METHOD AND APPARATUS FOR ONE PIECE FOOTWEAR CONSTRUCTION

Abstract

A bootie for use in a footwear item, a method of making the bootie, and a footwear item including the bootie are provided. The bootie provides the upper of the footwear item that will surround the wearer's foot. The bootie includes a body formed from a single air permeable, moisture vapor permeable, and waterproof sheet formed from a plurality of layers of material laminated together. The body has a bottom portion that is located under a wearer's foot in use. The body defines an opening through which a wearer's foot will extend when in use. A single bottom seam extends substantially an entire length of the bottom portion of the body between a toe-end and a heal-end of the body.

Description

CROSS-REFERENCE TO RELATED PATENT APPLICATION

This patent application claims the benefit of U.S. Provisional Patent Application No. 62/486,715, filed Apr. 18, 2017, the entire teachings and disclosure of which are incorporated herein by reference thereto.

FIELD OF THE INVENTION

This invention generally relates to footwear and more particularly to a one-piece upper of a shoe and a method of fabricating a one-piece upper of a shoe.

BACKGROUND OF THE INVENTION

At least some known shoe uppers are constructed of certain materials, including various fabrics and adhesives, that when assembled in layers have limited breathability. Similarly, footwear that is marketed as waterproof and breathable is constructed of multiple layers that might be waterproof and might be moisture vapor permeable but are not air permeable. The waterproof liner most commonly includes a layer of polyurethane or some other material that is not air permeable. This lack of air permeability seals in the wearer's foot without access to fresh air.

Construction of conventional uppers typically involves either the use of a pattern cutout from a material, or multiple pieces cut from a material and either the single piece or the multiple pieces assembled with stitching and adhesives to form a volume shaped to encompass a wearer's foot. Often, uppers are constructed in two parts, a liner and a shoe shell, wherein the waterproof liner must be assembled inside one or more layers of the shoe shell to complete the full upper of the shoe. However, methods used to improve the breathability of the shoe tend to reduce the waterproof capability of the shoe.

Further, as illustrated in FIG. 3 of U.S. Pat. Publ. No. 2010/0011619 (the '619 publication, which is reproduced herein), the upper of the shoe is often permanently attached to an insole by one or more insole seams, such as insole 304 being attached to bootie 302 seams 320 and 330 of the '619 publication. The permanent attachment of a separate insole piece to the bootie 302 adds additional expense to the manufacture of the shoe. More particularly, there is additional cost for the additional material forming the insole. Additionally, there is additional cost for forming seams 320 and 330. More particularly, the seams 320, 330 between the bootie 302 and insole 304 circumscribe the entire periphery of the insole 304. Thus, the manufacture is required to make substantially two seam passes along the length of the bootie 302 between the toe and heal of the bootie 302 to fully attach the insole 304 to the rest of the bootie 304. Typically, these seam passes will extend between 80 and 100 percent of the length of the bottom of the bootie between the toe and the heal.

Further yet, to prevent leaking of the bootie 302 and insole 304, the '619 publication further requires the addition of a sealing gasket 360 that covers the insole 304 and seams 320, 330. This adds additional cost to the manufacture of the shoe.

BRIEF SUMMARY OF THE INVENTION

Embodiments of the invention provide improvements over the current state of the art. More particularly, embodiments of the invention provide new and improved footwear components and methods of manufacturing footwear components to provide water impermeable and moisture vapor permeable footwear components, and particularly, booties that form the upper of a footwear items.

In a particular implementation of the invention, a method of fabricating a footwear item is provided. The method includes providing a single air permeable, moisture vapor permeable, and waterproof sheet formed from a plurality of layers of material laminated together. The method includes forming a bootie from the single air permeable, moisture vapor permeable, and waterproof sheet, the bootie having a bottom portion that is located under a wearer's foot in use. Forming the bootie includes stitching only a single bottom seam extending substantially an entire length of the bottom portion of the bootie between a toe-end and a heal-end of the bootie. The method includes attaching the bootie to an outsole such that an outside surface of the single air permeable, moisture vapor permeable, and waterproof sheet is directly exposed to the outside surrounding environment when in use on the wearer's foot.

In an embodiment, the method includes stitching at least one cross-stitching seam that extends transverse to the bottom seam.

In an embodiment, the bottom seam extends at least 80% of the length of the bottom portion between the toe-end and heal-end of the bootie.

In an embodiment, the method includes applying sealing material across the bottom seam.

In an embodiment, the sealing material is applied on an inside surface of the single air permeable, moisture vapor permeable, and waterproof sheet.

In an embodiment, the step of forming the bootie further includes stitching a rear assembly stitching seam proximate the heal-end of the bootie. The rear assembly stitching seam forms at least in part, an opening into the bootie through which a wearer's foot will extend when in use.

In an embodiment, the step of forming the bootie further includes stitching a front toe stitching seam over a curved portion of the toe-end of the bootie.

In an embodiment, the bottom seam, rear assembly stitching seam and front toe stitching seams are substantially aligned with one another.

In an embodiment, the bottom seam and front toe stitching seam are formed as a continuous seam.

In an embodiment, the single air permeable, moisture vapor permeable, and waterproof sheet comprises: a first layer comprising an air permeable, moisture vapor permeable, and waterproof membrane material, having a first side and a second side; a second layer comprising a padding material, having a first side and a second side, the second layer is positioned between the first layer and an outside environment when the footwear item is completed, the second layer configured to facilitate protecting the first layer from an outside surrounding environment. The first layer may be bonded to the second layer.

In an embodiment, the step of attaching the bootie to an outsole covers at least a majority of the single bottom seam with the outsole.

In an embodiment, the method includes attaching an external support frame comprising a strengthening material to the outer surface of the single air permeable, moisture vapor permeable, and waterproof sheet by one or more of the following: molding, stitching, adhesive bonding, heat welding (e.g. using a hot press), and high frequency welding.

In an embodiment, at least ten percent of a surface area of the outer surface of the single air permeable, moisture vapor permeable, and waterproof sheet is directly exposed to the outside surrounding environment.

In a further embodiment, a footwear item is provided. The bootie provides the upper of the footwear item that will surround the wearer's foot. The bootie includes a body formed from a single air permeable, moisture vapor permeable, and waterproof sheet formed from a plurality of layers of material laminated together. The body has a bottom portion that is located under a wearer's foot in use. The body defines an opening through which a wearer's foot will extend when in use. A single bottom seam extends substantially an entire length of the bottom portion of the body between a toe-end and a heal-end of the body.

In an embodiment, at least one cross-stitching seam formed in the bottom portion that extends transverse to the bottom seam.

In an embodiment, the bottom seam extends at least 80% of the length of the bottom portion between the toe-end and heal-end.

In an embodiment, a sealing material extends across the bottom seam to make the bottom seam waterproof. The sealing material is applied on an inside surface of the single air permeable, moisture vapor permeable, and waterproof sheet.

In an embodiment, the bootie includes a rear assembly stitching seam proximate the heal-end of the bootie. The rear assembly stitching seam forms at least in part, the opening into the bootie.

In an embodiment, the bootie includes a front toe stitching seam over a curved portion of the toe-end of the bootie.

In an embodiment, the bottom seam, rear assembly stitching seam and front toe stitching seams are substantially aligned with one another.

In an embodiment, the bottom seam and front toe stitching seam are formed as a continuous seam.

In an embodiment, the single air permeable, moisture vapor permeable, and waterproof sheet includes a first layer comprising an air permeable, moisture vapor permeable, and waterproof membrane material, having a first side and a second side. The sheet includes a second layer having a first side and a second side. The second layer is positioned between the first layer and an outside environment when the footwear item is completed. The second layer is configured to facilitate protecting the first layer from an outside surrounding environment. The first layer is bonded to the second layer.

In a further embodiment, an article of footwear is provided. The article of footwear includes an outsole and a bootie as outlined above coupled to the outsole. The bootie will surround the wearer's foot in use.

In an embodiment, the footwear item includes an external support frame comprising a strengthening material coupled to an outer surface of the bootie by one or more of the following: molding, stitching, adhesive bonding, heat welding (e.g. using a hot press) and high frequency welding.

In an embodiment, at least ten percent of a surface area of the outer surface of the single air permeable, moisture vapor permeable, and waterproof sheet is directly exposed to the outside surrounding environment.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a footwear item in accordance with an embodiment of the present invention;

FIG. 2 is an enlarged cross-section of a multi-layer laminate sheet used to form the upper shown in FIG. 1;

FIG. 3 is a perspective view of a prior art upper during construction with the inside facing outward;

FIG. 4 is a perspective view of a bootie during construction with the inside facing outward; and

FIG. 5 is a simplified illustration of a piece of material cut shape prior to forming the bootie of FIG. 4.

DETAILED DESCRIPTION OF THE INVENTION

A common limitation of footwear that is waterproof and moisture permeable is that such footwear is air impermeable. One example of an embodiment that does not exhibit the common air impermeability limitation is footwear having a one-piece upper made from a multi-layer laminate that is waterproof, moisture vapor permeable, and air permeable. The embodiments described herein include such one-piece upper and a method for constructing such a one-piece upper.

FIG. 1 is a perspective view of a footwear item 100 in accordance with an embodiment of the present invention. In the exemplary embodiment, footwear item 100 is illustrated as an athletic shoe. In various alternative embodiments, footwear item 100 may be another type of shoe, boot or footwear. Footwear item 100 includes an outsole 102, and an upper 104 configured to receive a foot (not shown) of a user (also referred to as a wearer). Upper 104 is formed from a bootie 106 that surrounds a user's foot. As will be described more fully, the bootie 106 is free of a separate insole attached to the bootie 106. In various other embodiments, the outsole 102 may be formed and coupled to upper 104 by one or more of injection molding and vulcanizing. Footwear item 100 includes a front lacing 108 that is engaged to upper 104 using a plurality of fasteners 110.

Moreover, footwear item 100 includes a tongue 112 configured to permit contraction and expansion of upper 104 of footwear item 100 so that footwear item 100 can accommodate insertions and removal of a foot. Tongue 112 also provides for adjustment of upper 104 so that footwear item 100 is firmly contacting and attached to the foot of the user when front lacing 108 is secured. In an alternative embodiment, front lacing 108 may be a hook and loop fastener material such as Velcro®. Tongue 112 is formed from existing material by tongue stitching 114. Fasteners 110 are attached to upper 104 at the edge of Tongue 112. In various alternative embodiments, fasteners 110 may be one or more of the following: eyelets, eye stays, loop fasteners, and hooks.

Footwear item 100 also typically includes an exoskeleton 116 that includes material attached or molded to the outside surface of upper 104. Exoskeleton 116 provides structural support to upper 104 and facilitates maintaining a shape of upper 104. Exoskeleton 116 also facilitates dispersing lacing tension forces that act upon fasteners 110 outwardly across an area surrounding where exoskeleton 116 is attached as opposed to isolating the forces only where fasteners 110 are attached to upper 104. In the exemplary embodiment, exoskeleton 116 is attached to upper 104 by high frequency welding. In various alternative embodiments, exoskeleton 116 is attached using at least one of, but not limited to, stitching, adhesive bonding, heat welding (e.g. using a hot press) and high frequency welding. In the exemplary embodiment, footwear item 100 includes a cap 118 formed by doubling over a top edge 119 of upper 104 and maintained in position using for example, but not limited to, cap stitching 120. In the exemplary embodiment, upper 104 is secured to outsole 102 using an attachment process such as an adhesive process. However, as noted above, other processes for securing the upper 104 to the outsole 102 may be used, such as one or more of injection molding and vulcanizing.

The terms ‘waterproof’ and ‘liquid impermeable’ are used interchangeably throughout the present disclosure. As used herein, ‘liquid impermeable’ is defined as that which upper 104, including the insole, does not leak as indicated by the presence of detectable liquid on the exterior of upper 104 when applied with water having maximum pressure of 200 millibar (2.901 p.s.i.g.) for one minute.

In an exemplary sense, ‘air permeability’ of bootie 106 can be defined by the test method designated ASTM D737-96, by the American Society for Testing and Materials. This is preferably measured by a Frazier Air Permeability Tester, a Textest FX 3300 Air Permeability Tester or an equivalent type of testing device. The air permeability needs to provide for air flow of at least 0.03 cubic centimeters per minute per square centimeter at a pressure of a 1.27 centimeter water column (0.05 cubic feet per minute per square foot at a pressure of a 0.5 inch water column) through bootie 106 portion of upper 104. Preferably, there is air flow of at least 0.05 cubic centimeters per minute per square centimeter at a pressure of a 1.27 centimeter water column (0.1 cubic feet per minute per square foot at a pressure of a 0.5 inch water column) through bootie 106. More preferably there is air flow of at least 0.15 cubic centimeter per minute per square centimeter at a pressure of a 1.27 centimeter water column (0.3 cubic feet per minute per square foot at a pressure of a 0.5 inch water column) through bootie 106 and most preferably there is air flow of at least 0.51 cubic centimeter per minute per square centimeter at a pressure of a 1.27 centimeter water column (1.0 cubic feet per minute per square foot at a pressure of a 0.5 inch water column) through bootie 106.

FIG. 2 is an enlarged cross-sectional view of an exemplary embodiment of a multi-layer laminated sheet 200 that may be used in the construction of upper (shown in FIG. 1). In the exemplary embodiment, multi-layer laminated sheet 200 includes five layers. In various other embodiments, other numbers of layers may be used including one or more of the layers outlined below. For instance, it is contemplated that three and four layer materials providing adequate breathability and waterproof characteristics can be used.

A first layer 210 is an air permeable, moisture vapor permeable, and waterproof membrane material having a first side 211 and a second side 212. A second layer 220 is a padding material that is waterproof, and has been made air permeable and moisture vapor permeable by perforating the padding material. Second layer 220 includes a first side 221 and a second side 222. Second layer 220 is configured to facilitate protecting first layer 210 from a surrounding environment such as rocks and other externalities that could puncture or otherwise physically damage first layer 210. A third layer 230 is an air permeable and moisture vapor permeable bonding material having a first side 231 and a second side 232. Additionally, third layer 230 can be waterproof. A fourth layer 240 is an air permeable and moisture vapor permeable material having a first side 241 and a second side 242. Fourth layer 240 is configured to facilitate protecting first layer 210 from an inside surrounding environment, such as abrasion by a wearer's foot or sock. Additionally, fourth layer 240 can be waterproof. A fifth layer 250 is an air permeable and moisture vapor permeable material having a first side 251 and a second side 252. Fifth layer 250 is configured to form an outside surface of upper 104 (shown in FIG. 1). Additionally, fifth layer 250 can be waterproof.

In the exemplary embodiment, first layer 210 is formed of an air permeable, moisture vapor permeable, and waterproof material that includes microporous membranes. An example of such material is eVENT® Fabric, which is a chemically treated expanded polytetrafluoroethylene (hereinafter also referred to as ePTFE) membrane commercially available from BHA Technologies, Inc. of Kansas City, Mo.

Other exemplary commercial available materials that may be used for forming multilayer laminated sheet 200 are Gore-Tex™ XCR™ also known as VISI000001, TETRATEX®, SUPOR®, VERSAPOR®, PORELLE®, MILLIPORE®, ENTRANT®, FOLIO I™, ACE-SIL®, FLEX-SIL®, MICROPOR-SIL®, and CELLFORCE®.

Second layer 220 in the exemplary embodiment includes a closed-cell foam such as a polyester fiber foam commercially available as Nu-foam®. In various alternative embodiments, second layer 220 includes at least one of an open-cell foam or other padding-type materials. Although in an exemplary embodiment, the closed-cell foam is waterproof, it is also air impermeable and water vapor impermeable without certain modifications. Therefore to ensure that second layer 220 is air permeable and moisture vapor permeable, the material is perforated prior to being laminated into multi-layer laminated sheet 200. Although second layer 220 is perforated with a plurality of holes to enable it to be air permeable and water vapor permeable, but not waterproof, one or more layers of multi-layer laminated sheet 200, and at least first layer 210, is still waterproof and thus ensures that multi-layer laminated sheet 200 is waterproof.

Third layer 230 includes a bonding material to facilitate bonding of first layer 210 and second layer 220. Third layer 230 facilitates a strong bond that is often otherwise unreliable without the use of third layer 230. In the exemplary embodiment third layer 230 includes a textile material, for example, but not limited to, scrims, tricot knits, and non-wovens.

Fourth layer 240 is configured to form an inside surface, or lining of upper 104 (shown in FIG. 1) and to facilitate protecting first layer 210 from abrasion caused by a wearer's foot (not shown). As such, fourth layer 240 is configured to be able to withstand periodic abrasion from the wearer's foot as well as provide a level of comfort for the wearer's foot. In the exemplary embodiment, fourth layer 240 includes a textile fabric using at least one of, but not limited to, woven, non-woven, or knit fabrics. Other exemplary fabrics that may be utilized for fourth layer 240 are warp knit fabrics, including the ECLIPSE 100H™ (an abrasive resistant polyester and nylon combination fabric), ECLIPSE 200S™ (an abrasive resistant polyester and nylon combination fabric) and ECLIPSE 400H™ (a lightweight, nylon fabric), all commercial available from Tempo Shain Corporation of Salem, Mass.

Fifth layer 250 is configured to form an outside surface, or shell (not shown) of upper 104 (shown in FIG. 1) and is visible as an outside of shoe 100 (shown in FIG. 1) when worn by a wearer. In an exemplary embodiment, the material used for fifth layer 250 includes, but is not limited to, woven, non-woven, and knit fabrics.

It is noted that the single layer sheet above includes five layers. However, this is an exemplary embodiment of a single layer sheet that provides the

FIG. 4 is view of a completed upper 400 in accordance with an exemplary embodiment of the present invention. The upper 400 is illustrated with the inside facing outward prior to attaching any combination of a midsole and an outsole 102 (shown in FIG. 1).

In an embodiment, the upper 400 will surround the user's foot with portions extending over the top as well as underneath the user's foot. Further, substantially the entire upper 400 is provided by bootie 402. Further yet, the entire bootie 402 is a body formed from a single piece of multi-layer laminated sheet 200. As noted above, the upper 400 may include an exoskeleton or other material attached to the outer surface (not shown) of the bootie 402. Further, an inner liner, such as a wear resistant liner, may be attached to an inner surface of the bootie 402 (inner liner not shown).

In the exemplary embodiment, a front toe stitching seam 422, a rear assembly stitching seam 440 and a bottom stitching seam 442 form the single-piece of multi-layer laminate sheet 200 (shown in FIG. 2) into bootie 402. To further form the shape of bootie 402 from the single-piece of multi-layer laminate sheet 200, one or more of a heal cross-stitching seam 446 and toe cross-stitching seam 448 may be added. These cross-stitching seams 446, 448 will extend transverse to the bottom stitching seam 442 and typically between 80 and 90 degrees relative to bottom stitching seam 442. The cross-stitching seams 446, 448 are generally aligned with a width direction, e.g. they extend between an inside of the foot and an outside of the foot that is generally perpendicular to the length direction aligned with seam 442. In an embodiment, the cross-stitching seams 446, 448 extend between 50 and 100 percent of the local width of the bottom portion of the bootie 402 proximate the corresponding cross-stitching seams 446, 448.

Unlike prior art configurations, upper 400 is free of a separate insole 304 (see FIG. 3) that is attached to bootie 302 as illustrated in the prior art design of FIG. 3. Instead, a portion 449 of the upper 400 that is located under the user's foot, e.g. the portion that would have otherwise been provided by separate insole 304 secured to the bootie or vamp and quarter, is provided directly by the single-piece of multi-layer laminate sheet 200. In this embodiment, only a single seam, namely bottom stitching seam 442, is aligned with and extends substantially the entire length of the bottom of the bootie, e.g. between about 80 and 100 percent of the entire length from the toe-end 460 to the heal-end 470. As noted, the prior art uses at least two passes extending substantially the entire the length of the bootie to secure the insole to the bootie or vamp and quarter.

Stitching seams 422, 440, 442, 446, 448 and 450 may use any of a wide variety of thread-type material, including, but not limited to, strands or cords and include spun fibers, spun fibers encircling a core filament, bonded fibers and monofilament-type material that may be coated with a liquid impermeable coating. Stitching seams 422, 440, 442, 446, 448 and 450 may also use any of a wide variety of stitching patterns that do not damage the integrity of single-piece of multi-layer laminate sheet 200, including, but not limited to zig zag. In addition, adhesives may be utilized as well as electro-die sealing methods. It is also understood that the exact location and number of seams 422, 440, 442, 446, 448 and 450 can vary depending on the type of footwear item being produced. For example, in some embodiments, stitching seams 422, 440 and 442 could be formed from a single stitching seam rather than three separate seams. Further yet, while only two cross-stitching seams are illustrated, additional cross-stitching seams could be added to further define the shape of bootie 402. Further, in some embodiments, cross-stitching seams 446, 448 may not be required.

Stitching seams 422, 440, 442, 446, 448 and 450 can be sealed with seam tape 424, 444, 451, 452, 453 and 454 positioned over stitching seams 422, 440, 442, 446, 448 and 450, respectively. Heat is then applied through the application of hot air, and pressure through a nip roll is then applied to the top of seam tape 424, 444, 451, 452, 453 and 454. The heat from the hot air is preselected to soften the adhesive in seam tape 424, 444, 451, 452, 453 and 454 without detrimentally affecting any of the desired qualities found in upper 400. An application of heat preferably ranges from about 150 degrees Celsius (302 degrees Fahrenheit) to about 250 degrees Celsius (482 degrees Fahrenheit) for most applications. However, the temperatures can reach or exceed 750 degrees Celsius. A preferred application of pressure is from about 3 kilograms per square centimeter (42.67 pounds per square inch) gauge to about 5 kilograms per square centimeter (71.12 pounds per square inch) gauge. However, the applied temperature and pressure are dependent on the type of material used for upper 400, the threads used to create seams 422, 440, 442, 446, 448 and 450, the adhesives and the type of material utilized for seam tape 424, 444, 451, 452, 453 and 454. By such a process, a solid structural weld is formed that provides at least a substantially liquid impermeable quality in seams 422, 440, 442, 446, 448 and 450 that is approximately equivalent to the liquid impermeability quality of the remainder of upper 400.

FIG. 5 illustrates the single-piece of multi-layer laminate sheet 200 cut to shape prior to forming bootie 402. With reference to both FIGS. 4 and 5, in one embodiment, at least a portion of rear assembly stitching seam 440 will be formed first securing edge portion 440A, to edge portion 440B sewing in direction illustrated by arrows 440C. When the rear assembly stitching seam 440 is formed, the opening of the bootie 402 through which the users foot extends when wearing the finished footwear item 100 is, at least in part established.

Thereafter, in one embodiment, the front of the toe is stitched using front toe stitching seam 422 securing edge portion 422A to edge portion 422B sewing in a direction illustrated by arrows 422C. This stitch may extend over a top of the toe region of the bootie 402 as well as around the curve of the toe of the bootie 402. Preferably, bottom stitching seam 442 and front toe stitching seam 422 are a single continuous seam. As such, after passing around the front of the toe illustrated by arrows 422C, the machinist will continue, in a continuous stitch, to sew along bottom edge portion 442A to bottom edge portion 442B sewing in a direction illustrated by arrows 442C to form bottom stitching seam 442. In a further embodiment, stitching seams 440, 442 and 422 are a single seam. In such an embodiment, the person sewing the bootie will typically start at the heal end and sew edge portions 440A, 440B running down the heal; then edge portions 442A, 442B running along the bottom from the heal-end to the toe-end; and then edge portions 422A, 422B running up and over the toe and ending proximate the tongue (see base of tongue 112 in FIG. 1). Alternatively, this could be reversed by starting proximate the toe-end and then finishing by stitching up the heal.

At this point, the bootie 402 has generally formed the shape in FIG. 4. However, after forming bottom stitching seam 442, the user can add heal cross-stitching seam 446 and toe cross-stitching seam 448 in a direction substantially transverse (e.g. between 80-90 degrees) to bottom stitching seam 442. The cross-stitching seams 446, 448 can be used to provide the final shape to the bootie 402. These cross-stitching seams 446, 448 can be used to close the notches formed between edges 422A, 442A; 422B, 442B; 442A, 440A; 422B, 440B that are cut out of the sheet proximate the toe end and the heal.

With reference to FIG. 5, portion 449 is illustrated by dashed lines and sections 449A, 449B prior to stitching. These sections 449A, 449B will be folded and located under the wearer's foot when fully assembled and will take the position of prior insole 304.

After these seams are stitched, the seam tape can be applied as described previously.

This arrangement significantly reduces the length of the amount of seams formed in forming the bootie from prior embodiments. This reduces the potential leak paths through the single-piece of multi-layer laminate sheet 200. This reduces the time to form the bootie. This also eliminates the need for an insole sealing gasket 360.

Thereafter, a liner may be attached to the bootie 402 to protect the inner surface of the bootie 402 and particularly to prevent the user's foot or socks from wearing directly on the inner layer of single-piece of multi-layer laminate sheet 200.

In a particular embodiment, after forming the bootie 402, the bootie is attached to outsole 102 as described above. The attachment of the bootie 402 to the outsole 102 will cover bottom stitching seam 442. In some embodiments, the outsole 102 will cover at least 80 percent of the bottom stitching seam 442. Typically, if an exoskeleton such as exoskeleton 116 is added, this will be applied to the outer surface of the bootie prior to forming the bootie. Further, a portion of the exoskeleton may run around toward the bottom of the bootie 402 such that it is located between the portion 449 and the outsole 102 to increase the structural strength provided by the exoskeleton.

While the bootie 402 generally forms the entire upper, preferably, any exoskeleton 116 or other material, e.g. design material such as for logos etc., applied to the outer surface of the bootie 402, and particularly the single-piece of multi-layer laminate sheet 200, covers as little as possible of the outer surface of the bootie 402 when the footwear item is fully assembled. This prevents the added material attached to the outer surface of the single-piece of multi-layer laminate sheet 200 from inhibiting the breathability of the bootie 402 and ultimately the footwear item. While it is preferred to have as much surface area of the bootie 402 directly exposed to the outside surrounding environment, i.e. in direct contact with the outside surrounding environment, as little as 10% of the outer surface of the single-piece of multi-layer laminate sheet 200 may be exposed to the surrounding environment when the footwear item is fully assembled. In other embodiments, at least 15% is exposed to the outside surrounding environment. More preferably at least 20% is exposed to the outside surrounding environment. This percentage is measured from the total surface area of the bootie 402 prior to attachment of the outsole 102.

Exemplary embodiments of the invention are described above in detail. The methods and components are not limited to the specific embodiments described herein, but rather, components of systems and/or steps of the methods may be utilized independently and separately from other components and/or steps described herein. For example, the methods may also be used in combination with other footwear construction methods, and are not limited to practice with only the construction methods as described herein. Rather, the exemplary embodiment can be implemented and utilized in connection with many other footwear applications.

Although specific features of various embodiments may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the invention, any feature of a drawing may be referenced and/or claimed in combination with any feature of any other drawing.

All references, including publications, patent applications, and patents cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.

The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) is to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.

Claims

1. A method of fabricating a footwear item, said method comprising:

providing a single air permeable, moisture vapor permeable, and waterproof sheet formed from a plurality of layers of material laminated together;

forming a bootie from the single air permeable, moisture vapor permeable, and waterproof sheet, the bootie having a bottom portion that is located under a wearer's foot in use, wherein forming the bootie includes: stitching only a single bottom seam extending substantially an entire length of the bottom portion of the bootie between a toe-end and a heal-end of the bootie; and

attaching the bootie to an outsole such that an outside surface of the single air permeable, moisture vapor permeable, and waterproof sheet is directly exposed to the outside surrounding environment when in use on the wearer's foot.

2. The method of claim 1, wherein forming the bootie further comprises stitching at least one cross-stitching seam that extends transverse to the bottom seam.

3. The method of claim 2, wherein the bottom seam extends at least 80% of the length of the bottom portion between the toe-end and heal-end of the bootie.

4. The method of claim 1, wherein forming the bootie further comprises applying sealing material across the bottom seam.

5. The method of claim 4, wherein the sealing material is applied on an inside surface of the single air permeable, moisture vapor permeable, and waterproof sheet.

6. The method of claim 1, wherein forming the bootie further includes stitching a rear assembly stitching seam proximate the heal-end of the bootie, the rear assembly stitching seam forming at least in part, an opening into the bootie through which a wearer's foot will extend when in use.

7. The method of claim 6, wherein forming the bootie further includes stitching a front toe stitching seam over a curved portion of the toe-end of the bootie.

8. The method of claim 7, wherein the bottom seam, rear assembly stitching seam and front toe stitching seams are substantially aligned with one another.

9. The method of claim 8, wherein the bottom seam and front toe stitching seam are formed as a continuous seam.

10. The method of claim 1, wherein the single air permeable, moisture vapor permeable, and waterproof sheet comprises:

a first layer comprising an air permeable, moisture vapor permeable, and waterproof membrane material, having a first side and a second side; and

a second layer comprising a padding material, having a first side and a second side, the second layer positioned between the first layer and an outside environment when the footwear item is completed, the second layer configured to facilitate protecting the first layer from the outside surrounding environment.

11. The method of claim 1, wherein attaching the bootie to an outsole covers at least a majority of the single bottom seam with the outsole.

12. The method of claim 1, further comprising

attaching an external support frame comprising a strengthening material to the outer surface of the single air permeable, moisture vapor permeable, and waterproof sheet by one or more of the following: molding, stitching, adhesive bonding, heat welding (e.g. using a hot press), and high frequency welding.

13. The method of claim 1, wherein at least ten percent of a surface area of the outer surface of the single air permeable, moisture vapor permeable, and waterproof sheet is directly exposed to the outside surrounding environment.

14. A footwear item comprising:

a bootie including: a body formed from a single air permeable, moisture vapor permeable, and waterproof sheet formed from a plurality of layers of material laminated together, the body having a bottom portion that is located under a wearer's foot in use, the body defining an opening through which a wearer's foot will extend when in use; a single bottom seam that extends substantially an entire length of the bottom portion of the body between a toe-end and a heal-end of the body; and

an outsole attached to the bootie such that an outside surface of the single air permeable, moisture vapor permeable, and waterproof sheet is directly exposed to an outside surrounding environment when in use on the wearer's foot.

15. The footwear item of claim 14, further comprising at least one cross-stitching seam formed in the bottom portion that extends transverse to the bottom seam.

16. The footwear item of claim 15, wherein the bottom seam extends at least 80% of the length of the bottom portion between the toe-end and heal-end.

17. The footwear item of claim 14, further comprising a sealing material across the bottom seam to make the bottom seam waterproof, the sealing material is applied on an inside surface of the single air permeable, moisture vapor permeable, and waterproof sheet.

18. The footwear item of claim 14, further comprising a rear assembly stitching seam proximate the heal-end of the bootie, the rear assembly stitching seam forming at least in part, the opening into the bootie.

19. The footwear item of claim 18, further comprising a front toe stitching seam over a curved portion of the toe-end of the bootie.

20. The footwear item of claim 19, wherein the bottom seam, rear assembly stitching seam and front toe stitching seams are substantially aligned with one another.

21. The footwear item of claim 20, wherein the bottom seam and front toe stitching seam are formed as a continuous seam.

22. The footwear item of claim 14, wherein the single air permeable, moisture vapor permeable, and waterproof sheet comprises:

a first layer comprising an air permeable, moisture vapor permeable, and waterproof membrane material, having a first side and a second side;

a second layer having a first side and a second side, the second layer positioned between the first layer and an outside environment when the footwear item is completed, the second layer configured to facilitate protecting the first layer from the outside surrounding environment.

23. The footwear item of claim 14 further comprising an external support frame comprising a strengthening material coupled to the outer surface of the single air permeable, moisture vapor permeable, and waterproof sheet by one or more of the following: molding, stitching, adhesive bonding, heat welding (e.g. using a hot press), and high frequency welding.

24. The footwear item of claim 14, wherein at least ten percent of a surface area of the outer surface of the single air permeable, moisture vapor permeable, and waterproof sheet is directly exposed to the outside surrounding environment.