the first assembly sole such as to be impermeable with respect to bonding material, such as glue or adhesive, for attaching a sole unit and/or with respect to liquid polymeric material used for providing a sole unit by molding or injecting. As used in this context, impermeable is meant to suppress penetration of any bonding material and/or liquid polymeric material into the outer material layer and/or first assembly sole to such extent that moisture transport from the first region between the outer material layer and the upper liner of the upper and/or between an outer peripheral part of the first outer assembly sole and the upper liner of the upper, to a second region underneath the upper bottom laminate is disturbed significantly. As the sole unit is attached to the upper assembly from below, impermeability is provided preferably with respect to the lower sides of the outer material layer and/or the first assembly sole. Typically, impermeability will be provided in regions where a seam connecting the outer material layer and the first assembly sole is formed, however it is advantageous if such impermeability also extends to adjacent regions of the outer material layer and/or first assembly sole, e.g. extends over the connection region.

Impermeability of the sole-sided end region of the outer material layer and/or first assembly sole, particularly in the connection region, with respect to bonding material for attaching a sole unit and/or with respect to liquid polymeric material for molding or injecting a sole unit has turned out to be advantageous, even in cases where the first assembly sole does not have any particular moisture transporting structures. One reason for this is that impermeability allows the use of bonding materials for attaching the sole unit being chemically more aggressive than other material conventionally used. In particular with respect to liquid polymeric material for molding or injecting, impermeability allows to use materials having melting or softening regions at rather high temperatures. If such materials were allowed to penetrate through the layer structure formed by the outer material layer and/or the first assembly sole, they would potentially harm the functional layers inside. Applicant reserves the right to draft claims protecting any embodiments where the sole-sided end region of the outer material layer is joined to the first assembly sole such as to be impermeable with respect to bonding material, such as glue or adhesive, for attaching a sole unit and/or with respect to liquid polymeric material used for providing a sole unit by molding or injecting without the first assembly sole having any particular moisture transporting structures.

In some embodiments an impermeable layer may be provided. Such impermeable layer covers the connection area of the sole-sided end region of the outer material layer and the first assembly sole. Preferably, such impermeable layer may be arranged on a sole-sided connection area of the sole-sided end region of the outer material layer and the first assembly sole, because typically a sole unit will be attached to the bottom side of the upper assembly. Hence, the impermeable layer will be in direct contact with any bonding material for attaching the sole unit and/or any liquid polymeric material.

In some examples the impermeable layer may be made of a material that is selected from structures comprising at least one barrier layer, such as an impermeable tape or film, such tape or film being in particular impermeable for injected polyurethane (PU) material. Further examples of the impermeable layer include adhesive tapes, or tapes used for sealing purposes, like Gore-Seam® Tape. In other examples, the impermeable layer can include a barrier comprising of metalized films, e.g. as described in the applicant's co-pending patent application PCT/EP2011/051265, or of polyethylene, in particular low density polyethylene LDPE. Alternatively, it is possible to apply the impermeable layer in the condition of a polymer dispersion which forms an elastic dry layer after application and drying by evaporation of solvent.

In some embodiments, the upper bottom laminate may be a two-layer laminate having a first water vapor permeable and waterproof functional layer which is arranged on a textile support layer, preferably on the surface directed to the inside of the upper assembly. In other embodiments, the upper bottom laminate is a three-layer laminate having the first water vapor permeable and waterproof functional layer which is arranged between a first and a second textile support layer. Also the upper functional layer may be included in an upper laminate being any one of a two layer laminate, a three layer laminate or a multi layer laminate as described.

In further embodiments a second water vapor permeable upper liner assembly sole (in the following: second assembly sole) may be arranged above the upper bottom laminate. Such second assembly sole may be used to close the lower ends of the upper liner towards the sole unit, typically as a first step in manufacturing the upper assembly. Once the upper liner is closed using the second assembly sole, the outer material layer of the upper can be closed towards the sole independently. This allows for selecting the most beneficial techniques for joining the upper liner with the second assembly sole and for joining the outer layer with the first assembly sole. Also this way of constructing an upper assembly using two independent assembly soles, one to close the upper liner towards the sole, and another to close the outer material layer towards the upper, is another aspect that has been proven to be advantageous independent of whether the first assembly sole has particular moisture transporting structures or not, and also independent of whether the sole-sided end region of the outer material layer is joined to the first assembly sole such as to be impermeable. Applicant also reserves the right to draft claims protecting any embodiments where the sole-sided end region of the upper liner is joined to the second assembly sole and the outer material layer of the upper is independently joined to the first assembly sole.

Also the second water vapor permeable upper liner assembly sole and the sole-sided end region of the upper liner may be joined to one another by stitching, e.g. using known types of stitches like Strobel or zig-zag stitches.

The second assembly sole may be joined along its outer periphery to the sole-sided edge of the upper liner. In embodiments where the second assembly sole is a component separate from the upper bottom laminate, such upper bottom laminate may be joined along its outer periphery with the outer side of the upper liner, preferably by adhesive bonding and in such a way that the bonding seals the joint waterproof. Such construction allows closing the upper liner, even in case such upper liner includes a functional layer, towards the sole by attaching the second assembly sole using stitches. In such stage, the upper assembly is not yet waterproof with respect to the upper bottom. Waterproofness with respect to the upper bottom is achieved by adding an additional upper bottom laminate on the bottom side of the second assembly sole. To this end, the bottom laminate is attached to the outer side of the lower end region of the upper liner via a bond providing a waterproof seal, e.g. via a waterproof adhesive bond. In a configuration as described the first functional layer included in the upper bottom and the second functional layer provided in the upper liner are joined to form a waterproof bonding area.

In other embodiments, the sole-sided end region of the upper liner and the upper bottom laminate may be joined without the use of an additional assembly sole. In such embodiments, the upper bottom laminate may be considered to provide the function of the second assembly sole. One example of such construction includes a so-called waterproof and water vapor permeable bootie. Such bootie generally has the shape of a sock which is inserted into the upper assembly formed by an outer layer and an upper bottom. In such bootie construction, the upper liner may be constructed as an upper liner laminate, forming a water vapor permeable and waterproof unit with the upper bottom laminate. In typical bootie construction, the bootie is a prefabricated component which is attached to the inner side of an outer layer of the upper followed by closing the upper towards the sole side using the first assembly sole. In other embodiments, first the outer layer of the upper may be placed on a last and closed on its bottom side by the first assembly sole, after which the last is removed and the bootie is inserted into the upper assembly and placed on the inner sides of the outer layer and first assembly sole.

Also in a construction of the upper assembly not having a second assembly sole, e.g. in a bootie construction, the sole-sided end region of the upper liner and the upper bottom laminate may joined to one another by stitching using known stitches like zig-zag stitches. In such configurations the bonding regions between different parts of the bootie need to be sealed, e.g. by using adhesives like hot-melt adhesives applied to the seams or seam tapes covering the seams. Alternatively, it is conceivable to inject liquid polymeric material to the connecting regions between different parts where two functional layers are connected with each other.

The upper assembly as described above is preferably intended to be used with waterproof and water vapor permeable footwear. Footwear is understood to include any types of shoes or boots. Such footwear will typically comprise an upper assembly as described before, and a sole unit attached to the upper assembly. The sole unit has at least one passage or exhibits porosities and is joined in particular to the lower surface of the upper assembly by adhesive bonding, molding or injecting. The lower surface of the upper assembly is intended to refer to sole side of the upper bottom and/or of the sole-sided end region of the upper.

In such footwear the at least one moisture transporting structure extends from an outer periphery of the first assembly sole and/or from the sole-sided outer material end region laterally inwards into the region being in liquid communication with the at least one passage or the porosities.

DEFINITIONS AND TEST METHODS

Footwear:

Footwear is considered to comprise any type of footgear having a closed upper portion (upper), and a sole or sole unit attached to the bottom side of the upper. The upper forms a pouch enclosing the foot and including a foot insertion opening.

Upper Outer Material:

Upper outer material refers to a material which forms the outside surface of the upper and thus of the upper assembly. The outer material may consists of leather, textile, plastic, other known materials, or combinations thereof, or is constructed therewith. The outer material generally is made of water vapor permeable material. The sole sided lower end of the upper outer material forms a region adjoining the upper edge of the sole or sole unit, or above a boundary plane between the upper and the sole or sole unit.

Assembly Sole (Insole):

The assembly sole is part of the upper bottom. A sole sided upper end region is joined with the assembly sole. Depending on shoe construction a first assembly sole for closing the outer material layer towards the sole or sole unit is provided and sometimes a second assembly sole for closing the upper inner liner towards the sole or sole unit may be provided.

Sole:

A shoe has at least one outsole, but can also have multiple kinds of sole layers which are arranged on top of each other and form a sole unit.

Outsole:

An outsole is that component of the sole/sole unit which touches the floor/ground or makes the main contact with the floor/ground in use. An outsole has at least one tread surface touching the floor.

Midsole:

In cases where the outsole is not attached directly to the upper assembly, a midsole can be inserted in between the outsole and the upper assembly. The midsole can e.g. provide for cushioning or damping, or may be used as filling material.

Bootie:

A bootie is a sock type inner liner of an upper assembly. A bootie forms a bag type liner of the upper assembly, which covers the interior of the footwear essentially completely. In a number of embodiments a waterproof and water vapor permeable bootie is provided. Such bootie typically is made of a plurality of different parts joined together in a waterproof manner.

Functional Layer:

Functional layer refers to a waterproof and/or water vapor permeable layer, e.g. in the form of a membrane or of an appropriately treated or finished material, e.g. a textile having undergone a plasma treatment. Further, the functional layer may be an upper bottom functional layer forming least one layer of an upper bottom of the upper assembly. The functional layer may also be provided in the form of an upper functional layer at least partly forming a lining of the upper. Both the upper functional layer but also the upper bottom functional layer may be provided as part of a multilayer, usually two, three or four layer, membrane laminate or functional layer laminate. The upper functional layer and the upper bottom functional layer can each be part of a functional layer bootie. In cases where, instead of a functional layer bootie, an upper functional layer and a separate upper bottom functional layer are used, these are sealed relative to each other in a waterproof way, particularly in the sole sided lower regions of the upper assembly. The upper bottom functional layer and the upper functional layer can be made of the same material or can be made of different materials.

Suitable materials for the waterproof and water vapor permeable functional layers are in particular polyurethane, polypropylene and polyester, including polyetherester and laminates thereof, as described for example U.S. Pat. No. 4,493,870. The functional layer may be constructed using microporous expanded polytetrafluoroethylene (ePTFE), as described e.g. in U.S. Pat. No. 3,953,566 and U.S. Pat. No. 4,187,390. The functional layer may also be constructed using expanded polytetrafluoroethylene provided with hydrophilic impregnants and/or hydrophilic layers, as described e.g. in U.S. Pat. No. 4,194,041. A. microporous functional layer is a functional layer whose average pore size is between about 0.2 μm and about 0.3 μm.

Laminate:

A laminate is an assembly consisting of multiple layers durably bonded to each other, generally by mutual adhering together. In the case of a functional layer laminate, a waterproof and water vapor permeable functional layer is provided with at least one textile layer. The at least one textile layer mainly serves to protect the functional layer during the processing thereof. This is referred to as a two layer laminate. A three layer laminate consists of a waterproof and water vapor permeable functional layer embedded between two textile layers. The bonding between the functional layer and the at least one textile layers is effected e.g. by means of a continuous water vapor permeable layer of adhesive or by means of a discontinuous layer of non water vapor permeable adhesive. In one embodiment, adhesive in the form of a dot shaped pattern may be applied between the functional layer and the textile layer, or between the functional layer and both of the textile layers. The dot shaped or discontinuous application of the adhesive is chosen because a uniform layer of an adhesive which itself is non water vapor permeable would block the water vapor permeability of the functional layer.

Barrier Layer:

A barrier layer serves as barrier against the penetration of substances, particularly in the form of particles or foreign bodies, e.g. small stones, through to a layer of material to be protected, more particularly through to a mechanically sensitive functional layer or functional layer laminate.

Waterproof:

A functional layer/functional layer laminate/membrane, if appropriate including seams provided on the functional layer/functional layer laminate/membrane, is considered to be waterproof in case it warrants a water inlet pressure of at least 1*10⁴ Pa. Preferably, the functional layer material warrants a water inlet pressure of above 1*10⁵ Pa. The water inlet pressure is measured by following test method: Distilled water at 20±2° C. is applied to a sample of 100 cm² of the functional layer with increasing pressure. The pressure increase of the water is 60±3 cm Ws per minute. The water inlet pressure is then equal to the pressure at which water first appears on the other side of the sample. Details of the procedure are described in ISO-0811 (1981).

Whether a shoe is waterproof can be tested e.g. using a centrifuge arrangement of the kind described in U.S. Pat. No. 5,329,807.

Water Vapor Permeable:

A functional layer/functional layer laminate is considered water vapor permeable in case it has a water vapor permeability number Ret of below 150 m²*Pa*W⁻¹. The water vapor permeability is tested in accordance with the Hohenstein skin model. This test method is described in DIN EN 31092 (02/94) and ISO 11092 (1993).

Wicking Characteristics and Test for Measuring Wicking Characteristics

A material or structural element, e.g. a filament, yarn or textile fabrics, is referred to as having wicking characteristics, in case it is able to transport moisture based on sorption, diffusion and/or capillarity processes. Thus a wicking material or structural element it is able to take off liquid or gaseous moisture from a first reservoir and transport such moisture along its extension to a second reservoir, as a consequence of its intermolecular or “micro” structure. In wicking materials, or in wicking structural elements, typically moisture will be able to flow against gravity, such that moisture spontaneously rises. Typical materials or structural elements having wicking characteristics include narrow spaces, such as thin tubes, or are porous materials, such as paper or absorbent textiles. Even some non-porous materials are known to have wicking characteristics, e.g. some types of carbon fibers or nano-materials. Particular wicking materials include naturally hydrophilic materials or materials having been subject to a hydrophilic treatment. Examples for such materials are cellulose, leather, any materials having a porous structure, natural fibers, synthetic fibers and surfaces based on these fibers.

A method for determining the rate of transport of water in textile fabrics is described in DIN 54924 (1997). Such method determines the rising height of water in a sample within a given period time. As far as wicking rates are mentioned herein, reference is made to DIN 54924 (1997).

Wicking rates have been determined according to DIN 54924 (1997) for two sample textile fabrics, as set out below:

Assembly		Thickness	Textile weight	Wicking rate
sole	material	in mm	in g/m2	in cm/2 hrs
Vildona SI	Mixture of	0.75-0.95	200-260	6.5
250E by the	80% PET and
company	20% CoPES
Freudenberg
Wp-White 44″	100% PES	0.8	173	6.5
by the company
Guan Cao Yue

Illustrative embodiments of the invention will be described in more detail with reference to the accompanying figures.

FIG. 1 shows a schematic cross section of a forefoot region of a shoe according to a first illustrative embodiment of the invention;

FIG. 2 shows a schematic cross section of a forefoot region of a shoe according to a further illustrative embodiment of the invention;

FIG. 3 shows schematic cross section of a forefoot region of a shoe according to a further illustrative embodiment of the invention;

FIGS. 4 to 14 show schematic bottom views of various exemplary upper assemblies having a first assembly sole according to embodiments.

All depictions hereinbelow are schematic and not necessarily realistic in respect of dimensions and scale. In all embodiments, same reference signs refer to same or corresponding components. Description of a component typically is given for one embodiment only. For other embodiments, reference is made to the description of the component with respect to the first embodiment, unless any differences are explicitly specified.

FIG. 1 shows a schematic cross section of a forefoot region of a shoe 100 comprising an upper assembly 10 according to a first illustrative embodiment of the invention and a sole unit 12. The sole unit 12 is attached to the bottom side of the upper assembly 10. In the embodiment 100 shown in FIG. 1 the sole unit 12 is attached to the upper assembly by overmolding, in particular by direct injecting of liquid polymeric material to the bottom of the upper assembly 10. In the specific embodiment shown, the injected polymeric material forms part of an outsole 44. The same construction is shown in FIGS. 2 and 3. It is to be noted that alternatively a sole unit having a prefabricated outsole 44 could be used, which is attached to the upper assembly by injecting liquid polymeric material forming a midsole, or the prefabricated sole unit 12 could be attached to the upper assembly 10 by gluing to the bottom of the upper assembly 10.

The upper assembly 10 comprises an upper 14 and an upper bottom 16. The upper bottom 16 is connected with its outer peripheral edge to the sole sided edge of the upper 10. The upper section of upper is not shown in FIGS. 1 to 3. However, it is to be understood that the upper section of the upper 10 forms a closed pocket into which the foot is to be inserted.

The upper 14 includes a water vapor permeable outer material layer 18 and an upper functional layer laminate 20 forming an upper liner. The upper functional layer laminate 20 comprises—from the outer side towards the inner side—a supporting textile layer in the form of a mesh layer 22, an upper functional layer or an upper membrane 24, and a supporting textile layer in the form of an upper liner layer 26. The outer material layer 18 has a sole sided lower end region 18a curved inwardly relative to the essentially vertically extending section of the upper 14. In the embodiments shown in FIGS. 1 to 3 the upper functional layer laminate 20 is a three layer laminate having the upper functional layer 24 sandwiched in between the upper liner layer 26 on its inner side and an upper supporting mesh layer 22 on its outer side. It is to be noted that, alternatively, the upper functional layer laminate 20 may be a two layer laminate 20 having the upper functional layer 24 supported by a supporting mesh layer 22 or liner layer 26, either on the inner or on the outer side. Further, in the embodiments shown in FIGS. 1 to 3, the laminate forms a closed pocket into which the foot is to be inserted. However, in some embodiments, the laminate 20 may not form a closed pocket, but only extend in the lateral sections of the upper 14 up to some height, such as to prevent penetration of water from the ground.

The multilayer upper bottom 16 comprises—from its lower side, i.e. its sole facing side, towards its upper side, i.e. its side directed towards the inside of the upper assembly, —the first assembly sole 30 (also called first insole), an upper bottom functional layer laminate 32 having an upper bottom functional layer or an upper bottom membrane 34 supported by a supporting textile layer 36, and a second assembly sole 38. In the embodiments shown in FIGS. 1 and 2, the upper bottom functional layer laminate 32 is a two layer laminate having an upper bottom functional layer 34 supported by a supporting textile layer 36. It is to be understood that, alternatively, in all embodiments the upper bottom functional layer laminate 32 may be a three layer laminate having an upper bottom functional layer 34 sandwiched in between a first supporting textile layer 36 and a second supporting textile layer 36, as exemplary shown for the embodiment of FIG. 3.

The sole sided end region 18a of the outer material layer 18 is joined by means of a stitch 28, e.g. a Strobel stitch or a zigzag stitch, to the outer peripheral end 30a of the first assembly sole 30. Thereby, during manufacture of the upper assembly 10, the outer material layer 18 of the upper 14 is closed towards the sole unit 12 via the first assembly sole 30.

Also the second assembly sole 38 is joined at its outer peripheral end by means of a stitch 40, e.g. a Strobel stitch or a zigzag stitch, to the sole sided end region of the upper liner 20. Thereby, during manufacture of the upper assembly 10, the upper liner 20 of the upper 14 is closed towards the sole 12 via the second assembly sole 38.

The upper bottom functional layer laminate 32 is arranged immediately below the second assembly sole 38 and above the first assembly sole 30. The upper bottom functional layer laminate 32 has a larger lateral extent than the second assembly sole. This allows the upper bottom functional layer laminate 32 to be connected, e.g. by gluing, in a waterproof manner to the sole sided end region of the upper functional layer laminate 20. In such connection, a waterproof seal is formed between the upper bottom functional layer 34 and the upper functional layer 24. The underside of the sole sided end region of the upper functional layer laminate 20 is connected by means of a sealing adhesive 42 in a waterproof manner to the upper side of the outer peripheral edge of the upper bottom functional layer laminate 32. The sealing adhesive 42 may either be superposed on the stitching 40 or may be arranged laterally outside of the stitching 40. In both cases the result is an allover waterproof and—when using not just waterproof but also water vapor permeable functional layers 24, 34—an allover water vapor permeable upper assembly 10.

The sealing adhesive 42 penetrates through the upper supporting mesh 22, thus providing a waterproof sealing between the two functional layers 24, 34 relative to each other, and serves to secure and seal the upper bottom functional layer laminate 32 to the upper functional layer laminate 20.

Preferably, the upper bottom functional layer laminate 32 is not joined to the first assembly sole 30 and not joined to the second assembly sole 38, but rather merely abuts such first and second assembly soles. If at all, the upper bottom functional layer laminate 32 may be slightly fixed with respect to the first assembly sole 30 and/or with respect to the second assembly sole 38 in a manner not affecting water vapor permeability, e.g. by spot gluing.

The sole sided lower end region of the upper functional layer laminate 20 is spaced from the sole sided lower end region 18a of the outer material layer 18, because of the outer peripheral edge of the upper bottom functional layer laminate 32. This creates an interspace or first region, designated as A in the drawings, in the sole-sided end region of the upper 14 between the upper functional layer laminate 20 on the inner side and the outer material layer 18 on the outer side, and/or between the upper functional layer laminate 20 on the inner side and the first assembly sole 30 on the outer side. Such first region or interspace A widens towards the sole-sided end region of the upper 14 where the upper 14 is closed by the upper bottom 16.

The outer periphery of the upper bottom functional layer laminate 32 forms an inner boundary of such first region or interspace A. The first region or interspace A is typically filled by air or by moisture (water in liquid and/or gaseous phase) vapor or by an air/moisture mixture.

The sole unit 12 is attached to the sole sided lower end region 18 of the outer material layer 18a by means of injecting liquid polymeric material such as to form an outsole 44 to the bottom of the upper assembly 10. Alternatively, the sole unit 12 may be a prefabricated sole unit and may be glued to the bottom of the upper assembly 10 using sole adhesive.

The sole unit 12 comprises the outsole 44 which forms the surrounding outer region thereof and which on its upper side extends somewhat upwardly in the outward direction in order to accommodate the curved region of the outer material layer 18 of the upper, where the sole-sided end region 18a of the outer material layer 18 is positioned. The outsole 44 also forms at least part of a tread surface 44a which, in use of the shoe, contacts the ground. The outsole 44 has a central cutout X in which are arranged—from the bottom to the upward direction—a supporting bar layer 46, a grid layer 48, and a barrier layer 50. The sole unit 12 has formed therein a number of through holes or perforations 52a, 52b. These through holes or perforations 52a, 52b are formed in the tread surface 44a and permit exchange of moisture between the tread surface 44a and the upper bottom functional layer 34. The trough holes or perforations 52a, 52b are in moisture transporting contact with a second region, designated as B in the drawings, underneath the upper bottom functional layer 34.

The outsole 44 can be made as a single piece, as shown in the figures, or can be made from two or more pieces, e.g. in different colors. The through holes or perforations 52a, 52b are made as large as possible in order to allow a correspondingly high water vapor permeability. The sole unit 12 is horizontally traversed by a barrier layer 50 which provides a mechanical protection for the upper bottom functional layer laminate 32 against damage by foreign bodies, e.g. small stones, which might penetrate into the through holes or perforations 52a, 52b. The barrier layer 50 extends somewhat into the outsole 44, and thus is anchored in the latter and durably connected thereto. This barrier layer may be constructed using a thermally consolidated fibrous material, so that it can additionally also be configured as a stabilizing material for the sole unit 12. Additional stability to the sole unit is provided by the supporting bar layer 46 and the grid layer 48.

As will be outlined in more detail below, the first assembly sole 30 is provided with a moisture transporting structure 54a, 54b. Such moisture transporting structure 54a, 54b is positioned in the outer peripheral regions of the first assembly sole 30 and provides for a moisture communication path connecting the first region or interspace A formed in between the upper functional layer laminate 20 and the outer material layer 18 of the upper 14 and/or the outer peripheral edge region 30a of the first assembly sole 30 with the second region B below the upper bottom laminate 32. Moisture having accumulated in the first region or interspace A thus is allowed to be transported away via such moisture transporting structure 54a, 54b to the second region B from where it can be transported to the outside via the through holes/perforations 52a, 52b formed in the sole unit 12.

Additionally or alternatively, a similar moisture transporting structure 54c, 54d may be provided in the sole sided edge region 18a of the outer material layer 19 of the upper, as is depicted schematically for the embodiments of FIGS. 2 and 3. Such moisture transporting structure 54c, 54d preferably will be in water transporting communication with the corresponding moisture transporting structure 54a, 54b in the first assembly sole and further supports the moisture communication path connecting the first region or interspace A with the region B. In some embodiments where the outer material layer 18 of the upper 14 extends far into the region under the upper bottom laminate 32, see FIG. 3, it may be conceivable to use only the moisture transporting structure 54c, 54d and omit a corresponding moisture transporting structure 54a, 54b in the first assembly sole.

In the embodiments of FIGS. 1 to 3, a connection region 56 is formed where the sole-sided end 18a of the outer material layer 18 is joined to the outer peripheral region 30a of the first assembly sole. Such connection region includes the areas where bonding between the sole sided end 18a of the outer material layer 18 and the outer peripheral region 30a of the first assembly sole 30 takes place, e.g. a seam covered by stitches 28, adhesive or the like, and/or seams where welding takes place. Further, the connection region 56 also includes regions of the outer material layer 18 and the first assembly sole 30 adjacent to such seam 28. In the embodiments show in FIGS. 1 to 3, the connection region 56 can be considered to extend as far upwards as the sole-sided end region 18a of the outer material layer 18 comes into contact with the sole unit 12. In footwear having a sole unit 12 provided with through holes and/or perforations 52a, 52b, as is the case in the embodiments of FIGS. 1 to 3, the connection region 56 may be considered to reach as far inwards from the joint 28 as an outer peripheral region 30a of the first assembly sole 30 encloses an inner peripheral region 30b of the assembly sole 30 overlying the through holes/perforations 52a, 52b when the sole unit 12 is attached to upper assembly 10.

In the embodiments of FIGS. 1 to 3 the sole-sided end region 18a of the outer material layer 18 is joined to the first assembly sole 30 such as to be impermeable with respect to bonding material, such as glue or adhesive, for attaching a sole unit 12 and/or with respect to liquid polymeric material used for providing a sole unit 12 by molding or injecting. As used in this context, impermeable refers to suppressing penetration of any bonding material and/or liquid polymeric material into the outer material layer 18 and/or first assembly sole 30 to such extent that moisture transport from the first region A to the second region B underneath the upper bottom laminate 32 is disturbed significantly.

As can be seen from FIGS. 1 to 3, the sole unit 12 is attached to the upper assembly 10 from below. Hence, impermeability is provided preferably with respect to the lower sides of the sole sided end region 18a of the outer material layer 18 and/or with respect to the bottom side of the first assembly sole 30. In the embodiments shown in FIGS. 1 and 2, also the region of the seam 28 joining the outer material layer 18 with the first assembly sole 30 is provided in such a way as to be impermeable with respect to liquid polymeric material for injecting the outsole 44 and/or with respect to sole adhesive. In the embodiment of FIG. 3 such seam 28 is arranged inside the region of the outer material layer 18 coming into contact with liquid polymeric outsole material or with sole adhesive. As the barrier layer 50 will be pressed against the first assembly insole when the sole unit is attached, either be molding or by gluing, penetration of liquid polymeric material and/or sole adhesive to the joint 28 is prevented also in the embodiment of FIG. 3.

Impermeability with respect to liquid polymeric material and/or sole adhesive allows the use of bonding materials for attaching the sole unit 12 being chemically more aggressive than other materials conventionally used. In particular with respect to liquid polymeric material for molding or injecting, the described impermeability allows to use materials having melting or softening regions at rather high temperatures. If such materials were allowed to penetrate through the layer structure formed by the outer material layer 18 and/or the first assembly sole 30, they would potentially harm the functional layers 24, 34 inside.

In the embodiment of FIG. 1 an impermeable layer 58 is provided on the outer side of the sole-sided end region 18a of the outer material layer 18 and on the bottom side of the first assembly sole 30. Such impermeable layer 58 extends over the connection area of the sole-sided end region 18a of the outer material layer 18 and the outer peripheral region 30a of the first assembly sole 30. It also covers the seam 28 which joins the outer material layer 18 with the first assembly sole 30. When attaching the sole unit 12, the impermeable layer 58 comes into direct contact with any bonding material for attaching the sole unit 12 and/or with any liquid polymeric material used for injecting the outsole 44.

In some examples the impermeable layer may be made of a tape or film material that is selected from at least one of polyurethane or silicone based materials. and that is attached by gluing. In another example the impermeable layer may be formed by liquid or viscous adhesive material, e.g. polyurethane and/or reactive hotmelt type adhesive material. After drying and/or curing and/or hardening, such adhesive material forms a layer which is impermeable with respect to liquid or viscous sole material. Suitable liquid or viscous adhesives should have a sufficiently high viscosity. E.g. typical sole adhesive used to bond the sole unit to the upper assembly is an adhesive with a molecular weight above 100,000. Such adhesive has been used successfully to provide the impermeable layer. Examples are the following adhesives/adhesive systems: Fuller Ultraflex 4320+Fuller Hardener FCUV, Kömmerling Köraplast 188, ZHONG BU type PL 755+8% hardener 318.

In the embodiment of FIG. 2 a ring shaped protective element 58′ is used instead of an impermeable layer 58. Such ring shaped protective element 58′ may be formed by applying a suitable adhesive, in particular a hot melt adhesive, to the joint 28, after the sole sided end region 18a of the outer material layer 18 and the outer peripheral edge region 30a of the first assembly sole 30 have been joined to each other. The ring shaped protective element 58′ is applied from the outer side of the sole-sided end region 18a of the outer material layer 18 and from the bottom side of the first assembly sole 30. Thereby an impermeable seal is provided which covers the seam 28 formed in between the sole-sided end region 18a of the outer material layer 18 and the outer peripheral part 30a of the first assembly sole 30, but also regions immediately adjacent to such seam 28. Applying a ring shaped protective element 58′ is easier in case the joint 28 is located on a mostly horizontally extending region of the upper assembly 10. For this reason, in the embodiment of FIG. 2 the outer material layer 18 of the upper extends relatively far down almost into the region under the upper bottom laminate 32.

In all other aspects, the embodiment shown in FIG. 2 is identical to the embodiment of FIG. 1. To avoid duplication, it is referred to the description of FIG. 1 above which also applies to the embodiment of FIG. 2.

In the embodiment of FIG. 3 the outer material layer 18 is particularly long, and in fact longer than the upper liner 20. The outer material layer 18 extends over the lower curved region where the upper assembly 10 changes from a generally vertical extension into a generally horizontal extension which typically defines the upper bottom 16. The outer material layer 18 in fact extends laterally inwards into a region below the upper bottom laminate 32. The outer material layer 18 may even reach into the region below the upper bottom laminate 32 to such extend that it enters into a laterally inward region of the upper bottom 16 which, in a state in which a sole unit 12 is attached to the upper assembly 10, is superposed on the region where the through holes and/or perforations 52a, 52b are formed in the sole unit 12. With such configuration, the connection region 56, i.e. the joint 28 including the regions adjacent to it and coming into contact with any liquid polymeric material for injecting the outsole 44 and/or any sole adhesive, is formed by the joint 28 and the outer/bottom side of the sole-sided end region 18a of the outer material layer 18. When injecting the outsole 44, it is possible to press the barrier layer 50 against the bottom side of the sole-side end region 18a of the outer material layer 18 firmly enough to avoid penetration of liquid sole material. Similarly, when attaching a sole unit 12 using a sole adhesive, it is possible to use a configuration where sole adhesive is applied to the outer peripheral region of the of the sole unit 12 only, but is not applied to the region where the barrier layer 50 is superposed on the sole-sided end region 18a of the outer material layer 18. When attaching the sole unit 12 to the upper assembly 10 under pressure, the barrier layer 50 is pressed against the sole-sided end region 18a of the outer material layer 18. Hence, an impermeable seal is provided which prevents penetration of liquid polymeric material and/or sole adhesive towards the upper bottom functional layer laminate 32.

The embodiment of FIG. 3 further differs from the embodiments of FIGS. 1 and 2 in that no second assembly sole is used for closing the upper 14 towards the sole unit 12. Rather, the upper bottom functional layer laminate 32 also provides the function of the second assembly sole 38 as used in the embodiments of FIGS. 1 and 2. The upper bottom functional layer laminate 32 and the upper liner 20 (e.g. in the form of an upper functional laminate) are joined to each other at joint 40 by any known method, e.g. by stitching (like Strobel stitch or zigzag stitch) which produces a stitched seam 40. In order to make such joint 40 waterproof, a sealing material 42, e.g. a hot-melt adhesive, is applied to the joint 40 connecting the upper bottom functional layer laminate 32 and the upper liner 20. The sealing material is applied in liquid state and penetrates into the joint 40. After curing, the sealing material 42 makes the joint 40 between the upper bottom laminate 32 and the upper liner 20 waterproof. Other types of sealing materials 42, in particular seam tapes or sealing adhesives, might be used as known to the person skilled in the art.

In the embodiment of FIG. 3 a direct joint between the upper bottom laminate 32 together with the upper liner 20, on one side, and the first assembly sole 30 and/or the sole-sided end region 18a of the outer material layer 18, on the other side, is not necessary. Rather, the liner structure made up by the upper bottom laminate 32 and the upper liner 20 may be simply inserted inside the outer structure made up by the outer material layer 18 and the first assembly sole 30. While in FIG. 3 an embodiment is shown where the upper 14 including upper liner 20 and outer material layer 18 is basically put on a last, and closed on the bottom side by subsequently attaching the upper bottom laminate 32 to the upper liner (with waterproofing of the joint 40), and attaching the first assembly sole 30 to the outer material layer 18, such configuration is also highly advisable for shoe constructions of the bootie type where a prefabricated waterproof and water vapor permeable bootie is arranged inside an outer layer structure 18, 30 of the upper assembly 10.

As mentioned above, in the embodiment of FIG. 3 the upper bottom laminate 32 is configured in the form of a three layer laminate. However, also a two layer laminate could be used. Vice versa, the three layer laminate 32 of FIG. 3 could be used with the embodiments of FIGS. 1 and 2 as well.

In all other aspects, the embodiment shown in FIG. 3 is identical to the embodiment of FIG. 1. To avoid duplication, it is referred to the description of FIG. 1 above which also applies to the embodiment of FIG. 3.

FIGS. 4 to 14 show schematic bottom views of various exemplary upper assemblies 10 having a first assembly sole 30 according to the embodiments. In each Figure, the upper assembly is designated by 10 and the first assembly sole, although being configured differently in each embodiment is designated by the same reference sign 30. Further, the sole sided end region of the outer material layer 18 of the upper is designated by 18a. The joint between the sole sided end region 18a of the outer material layer 18 and the first assembly sole 30 is designated by 28 in each figure. In all embodiments, the first assembly sole 30 and/or the outer material layer 18 of the upper is provided with a moisture transporting structure 54. In FIGS. 1 to 3 such moisture transporting structures have been designated by 54a, 54b, 54c, 54d. In FIGS. 4 to 14 only the reference sign 54 will be used, despite the moisture transporting structures differing from each other. It is to be understood that each of the moisture transporting structures 54a, 54b, 54c, 54d shown in FIGS. 1 to 3 can have a configuration of any of the moisture transporting structures 54 shown in FIGS. 4 to 14. Moreover, it is to be noted that different of the moisture transporting structures 54, each shown exemplary in any of FIGS. 4 to 14, may be combined in a same upper assembly.

In the embodiment of FIG. 4, the first assembly sole 30 as a whole is made from a material having wicking characteristics with respect to moisture, and thus the material of the first assembly sole 30 forms the moisture transporting structure 54. The first assembly sole 30 extends over the complete upper bottom 16.

A material is referred to as having “wicking characteristics” in case it is able to take off liquid or gaseous moisture from a first reservoir and transport such moisture along its extension to a second reservoir, as a consequence of its molecular or “micro” structure, see above. Examples for such wicking materials are hydrophilic natural fibers like cotton, and hydrophilic synthetic fibers like hydrophilic polyethylene, polyester and copolyester, or any fibers subject to a hydrophilic treatment, and mixtures thereof. All these materials not only provide for sufficient wicking efficiency, but at the same time provide for sufficient stability and flexibility to be used as an assembly sole.

For this reason, the first assembly sole and/or the sole-sided outer material end region, in regions where a moisture transporting structure is provided, preferably includes materials capable of transporting moisture, e.g. and/or may be provided with a moisture conduit structure capable of allowing or even promoting transport of moisture, e.g. channel structures or wicking filaments.

As a further possibility, the first assembly sole and/or the sole-sided outer material end region may be provided with a moisture conduit structure, e.g. with a channel like structure, with an arrangement of wicking filaments, and/or with suitable perforations and/or recesses. In this case, the first assembly sole and/or the sole-sided outer material end region, in principle, need not be made of a material having wicking characteristics as a consequence of its molecular or “micro” structure, since the wicking effect is achieved by the “macroscopic” moisture conduit structure. The first assembly sole and/or the sole-sided outer material end region may be made of an even water impermeable material. Of course, all possibilities may be combined in the sense that a material having wicking characteristics is used which is additionally provided with a macroscopic moisture conduit structure, in order to maximize moisture transport efficiency.

In the embodiment shown in FIG. 5 the first assembly sole 30 is provided with an arrangement of filaments or yarns 60a, 60b, 60c (only three filaments are designated exemplary). Each of these filaments 60a, 60b, 60c has wicking characteristics, i.e. is capable of transporting moisture along its longitudinal extension. Such wicking characteristics basically results from the wicking filaments being made of material having wicking characteristics and/or the particular shape of configuration of the filaments or yarns. All materials mentioned above are potential candidates for making such wicking filaments, but additionally materials can be used that do not provide for sufficient stability and flexibility as required for an assembly sole in the design of footwear, because the wicking filaments 60a, 60b, 60c are incorporated into a base material of the first assembly sole which itself need not have wicking characteristics. As can be seen in FIG. 5, the wicking filaments preferably form a grid like structure and extend from the lateral edges of the first assembly sole towards laterally inner regions or cross the first assembly sole thereby connecting two opposed lateral edges.

As can be seen in FIG. 6, besides wicking filaments 60a, 60b, 60c as provided in FIG. 5, also the sole sided end region 18a of the outer material layer at least on its inner side may be provided with wicking filaments 60c, 60d, 60e. These wicking filaments 60c, 60d, 60e may be made of the same materials and may have the same configuration as the wicking filaments 60a, 60b, 60c of the first assembly sole 30. Thereby a first moisture transporting structure 54 is provided by the first assembly sole 30, and a second moisture transporting structure 54 is provided by the outer material layer 18. The first and second moisture transporting structures 54, 54 are in moisture transporting communication with each other. Therefore, in a preferred configuration the wicking filaments 60c, 60d, 60e of the second moisture transporting structure are oriented towards the lower edge of the outer material layer 18, i.e. towards the joint 28.

As can be seen in FIG. 7, the moisture transporting structure 54, in the case shown formed by an arrangement of wicking filaments as described above, need not cover the first assembly sole as whole. In the embodiment shown only the region of the forefoot, where most moisture accumulation is expected, is provided with a moisture transporting structure 54.

FIG. 8 shows another example where the first assembly sole 30 is only in parts thereof provided with moisture transporting structures 54. In this example the first assembly sole 30 is made of different material which are connected to each other. In the forefoot region on both lateral sides, the first assembly sole is made of a material having wicking characteristics, thus forming two moisture transporting structures 54, 54 in such regions. In all other regions the first assembly sole 30 is made of a conventional insole material without any particular wicking characteristics.

Similarly in FIG. 9 the first assembly sole 30 includes regions which provide a moisture transporting structure 54 and other regions which do not. Basically the first assembly sole 30 is made of a material not having any particular wicking characteristics and not being provided with any moisture conduit structure. Only the forefoot region includes two water transporting structures 54. Each of these water transporting structures 54 spans the upper bottom 16 in lateral direction. Thus, moisture accumulating at the lateral sides of the upper bottom 16 will be transported towards the central region of the upper bottom 16 which is to be superposed on the through holes and/or perforations 52a, 52b formed in sole unit 12.

In the example of FIG. 10 the first assembly sole 30 includes a central region 30b which is made from a conventional insole material, and thus does not provide any particular moisture transporting structure. The central region 30b is surrounded by an outer peripheral region 30a made of a material having wicking characteristics, as described above. The outer peripheral region provides for a moisture transporting structure 54. Such moisture transporting structure 54 is adjacent to joint 28 with the sole sided end region 18 of the outer material layer 18.

Also in the example of FIG. 11 the first assembly sole 30 includes a central region 30b which is made from a conventional insole material, and thus does not provide any particular moisture transporting structure. The central region 30a is surrounded by an outer peripheral region 30a which is provided with a moisture conduit structure 54 in the form of an arrangement of a plurality of moisture transport conduits 62a, 62b, 62c. These moisture transport conduits 62a, 62b, 62c are oriented generally radially extending from an outer peripheral edge of the first assembly sole basically radial inwards. After a sole unit 12 is attached to the upper assembly 10, the moisture transport conduits 62a, 62b, 62c extend into a region B below the upper bottom laminate 32 and in moisture communication with through holes and/or perforations 52a, 52b formed in the sole unit 12. The moisture transport conduits 62a, 62b, 62c are open towards the bottom side of the first assembly sole 30, and thus visible in the bottom view of the upper assembly shown in FIG. 11. Moisture transported in such channels towards the central region 30b of the first assembly sole 30 can be transported outside efficiently.

The example of FIG. 12 is identical to the example of FIG. 11, except that the moisture transport conduits 62a, 62b, 62c are open towards the upper side of the first assembly sole 30, but not towards the bottom side. Thus the moisture transport conduit 62a, 62b, 62c are not visible in the bottom view of the upper assembly shown in FIG. 12. This is indicated by dotted lines. Moisture transported in such channels 62a, 62b, 62c towards the central region 30b of the first assembly sole 30 can be transported outside via perforations 64 formed in the central region 30b of the first assembly sole 30.

The examples shown in FIGS. 13 and 14 correspond to the examples shown in FIGS. 11 and 12, respectively. The only difference is that in FIGS. 13 and 14 also the outer material layer 18 is in its sole sided edge region 18a provided with an arrangement of moisture conduit channels 62d, 62e, 62f, such arrangement of moisture conduit channels forming a second moisture transporting structure 54, in addition to the first moisture transporting structure 54 formed by the arrangement of moisture conduit channels 62a, 62b, 62c formed in the outer peripheral region 30a of the first assembly sole 30. The moisture conduit channels 62a, 62d; 62b, 62e; 62c, 62f of the first and second moisture transporting structures 54, 54 are all oriented basically in radial direction and are positioned such as to correspond to each other. This provides for efficient transport of moisture from the first region A to the second region B.

Claims

1. Upper assembly for footwear, comprising

an upper having a sole-sided upper end region, and an upper bottom,

said sole-sided upper end region being joined to said upper bottom;

said upper including an outer material layer having a sole-sided outer material end region, and an upper liner;

said upper bottom comprising a first water vapor permeable assembly sole and an upper bottom laminate including a first water vapor permeable and waterproof functional layer;

wherein said outer material layer in said sole-sided outer material end region is joined to said first water vapor permeable assembly sole; and

wherein said first assembly sole and/or said sole-sided outer material end region of said upper comprises at least one moisture transporting structure adapted to transport moisture away from a first region (A) between said outer material layer and said upper liner of said upper and/or between an outer peripheral part of said first outer assembly sole and said upper liner of said upper, to a second region (B) underneath said upper bottom functional layer.

2. Upper assembly according to claim 1, wherein said second region (B) underneath said upper bottom functional layer is positioned such as to be, in a state in which a sole unit is attached to the lower surface of said upper assembly, in moisture permeable communication with at least one passage, or with a region exhibiting porosities, formed in said sole unit.

3. Upper assembly according to claim 1, wherein said first region (A) between said outer material layer of the upper and/or between an outer peripheral part of said first outer assembly sole and said upper liner of the upper is positioned such as to be, in a state in which a sole unit is attached to said upper assembly, covered by sole material and/or sole adhesive.

4. Upper assembly according to claim 1, wherein said first assembly sole and/or the sole-sided outer material end region, at least in said moisture transporting structure, comprises at least one wicking material.

5. Upper assembly according to claim 4, wherein said wicking material includes a material selected from the group including hydrophilic natural fibers, hydrophilic synthetic fibers, fibers subject to a hydrophilic treatment, and mixtures thereof.

6. Upper assembly according to claim 1, wherein said first assembly sole and/or the sole-sided outer material end region, at least in said moisture transporting structure, is provided with at least one moisture conduit structure.

7. Upper assembly according to claim 6 wherein said water conduit structure comprises at least one wicking filament, perforation and/or recess.

8. Upper assembly according to claim 1, wherein said first assembly sole, at least in the region laterally inside said moisture transporting structure, is made of a moisture permeable material and/or is provided with perforations.

9. Upper assembly according to claim 1, wherein said moisture transporting structure extends over said first assembly sole as a whole.

10. Upper assembly according to claim 1, wherein said moisture transporting structure provides for a moisture transport rate of at least 1 cm per 2 hours, preferably of at least 2 cm per 2 hours, more preferably of at least 3 cm per 2 hours, even more preferably of at least 4 cm per 2 hours, and most preferably of at least 6 cm per 2 hours.

11. Upper assembly according to claim 1, wherein said outer material layer is not joined directly to said upper bottom laminate.

12. Upper assembly according to claim 1, wherein said upper liner is configured as an upper liner laminate having a second water vapor permeable and waterproof functional layer.

13. Upper assembly according to claim 1, wherein said outer material layer is shorter than said upper liner.

14. Upper assembly according to claim 1, wherein said first assembly sole is arranged underneath said upper bottom laminate.

15. Upper assembly according to claim 1, wherein said sole-sided end region of said outer material layer is joined to said first assembly sole, preferably by stitching.

16. Upper assembly according to claim 1, wherein said sole-sided end region of said outer material layer is joined to said first assembly sole such as to be impermeable with respect to bonding material, such as glue or adhesive used for attaching a sole and/or with respect to liquid polymeric material used for providing a sole by molding or injecting.

17. Upper assembly according to claim 16, wherein an impermeable layer is provided that covers a connection area of said sole-sided end region of said outer material layer and said first assembly sole.

18. Upper assembly according to claim 17, wherein said impermeable layer is arranged on a sole-sided connection area of the sole-sided end region of said outer material layer and said first assembly sole.

19. Upper assembly according to claim 17, wherein said impermeable layer comprises a material that is selected from at least one of an impermeable tape or film, an adhesive tape, a tape used for sealing purposes, a barrier comprising at least one metalized film, polyethylene, a polymer dispersion which forms an elastic dry layer after application and drying by evaporation of solvent.

20. Upper assembly according to claim 1, wherein said upper bottom laminate is a two-layer laminate having said first water vapor permeable and waterproof functional layer which is arranged on a textile support layer.

21. Upper assembly according to claim 1, wherein said upper bottom laminate is a three-layer laminate having said first water vapor permeable and waterproof functional layer which is arranged between a first and a second textile support layer.

22. Upper assembly according to claim 1, wherein a second water vapor permeable assembly sole is arranged above said upper bottom laminate.

23. Upper assembly according to claim 22, wherein said second water vapor permeable assembly sole and the sole-sided end region of said upper liner are joined to one another, preferably by stitching.

24. Upper assembly according to claim 22, wherein said upper bottom laminate and the outer surface of the sole-sided end region of said upper liner are joined to one another, preferably by adhesive bonding.

25. Upper assembly according to claim 22, wherein said first functional layer and said second functional layer are joined to form a waterproof bonding area.

26. Upper assembly according to claim 1, wherein the sole-sided end region of said upper liner and said upper bottom laminate are joined without the use of an additional assembly sole.

27. Upper assembly according to claim 26, wherein said upper liner is constructed as an upper liner laminate, forming a water vapor permeable and waterproof unit with said upper bottom laminate.

28. Upper assembly according to claim 26, wherein said sole-sided end region of said upper liner and said upper bottom laminate are joined to one another by stitching.

29. Footwear, comprising an upper assembly according to claim 1 and a sole unit attached to said upper assembly, said sole unit having at least one passage or exhibiting porosities, and said sole unit being joined in particular to the lower surface of said upper assembly by adhesive bonding, molding or injecting.

30. Footwear according to claim 29, wherein said at least one moisture transporting structure extends from an outer periphery of said first assembly sole and/or from said sole-sided outer material end region laterally inwards into said region (B) being in liquid communication with said at least one passage or said porosities.