Breathable Shoe with Barrier for Protection from Wind and Water

Abstract

Shoes have an upper which is highly breathable and made of air-permeable materials. A barrier is attached to the sole with a water-tight bond and circumscribes the shoes. The barrier is impermeable to wind and water. Optionally, the barrier is present only in a front section of the shoes, in which case the barrier terminal ends are bonded to to an outer surface of the shoe. The barrier extends upwardly from the sole about 0.5-6 inches. The barrier may be curved such that it extends over a front section of the shoe, optionally following the shape of the upper. The barrier provides significant protection from wind and water, but does not greatly impair breathability of the upper.

Description

FIELD OF THE INVENTION

The present invention relates generally to shoes and in particular to shoes that have a highly breathable upper and a barrier that protects from wind and water.

BACKGROUND OF THE INVENTION

Shoes with high air permeability are comfortable and popular for sports and activities. Unfortunately, because the upper has high air permeability, it cannot be waterproof. Highly breathable shoes typically have little or no protection from water infiltration. There is a strong tradeoff between breathability and water protection. Some shoes use special microporous fabrics that allow some vapor transmission and water protection, but the tradeoff means that water protection is incomplete and air permeability is low.

Also, breathable shoes with high air permeability do not protect against wind.

It would be an advantage to provide highly breathable shoes with significant wind and water protection. This combination of features is impossible to achieve with conventional shoe designs which inherently require undesirable tradeoffs between breathability and water protection.

SUMMARY

Provided is a breathable shoe with a barrier for wind and water protection. The shoe comprises a sole, and a shoe upper attached to the sole. The shoe upper is breathable. At least 20% of the surface area of the shoe upper has an air permeability of at least 40 SCFM/SF (as measured by the ASTM D-737 test for air permeability). The shoe also comprises a barrier attached to the sole and circumscribing the shoe. The barrier is impermeable to wind and water. The attachment between the barrier and sole is water-tight. The barrier is at least 0.5 inches tall everywhere around the shoe.

AT least 20% of the surface area of the upper in a front section of the shoe has an air permeability of at least 40 SCFM/SF. Alternatively, at least 40% of the surface area of the upper in a front section of the shoe has an air permeability of at least 70 or 120 SCFM/SF. The upper in the front section can have an average air permeability in the range of 40-400 SCFM/SF. The barrier can be 1-6 inches tall.

The barrier may have an inward curve such that it extends over the upper in the front section. The barrier covers some of the upper in the front section when viewed in a top view. The barrier and upper in the front section may be separated by a gap. Spacers may be disposed in the gap to maintain a desired gap thickness. The spacers may be attached to the upper or attached to the barrier (preferably not both).

In another embodiment, the upper in the front section has an average air permeability of at least 40, 80, or 120 SCFM/SF

In another embodiment, the barrier does not circumscribe the shoe. The barrier extends around the front section but does not extend around the heel of the shoe. The barrier has terminal ends that are attached to a middle section or rear section of the upper, with a watertight attachment. Portions of the shoe that are unprotected by the barrier (e.g. the heel) are at least partially water resistant or waterproof.

DESCRIPTION OF THE FIGURES

FIGS. 1A and 1B show a perspective view and cross sectional view of an embodiment of the present invention.

FIG. 2 shows a top view illustrating definitions for front, middle and rear sections of the shoe.

FIG. 3 shows a cross sectional view of an embodiment in which there is contact between the barrier and the upper.

FIG. 4 shows an embodiment in which the barrier does not circumscribe the shoe.

FIGS. 5A and 5B show cross sectional views of embodiments in which the barrier is curved away from or toward the shoe.

FIG. 6 shows an embodiment in which the barrier has an inward curve and extends over the upper in the front section of the shoe.

FIG. 7 shows a cross sectional view of the embodiment of FIG. 7.

FIG. 8 shows an embodiment in which the barrier can be temporarily closed by bringing edges of the barrier together.

FIG. 9 shows an embodiment in which shoelace or string is used to bring edges of the barrier together and temporarily close the barrier.

FIG. 10 shows an embodiment in which hook-and-loop fastener is used to bring edges of the barrier together and temporarily close the barrier.

FIG. 11 shows an embodiment in which a cover can be removably placed over the uncovered area.

FIG. 12 shows a cross sectional view of the embodiment of FIG. 1 with a removably attachable cover.

FIG. 13 shows a perspective and cross sectional view of an embodiment with a removably attachable dome-shaped cover.

DETAILED DESCRIPTION

The present invention provides shoes with high breathability and, simultaneously, protection from wind and water. The shoe upper is made of highly air-permeable material, such as mesh fabric, leather with holes, or loose-knit fabrics. The upper is bonded to an outsole, as known in the art. A barrier is attached to the outsole. The barrier may completely circumscribe the shoe. The barrier is made of wind and water-impermeable material, such as closed-cell foam, rubber, rubber foam, leather, fabrics or combinations of these materials. The barrier blocks wind and water splashes and puddles, but does not greatly impair air permeation through the upper. Accordingly, the present shoes have a unique and desirable combination of exceptional breathability and high protection from water and wind.

FIGS. 1A and 1B show perspective and cross sectional views of an embodiment of the present invention. The present shoe has an upper 20, which includes a toe box 22. The toe box 22 includes areas indicated by arrows. The shoe has conventional shoelaces 24 or other closure mechanism. A barrier 26 circumscribes the shoe. The barrier 26 is attached to the outsole 28. In other embodiments of the present invention, the barrier 26 may be attached to an insole 30 in places.

Preferably, but optionally, the barrier 26 and upper 20 are not in contact (unless perhaps the shoe is flexed in specific ways), and are separated by a space 32. The space 32 tends to maintain breathability of the upper. The space 32 allows air permeation through side portions of the upper 20.

The barrier 26 has a height 34, which is measured from a top of the outsole 28. The height 34 can be in the range of about 0.5-6 inches. In some embodiments, the barrier 26 can be taller than 6 inches. The height is measured in the vertical direction, perpendicular to the outsole 28.

The barrier 26 has a thickness 36. Optionally, the thickness 36 can be in the range of 0.05-0.5 inches. The thickness 36 of the barrier 26 depends on the material it is made of and its desired properties, such as flexibility, protection from hazards (such as snake bite, explained below) or other factors.

The barrier 26 should be flexible such that it bends with the shoe during walking and does not interfere with bending of the shoe and does not create an undesirable stiffness in the shoe. The barrier 26 should also be firm and lightweight enough to stand without bending from its own weight. Closed cell ethyl vinyl acetate foam is a suitable material for the barrier that meets these requirements.

The barrier 26 can be made of many materials as noted, such as closed cell foams (rubber or plastic foams or combinations thereof), leather, fabrics or the like. The barrier can comprise a single material, or combinations of materials, which can be laminated for example. In one embodiment, the barrier is made of fabric and closed cell foam laminated together. The fabric can be disposed on the interior or exterior surface of the barrier, and can have decorative features such as prints or designs.

The barrier 26 can be made by injection molding of plastic, rubber, plastic-rubber foams or the like. The barrier 26 and outsole 28 can comprise a single part, made by molding for example. Alternatively, the barrier 26 and outsole 28 comprise two separate parts, joined by glue.

FIG. 2 shows a top view of a shoe according to the present invention, illustrating how front section 40, middle section 42 and rear section 44 of shoe are defined in the appended claims. The front section 40 is defined as areas in front of a shoe closure 46. The shoe closure determines the locations of boundaries 48 50 between the front, middle and rear sections. The toe box 22 is entirely contained within the front section 40 and will typically be considered slightly smaller than the front section 40.

All air permeability figures herein are defined in terms of the ASTM D-737 test, an industry standard test for air permeability of fabrics and other sheet materials. This test measures air permeability in units of standard cubic feet per minute per square foot (SCFM/SF) at a pressure of 0.5 inches water.

The barrier 26 is impermeable to wind and water. For wind, this may be defined as having an air permeability of less than 1, 2 or 5 SCFM/SF.

The upper 20 has high air permeability in at least some areas. The toe box area 22 may have a higher air permeability than any other portion of the upper 20. In one embodiment, at least 20% of the shoe upper has an air permeability of at least 40 SCFM/SF. In other embodiments, at least 25% or 40% or 50% of the upper 20 in the toe box area 22 or front section 40 has an air permeability of at least 40, 60, 80, 120, 160, 200 or 300 SCFM/SF.

Some portions of the shoe, such as a heel area 38, may have very low or essentially zero air permeability. The middle section 42 may have an intermediate level of air permeability, lower than the rear section 44, but higher than the front section 40. This is optional however. The heel area 38 may have high air permeability, comparable to the toe box 22.

The shoe upper can be continuous fabric or other material, with no holes larger than about 1/32″, 1/16″, ¼″, ½″ or ¾″ diameter. Mesh fabric is considered continuous fabric despite the presence of small holes. Leather or other material with holes is also considered continuous material despite the presence of holes. Also, the upper may comprise many small holes such as eyelets (e.g. 1/16″-¼″ inch in diameter). The upper may comprise a low-permeability material (e.g. with permeability less than 5 SCFM/SF, e.g. leather) with a plurality of holes that provide suitably high air permeability, when averaged over an area (e.g. averaged over the entire toe box 22).

It is not necessary for the entire shoe surface or upper surface to have high permeability. Typically, the most breathable portion of the shoe is the toe box 22. The heel (rear section) is typically the least breathable, and may have zero or almost zero air permeability (e.g. air permeability of less than 2 or 3 SCFM/SF by ASTM D-737). The heel portion may also be waterproof or water resistant.

In some embodiments, at least 4, 6, 8, 12, or 14 square inches of upper surface area has air permeability of at least 40, 50, 70, 90, 120, or 150 SCFM/SF according to ASTM D-737. In some embodiments, at least 2, 4, 6, or 8 square inches of the upper 20 in the toe box comprises has high permeability of at least 40, 50, 70, 90, 120, or 150 SCFM/SF.

FIG. 3 shows an embodiment in which there is contact 52 between the barrier 26 and the shoe upper 20. Preferably such contact is limited to a small area or length. For example, contact between barrier 26 and upper 20 can occur over a distance of less than 1, 2, or 3 inches or over a surface area of less than 0.5, 1, or 2 square inches per shoe. The barrier-upper contact 52 is incidental, rubbing contact and occurs for some flexing shapes of the shoe in some portions of the walking stride. The barrier 26 and shoe upper 20 are not bonded or glued at the contact 52.

FIG. 4 shows an embodiment in which the barrier 26 does not circumscribe the shoe. The barrier 26 has terminal ends 54 55 that are bonded to the rear section 44 (or optionally the middle section 42, which is not illustrated in FIG. 4) of the shoe. The bond 56 between terminal ends 54 55 and the rear section 44 is preferably watertight. In this embodiment, the portion of the shoe unprotected by the barrier 26 (indicated by line 58) is waterproof or at least partially water resistant. In other words, the portion of the shoe between the terminal ends 54 55 (which includes the heel) is waterproof or water resistant.

FIGS. 5A and 5B show cross sectional views of embodiments in which the barrier is not vertical. FIG. 5A shows an embodiment in which the barrier 26 is curved away from the shoe. FIG. 5B shows an embodiment in which the barrier 26 is curved toward the shoe. Both embodiments are within the scope of the appended claims.

FIGS. 6 and 7 show a top view and cross sectional view of an embodiment in which the barrier 26 has an inward curve 66 such that the upper in the front section 40 is covered in the top view. The upper 20 in the front section 40 is not completely covered. The upper in the front section has an uncovered area 60 and a covered area 62.

The covered area can comprise 0-80% of the upper in the front section.

The uncovered area 60 of the upper can comprise at least ½, 1, or 2 square inches in surface area. Optionally, the uncovered area can comprise at least about 10 or 20% of the surface area of the upper 20 in the front section 40. Preferably, the upper in the uncovered area 60 has high air permeability of at least 40, 70, 90, 120, 150, or 200 SCFM/SF.

As illustrated in FIG. 7, the barrier 26 may also have an upward curve 68. The upward curve 68 will tend to prevent water from splashing into the uncovered area 60. The upward curve 68 is located adjacent to the uncovered area 60.

The barrier 26 and upper 20 are separated by a gap 70. The gap 70 improves breathability by allowing air access to the upper 20 The gap thickness can be in the range of about 1/16″-¾″ for example. The gap thickness can be nonuniform, for example larger at a top of the barrier 26 and smaller at a bottom of the barrier 26. For example, the gap can taper to about zero thickness at the bottom. To maintain a desired gap thickness, spacers 72, 74 can be disposed within the gap 70. Spacers 72 are attached to the upper 20, and not attached to the barrier 26. Spacers 74 are attached to the barrier 26, and not attached to the upper 20. It is preferable for the spacers to be attached on only one side, i.e. attached to the barrier 26 or the upper 20, but not both. One-sided attachment of the spacers allows the barrier 26 and upper 20 to flex and move independently.

The spacers 72 can comprise closed cell foam, rubber or plastic and can be glued to the upper 20 or barrier 26. Alternatively, the spacers can be integral with the barrier 26, for example created in the same molding (e.g. injection molding) process used to create the barrier. Also, the spacers 72 74 can have thicknesses that vary with location. The spacers 72 74 can be positioned every 1-2 inches to maintain the gap thickness. A single shoe may have 1-40 spacers for example.

FIG. 8 shows an embodiment in which edges 77 of the barrier 26 adjacent to the uncovered area 60 (not present in FIG. 8) are temporarily and releasably joined by an edge coupler. Closing the uncovered area with the edge coupler provides enhanced wind and water protection. There are many type of edge coupler that can bring the barrier edges 77 together. For example, FIG. 9 shows an embodiment in which a shoelace or string 79 is used to bring the edges 77 together. The string is threaded through a series of holes in the barrier edges 7, and then tightened. FIG. 10 shows a cross sectional view of an embodiment in which hoop-and-loop fastener 80 is disposed on inside surfaces of the barrier edges 77. Additionally, a zipper, snap-buttons, or magnets can be used to temporarily and releasably join the edges 77. The edge coupler recited in the appended claim includes any of these devices. The present invention is not limited by method or means for joining the edges 77.

It is noted that in the embodiment of FIG. 1, the entire front section and toe box are uncovered in a top view and comprise all or part of the uncovered area 60.

FIG. 11 shows an embodiment in which a removable cover 82 can be placed over the uncovered area 60 (in which case the “uncovered area” becomes covered). The cover 82 can be temporarily and releasably held in place by hook-and-loop fastener material 84. The cover 82 can be made of the same material as the barrier 26

FIG. 12 shows a cross sectional view of the embodiment of FIG. 1 with the removably attachable cover 82. Hook-and-loop fastener material 84 is attached to an inside surface 88 of the barrier 26, and to a bottom surface 90 of the cover (by way of fabric strip 92). The cover 82 extends across a full width 94 of the shoe, thereby providing almost complete protection from wind and water (e.g. rain) that cannot be blocked by barrier 26.

FIG. 13 shows a perspective and cross sectional view of an embodiment with a removably attachable dome-shaped cover 96. The dome cover 96 is attachable to the barrier 26 by hook-and-loop fastener 84. The dome cover 96 has an overhang 98 that prevents water from entering the barrier 26.

Claims

1. A breathable shoe with wind and water protection, comprising:

a) a sole;

b) a shoe upper attached to the sole, wherein at least 20% of a surface area of the upper has an air permeability of at least 40 SCFM/SF;

b) a barrier attached to the sole along a perimeter of the sole, wherein the barrier is impermeable to wind and water, wherein the barrier-sole attachment is water-tight, wherein the barrier circumscribes the shoe and wherein the barrier is at least 0.5 inches tall everywhere.

2. The shoe of claim 1 wherein the barrier has an inward curve such that it covers some of the upper in a front section in a top view.

3. The shoe of claim 2 further comprising an uncovered area in the front section, wherein the uncovered area is not covered by the barrier in a top view.

4. The shoe of claim 3 wherein the barrier has an upward curve next to the uncovered area.

5. The shoe of claim 3 further comprising an edge coupler for bringing together edges of the barrier adjacent to the uncovered area.

6. The shoe of claim 30 further comprising a gap between the barrier and the upper, and at least two spacers disposed in the gap.

7. The shoe of claim 5 wherein the spacers are attached to the upper or are attached to the barrier, and wherein no spacers are attached to both the upper and the barrier

7. The shoe of claim 1 wherein at least 40% of the surface area of the upper in a toe box has an air permeability of at least 40 SCFM/SF.

8. The shoe of claim 1 wherein at least 40% of the surface area of the upper in a front section has an air permeability of at least 70 SCFM/SF.

9. The shoe of claim 1 wherein at least 40% of the surface area of the upper in a front section has an air permeability of at least 120 SCFM/SF.

10. The shoe of claim 1 wherein the barrier has a height in the range of 1-6 inches tall everywhere around the shoe.

11. The shoe of claim 1 wherein the upper in a toe box has an average air permeability in the range of 40-400 SCFM/SF.

14. The shoe of claim 1 further comprising a cover that is removably attachable over an uncovered area of the upper in a front section, and wherein the cover is impermeable to water.

15. A breathable shoe with wind and water protection, comprising:

a) a sole;

b) a shoe upper attached to the sole, wherein the upper in a front section has an average air permeability of at least 40 SCFM/SF;

b) a barrier attached to the sole, wherein the barrier is impermeable to wind and water, wherein the barrier-sole attachment is water-tight, wherein the barrier circumscribes the shoe and wherein the barrier is at least 0.5 inches tall everywhere around the perimeter of the shoe.

16. The shoe of claim 15 wherein the upper in the front section has an average air permeability of at least 80 SCFM/SF.

17. The shoe of claim 15 wherein the upper in the front section has an average air permeability of at least 120 SCFM/SF.

18. The shoe of claim 15 wherein the barrier has an inward curve such that it covers some of the upper in a front section in a top view.

19. The shoe of claim 18 further comprising an uncovered area in the front section, wherein the uncovered area is not covered by the barrier in a top view.

20. The shoe of claim 19 wherein the barrier has an upward curve next to the uncovered area.

21. The shoe of claim 19 further comprising an edge coupler for bringing together edges of the barrier adjacent to the uncovered area.

22. The shoe of claim 18 further comprising a gap between the barrier and the upper, and at least two spacers disposed in the gap.

23. The shoe of claim 22 wherein the spacers are attached to the upper or are attached to the barrier, and wherein no spacers are attached to both the upper and the barrier.

24. The shoe of claim 15 wherein the barrier has a height in the range of 1-6 inches tall everywhere around the shoe.

25. The shoe of claim 15 wherein the upper in a toe box has an average air permeability in the range of 40-400 SCFM/SF.

26. The shoe of claim 15 further comprising a cover that is removably attachable over an uncovered area of the upper in a front section, and wherein the cover is impermeable to water.

27. A breathable shoe with wind and water protection, comprising:

a) a sole;

b) a shoe upper attached to the sole, wherein the upper in a front section has an average air permeability of at least 40 SCFM/SF;

c) a barrier attached to the sole in the front section of the shoe, wherein the barrier is impermeable to wind and water, wherein the barrier-sole attachment is water-tight, wherein a barrier height is at least 0.5 inches everywhere, and wherein the barrier does not extend around a heel of the shoe; and

d) terminal ends of the barrier attached to the upper in a middle section or rear section with a water-tight bond, and wherein portions of the shoe unprotected by the barrier are water resistant or waterproof.

28. The shoe of claim 30 wherein a heel of the shoe is unprotected by the barrier, and wherein the heel is waterproof.

29. The shoe of claim 27 wherein the upper in the front section has an average air permeability of at least 80 SCFM/SF.

30. The shoe of claim 27 wherein the upper in the front section has an average air permeability of at least 120 SCFM/SF.

31. The shoe of claim 27 wherein the barrier has an inward curve such that it covers some of the upper in a front section in a top view.

32. The shoe of claim 31 further comprising an uncovered area in the front section, wherein the uncovered area is not covered by the barrier in a top view.

33. The shoe of claim 32 wherein the barrier has an upward curve next to the uncovered area.

34. The shoe of claim 32 further comprising an edge coupler for bringing together edges of the barrier adjacent to the uncovered area.

35. The shoe of claim 31 further comprising a gap between the barrier and the upper, and at least two spacers disposed in the gap.

36. The shoe of claim 35 wherein the spacers are attached to the upper or are attached to the barrier, and wherein no spacers are attached to both the upper and the barrier.

37. The shoe of claim 27 wherein the barrier has a height in the range of 1-6 inches tall everywhere around the shoe.

38. The shoe of claim 27 further comprising a cover that is removably attachable over an uncovered area of the upper in a front section, and wherein the cover is impermeable to water.