US20210076775A1

US20210076775A1 - Shoes with water-resistant membranes and coating

Info

Publication number: US20210076775A1
Application number: US16/935,028
Authority: US
Inventors: Jamie McLellan; Thomas Jad Finck; Lisa Halbower-Fenton; James Romero; Uidong Cho; Joseph Zwillinger; Timothy Brown; Dennice Quijano Barerra; Romesh Patel
Original assignee: Allbirds Inc
Current assignee: Allbirds Inc
Priority date: 2019-09-17
Filing date: 2020-07-21
Publication date: 2021-03-18

Abstract

A shoe may include an upper portion that includes one or more textile (e.g., wool) layers and one or more water-resistant membranes for providing or enhancing water resistance of the shoes. The water-resistant membranes may be positioned between the textile layers to provide or enhance water resistance without affecting the appearance and/or feel of the interior and exterior surfaces of the upper portion. The shoe may include a durable water repellent coating along at least a portion of an exterior surface for water resistance and durability. The shoes described herein may be constructed at least partially using bio-based materials.

Description

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application is a nonprovisional patent application of and claims the benefit of U.S. Provisional Patent Application No. 62/901,684, filed Sep. 17, 2019 and titled “Shoes with Water-Resistant Membranes and Coating,” the disclosure of which is hereby incorporated herein by reference in its entirety.

FIELD

Embodiments described herein relate to footwear, and in particular, to shoes having features as described herein.

BACKGROUND

Shoes are widely used for protecting and providing comfort to wearers' feet. Traditional shoes include an upper portion that is formed by attaching multiple separate components together. In some cases, traditional shoes formed of bio-based materials, such as wool, are not designed to repel water and other contaminants. In some cases, traditional shoes are constructed entirely from synthetic materials, the production and use of which may be harmful to the environment and may prevent the shoes from being recycled.

SUMMARY

Certain embodiments described herein generally relate to, include, or take the form of a shoe comprising a sole and an upper portion. The sole defines a tread surface and a top surface opposite the tread surface. The upper portion is attached to the top surface of the sole and comprises an outer textile layer comprising wool, an inner textile layer comprising wool, a first water-resistant membrane, and a second water-resistant membrane. The first water-resistant membrane is positioned between the outer textile layer and the inner textile layer and extends from a lower perimeter of the upper portion to a first boundary a first distance from the lower perimeter. The second water-resistant membrane is positioned between the outer textile layer and the inner textile layer and extends from the lower perimeter of the upper portion to a second boundary a second distance greater than the first distance from the lower perimeter.
Other embodiments described herein may relate to a shoe that includes an upper portion and a tongue. The upper portion defines a gap and comprises a first membrane region and a second membrane region. The first membrane region comprises a first water-resistant membrane positioned between an outer textile layer and an inner textile layer. The second membrane region comprises a second water-resistant membrane positioned between the outer textile layer and the inner textile layer. The tongue comprises a third water-resistant membrane and is configured to be positioned at least partially in the gap defined by the upper portion.
Still other embodiments described herein may relate to an upper portion for a shoe comprising a first membrane region and a second membrane region. The first membrane region comprises a first part of an outer textile layer, a first part of an inner textile layer, and a first water-resistant membrane comprising bio-based thermoplastic polyurethane and positioned between the first part of the outer textile layer and the first part of the inner textile layer. The second membrane region comprises a second part of the outer textile layer, a second part of the inner textile layer, and a second water-resistant membrane comprising bio-based thermoplastic polyurethane and positioned between the second part of the outer textile layer and the second part of the inner textile layer. The outer textile layer is knit as a single, unitary piece comprising wool and at least a part of the first membrane region overlaps the second membrane region.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference will now be made to representative embodiments illustrated in the accompanying figures. It should be understood that the following descriptions are not intended to limit this disclosure to one preferred embodiment. To the contrary, the disclosure provided herein is intended to cover alternatives, modifications, and equivalents as may be included within the spirit and scope of the described embodiments, and as defined by the appended claims.

FIG. 1A illustrates an example shoe having an upper portion that includes one or more water-resistant membranes;

FIG. 1B illustrates an example shoe having an upper portion that includes one or more water-resistant membranes;

FIGS. 2A-2C illustrate the example shoe of FIG. 1A showing locations of membrane regions of the upper portion;

FIG. 2D illustrates a cross-section of the example shoe of FIG. 1A showing water-resistant membranes positioned between textile layers of the upper portion, taken through section line A-A of FIG. 2B;

FIG. 2E illustrates a bottom view of the example shoe of FIG. 1A showing example tread surfaces on the sole; and

FIG. 3 illustrates the example shoe of FIG. 1A.

The use of the same or similar reference numerals in different figures indicates similar, related, or identical items.
Additionally, it should be understood that the proportions and dimensions (either relative or absolute) of the various features and elements (and collections and groupings thereof) and the boundaries, separations, and positional relationships presented therebetween, are provided in the accompanying figures merely to facilitate an understanding of the various embodiments described herein and, accordingly, may not necessarily be presented or illustrated to scale, and are not intended to indicate any preference or requirement for an illustrated embodiment to the exclusion of embodiments described with reference thereto.

DETAILED DESCRIPTION

Reference will now be made in detail to representative embodiments illustrated in the accompanying drawings. It should be understood that the following description is not intended to limit the embodiments to one preferred embodiment. To the contrary, it is intended to cover alternatives, modifications, and equivalents as can be included within the spirit and scope of the described embodiments as defined by the claims.
The shoes described herein include various features to improve performance, increase manufacturing efficiency, and provide environmental benefits over traditional shoes. In some cases, a shoe includes an upper portion that includes one or more textile (e.g., wool) layers and one or more water-resistant membranes for providing or enhancing water resistance of the shoes. The water-resistant membranes may be positioned between the textile layers to provide or enhance water resistance without affecting the appearance and/or feel of the interior and exterior surfaces of the upper portion.
In some cases, the shoes described herein may be constructed at least partially using bio-based materials. As used herein, the term “bio-based materials” may refer to materials made from substances derived at least partially from living or once-living organisms. The upper portion may include a bio-based material. For example, the textile layers of the upper portion may include wool and the water-resistant membranes may include bio-based plastic made using corn sugar. Additionally or alternatively, other components of the shoes may include bio-based materials. For example, sole of the shoe may include a bio-based foam material made using sugarcane, the insole of the shoe may include a bio-based foam material made using castor bean oil, and the eyelets and the shoelace aglets of the shoe may include a bio-based plastic made using corn sugar. In some cases, the shoes described herein may be constructed at least partially using recycled materials. For example, a shoelace of the shoe may be constructed at least partially from recycled plastic bottles.
In various embodiments, the bio-based and recycled materials used in the shoes described herein provide significant environmental benefits over traditional shoes. Using bio-based materials as a substitute for synthetic materials may result in fewer harmful emissions associated with manufacturing the shoe by reducing or eliminating processing of harmful chemicals, such as the petroleum products used to manufacture most synthetic fibers. Similarly, bio-based materials are more ecologically sustainable than many synthetic materials because they are derived from renewable resources (e.g., plant fibers, animal fibers, sugarcane, corn sugar) rather than nonrenewable resources (e.g., petroleum products). The bio-based materials selected for use in the shoes may be certified by accreditation programs that ensure sustainability and animal welfare. For example, the wool used in the textile layers of the upper portion may be ZQ certified. Similarly, using recycled materials instead of new materials reduces waste sent to landfills and incinerators and conserves natural resources, prevents pollution, and saves energy related to the collection and processing of new raw materials.
In addition to using bio-based and recycled materials, the shoes described herein may include various features to make recycling the shoes easier. The shoe may have fewer components to separate from one another as part of the recycling process.
As noted above, in addition to the environmental benefits, the shoes described herein may have improved performance over traditional shoes. In various embodiments, the water-resistant membranes of the shoe may provide enhanced water resistance while maintaining the comfort of the shoe, including softness, breathability, and the ability of a wearer to comfortably wear the shoe with or without socks.
One or more water-resistant membranes may line at least a portion of the upper portion to provide water resistance. One or more water-resistant membranes may form intermediate layers of the upper portion (e.g., layers that are positioned between two or more layers). For example, one or more water-resistant membranes may be positioned between textile layers of the upper portion. A water-resistant membrane may form a layer of the upper portion and extend across an entirety of the upper portion, or the water-resistant membrane may form a layer of the upper portion in one or more “membrane regions” of the upper portion and not be present in other regions of the upper portion. A water-resistant membrane may extend around an entirety or a substantial entirety of the upper portion. The membrane regions may extend around the shoe from a lower perimeter of the upper portion to a boundary that extends around the shoe. In some cases, the shoe includes two overlapping membrane regions, including a first membrane region that extends to a first boundary and a second membrane region that extends to a second boundary farther from the lower perimeter than the first boundary.
As noted above, the water-resistant membrane may form some or all of an intermediate layer of the upper portion. Additionally or alternatively, the water-resistant membrane may form some or all of an innermost layer of the upper portion (e.g., a layer that is the closest layer to a wearer's foot and/or forms an interior surface of the upper portion) or an outermost layer of the upper portion (e.g., a layer that forms an exterior surface of the upper portion). In some cases, a water-resistant membrane may extend across multiple components of the shoe. A water-resistant membrane may extend along a surface of, or within, the upper portion and also extend along a surface of, or within, another component of the shoe, such as the outsole, the strobel, the tongue, or the like. For example, a water-resistant membrane may be positioned along a seam between the upper portion of the shoe and the outsole of the shoe to prevent water and other contaminants from entering the interior of the shoe via the seam or surrounding areas. The membrane may extend across a portion of the seam or may extend all the way around or substantially all the way around the shoe along the seam. In some cases, the water-resistant membrane may extend farther from the seam in a toe section of the shoe, for example to provide additional water resistance in the toe section.
In some cases, the shoe is designed to allow a wearer to wear the shoe without socks. In various embodiments, the shoe may include features to improve the performance of the shoe when worn without socks. The upper portion may improve the comfort of the shoe by reducing or eliminating seams that may irritate wearers, especially when lacking socks. In some cases, the upper portion defines an interior surface of a cavity adapted to receive a wearer's foot in addition to defining an exterior surface of the shoe.
As noted above, the upper portion may include one or more textile layers. In some cases, an outer textile layer defines at least a portion of the exterior surface of the upper portion, and an inner textile layer defines at least a portion of the interior surface of the upper portion. In some cases, the textile properties of the interior surface are different than the textile properties of the exterior surface. For example, the interior surface may be brushed, flocked, or otherwise have different textile properties to soften a tactile feel of the interior surface. In some cases, the interior surface may include one or more different materials than the exterior surface. For example, the textile may include different fiber types or fiber ratios at the interior surface and the exterior surface. The above-mentioned features may provide particular advantages to wearers wearing the shoes without socks, because the wearer's foot may directly contact the upper portion while the shoes are worn.
In various embodiments, the upper portion is attached to a first side of a sole that defines, on a second opposite side, a tread surface that is adapted to contact the ground or other surfaces while the shoe is worn. Additionally or alternatively, the sole may include one or more traction pads defining the tread surface and adapted to contact the ground or other surfaces while the shoe is worn. The sole may be attached to the upper portion, for example using an adhesive. The shoe may define a cavity adapted to receive a wearer's foot. In some cases, an insole may be positioned in the cavity. In some cases, the insole cooperates with the upper portion to define the interior surface of the shoe.
As used herein, “textile” or “fabric” may refer to a flexible material consisting of a network of natural and/or artificial fibers (e.g., yarn or thread formed into a sheet) formed by any suitable process, including, but not limited to, weaving, knitting, spreading, crocheting, knotting, felting, bonding, braiding, and carpeting.
As used herein, “textile properties” may refer to properties that define the dimensions and characteristics of a textile, including, but not limited to, fiber properties (e.g., fiber type, size, and length), yarn properties (e.g., yarn diameter, twist, weight, size, count, fiber content or fiber ratio, ply, and strand count in plied yarn), weight, thickness, fabric structure, fabric density, weave properties (e.g., weave type, warp and filling yarn count), knit properties (e.g., knit type, wale and course count), finishes or coatings (e.g., chemicals, resins, starches, and waxes), and mechanical effects (e.g., calendaring, napping, flocking, and brushing).
As used herein, “textile characteristics” may refer to measures of the textile's performance, including, but not limited to, stiffness (e.g., resistance to stretching or bending), flexibility (e.g., reduced stiffness), breathability (e.g., air permeability), water resistance, moisture wicking, odor resistance, durability characteristics, visual characteristics (e.g., textile appearance), and tactile characteristics (e.g., textile feel). As used herein, “water resistance” may refer to the ability of the shoe to prevent or reduce the entry of water, other liquids, or other contaminants into the cavity of the shoe and/or into other parts of the shoe. As used herein, “durability” may refer to the ability of materials (e.g., a textile) or objects (e.g., a shoe) to resist wear, deformation, and/or damage and/or to maintain its textile properties, structure, visual characteristics, and/or tactile characteristics. As used herein, “durability characteristics” may refer to measures of a textile's durability, including, but not limited to, abrasive strength (e.g., resistance to abrasion), bursting strength (e.g., ability to withstand forces applied at right angles to the plane of the fabric), and tensile strength (e.g., ability to withstand forces applied along the plane of the fabric).
FIG. 1A illustrates an example shoe 100 a having an upper portion 110 a that includes one or more water-resistant membranes. The upper portion 110 a may define a shape or structure of the shoe 100 a, and may be adapted to contain, comfort, and/or protect a foot of a wearer wearing the shoe 100 a. As described above, the shoe 100 a may include an upper portion 110 a that includes one or more textile layers and one or more regions with water-resistant membranes.
As noted above, the water-resistant membranes may be positioned between an outer textile layer that defines at least a portion of the exterior surface of the upper portion 110 a and an inner textile layer that defines at least a portion of the interior surface of the upper portion 110 a. Additionally or alternatively, the upper portion 110 a may include one or more coatings for water resistance. In some cases, the coating is a durable water repellent (DWR) coating that is disposed on one or more layers of the upper portion 110 a. In some case, the DWR coating is disposed on only one surface (e.g., an exterior surface) of a layer (e.g., an outer textile layer). Applying the coating to only one surface may allow the upper portion to wick moisture via the non-coated surface to improve breathability and comfort of the shoe. The DWR coating may be any suitable type of coating, including, fluoropolymers, acrylic acid/stearyl acrylate copolymers, and the like. In some embodiments, the coating may lack C8 fluoropolymers and/or perfluorooctanoic acid.
The coating(s) and/or water-resistant membrane(s) may improve the water resistance of the shoe 100 a, for example by preventing or reducing water, other liquids, and other contaminants from entering the interior of the shoe through the upper portion. The coating(s) and/or water-resistant membrane(s) may improve the durability of the shoe 100 a. For example, the coating(s) may improve durability characteristics of the shoe 100 a, such as abrasive strength, reduce staining, and the like. Positioning the water-resistant membrane(s) between textile layers may improve durability of the shoe 100 a by protecting the water-resistant membrane(s) from damage from a wearer's foot and/or objects or substances outside the shoe 100 a.
Additionally or alternatively, the coating(s) and/or water-resistant membrane(s) may improve the comfort of the shoe 100 a, for example by providing water resistance while maintaining softness, breathability, and the ability of a wearer to comfortably wear the shoe with or without socks. The water-resistant membrane(s) may provide structural support to the shoe by increasing a stiffness of the upper portion 110 a. Positioning the water-resistant membrane(s) between textile layers may improve the comfort of the shoe 100 a by removing seams along the interior surface that may irritate a wearer.
The upper portion 110 a may define a first part of an exterior surface of the shoe, and a sole 120 a may define a second part of the exterior surface of the shoe. The upper portion 110 a may cooperate with one or more additional shoe components to define a cavity 160 a for receiving a wearer's foot (not shown in FIG. 1A). Additionally, the upper portion 110 a may define a first part of an interior surface of the shoe 100 a. As noted above, the upper portion 110 a may include one or more layers. In some cases, an outer layer of the upper portion 110 a defines at least a portion of the exterior surface of the upper portion, and an inner layer of the upper portion defines at least a portion of the interior surface of the upper portion. In some cases, textile characteristics may vary between the interior surface and the exterior surface to achieve desired shoe performance. Additionally, textile characteristics and materials may vary at different locations on the interior surface.
As noted above, the upper portion 110 a may include one or more textile layers, such as wool layers. In various embodiments, the textile that is used to form the textile layers of the upper portion 110 a may be constructed by any suitable process, including, but not limited to, weaving, knitting, spreading, crocheting, knotting, felting, bonding, braiding, and carpeting. In some cases, a first layer may have first textile properties and a second layer may have second textile properties. In some cases, multiple layers are formed together as part of a construction process. The first and second layers may be interlaced with one another. For example, the structure of the first layer may be interlaced with the structure of the second layer.
The textile layers may be formed of any suitable material or combination of materials. For example, a woven or knit textile may be formed using one or more types of yarn. The yarn may be formed using one or more natural or synthetic fibers twisted or otherwise bound together. Example fibers include cellulose fibers (e.g., eucalyptus fiber, bamboo fiber, rayon, and modal), wool, cotton, silk, polyester, nylon, and the like. In some cases, the yarn is formed using a blend of two or more fibers. For example, the yarn may be a blend of wool, nylon, and elastane (e.g., SPANDEX). In some cases, the yarn is a plied yarn that includes multiple strands of yarn twisted or braided together.
The shoe 100 a may include a tongue 130 a that covers or conforms to the top of the wearer's foot. The tongue 130 a and the upper portion 110 a may cooperate to retain a wearer's foot in the cavity 160 a. In some cases, the tongue 130 a is adapted to be positioned between a shoelace 150 a and the wearer's foot. In some cases, the tongue 130 a and the upper portion 110 a cooperate to define an opening 170 a into the cavity 160 a.
In various embodiments, the tongue 130 a may be connected to (e.g., integrally formed with or attached to) the upper portion 110 a. In some cases, the tongue 130 a is integrally formed with the upper portion 110 a (e.g., formed from the same textile layer(s) as the upper portion). In other cases, the tongue is a separate component that is attached to the upper portion, for example by stitching, adhesives, or the like. The tongue 130 a may be formed using the same or similar materials and processes as discussed above with respect to the upper portion 110 a. The tongue 130 a may include textile layers and/or water-resistant membranes similar to the upper portion 110 a.
In some cases, the shoe 100 a includes eyelets 140 a and shoelaces 150 a passing through they eyelets. Together they may retain the shoe 100 a to the wearer's foot, for example by tightening the shoe 100 a around the wearer's foot. The eyelets 140 a and the shoelaces 150 a are discussed below in more detail with respect to FIGS. 2A-2B.
The shoe 100 a may also include a sole 120 a that defines a tread surface that is adapted to contact the ground or other surfaces while the shoe is worn. The sole 120 a may be attached to the upper portion 110 a, for example using an adhesive. The sole 120 a is discussed in more detail below with respect to FIGS. 2C and 2D.
In various embodiments, the shoe 100 a may be assembled by attaching the eyelets 140 a and (optionally) the tongue 130 a to the upper portion 110 a and attaching the upper portion 110 a to the sole 120 a using an adhesive or other fastening method. An insole may be inserted into the cavity 160 a, and the laces 150 a may be threaded through the eyelets 140 a.
The shoe of FIG. 1A is configured as a low-top shoe, but the embodiments described herein are meant to encompass other types of shoes as well. FIG. 1B illustrates an example shoe 100 b having an upper portion 110 b that includes one or more water-resistant membranes. The shoe 100 b is configured as a mid-top or high-top shoe, and includes the same or similar structure and functionality as described with respect to the shoe 100 a, including an upper portion 110 b, a sole 120 b, a tongue 130 b, eyelets 140 b, and laces 150 b.
FIGS. 2A-2C illustrate the example shoe 100 a of FIG. 1A showing locations of membrane regions of the upper portion 110 a. As shown in FIGS. 2A-2C, the shoe 100 a may define a first membrane region 210 a that extends around the shoe from a lower perimeter 214 of the upper portion 110 a to a first boundary 212 a that extends around the shoe. Additionally or alternatively, the shoe 100 a may define a second membrane region 210 b that extends around the shoe from the lower perimeter 214 of the upper portion 110 a to a second boundary 212 b that extends around the shoe. In various embodiments, membrane regions may overlap with one another. Water-resistant membranes positioned between the textile layers of the upper portion 110 a may enhance or provide water resistance of the shoe 100 a.
In some cases, as shown in FIG. 2A, each boundary of the first and/or second membrane regions 210 a, 210 b may be selected to be a substantially constant distance from the ground (or other surface) around an entirety of the shoe when the shoe is placed on the ground (or other surface). For example, for the second membrane region 210 b, the substantially constant distance may be approximately equal to a distance between a lowermost eyelet 140 a of the shoe and the ground (or other surface) when the shoe is placed on the ground (or other surface).
One or more water-resistant membranes in the first membrane region 210 a may provide additional water resistance along a seam 222 between the upper portion 110 a and the sole 120 a, thereby reducing water ingress at the seam. In some cases, as shown and described with respect to FIG. 2C below, the sole 120 a may overlap part of the upper portion 110 a, such that the lower perimeter of the upper portion is beneath part of the sole 120 a. The sole 120 a and the upper portion 110 a may meet at a seam 222. The first membrane region 210 a may extend around the upper portion 110 a and be positioned beneath the seam.
One or more textile layers or water-resistant membranes of the upper portion 110 a may be knit or otherwise formed as a single, unitary piece, in which an entire top surface is defined by a single piece and an entire bottom surface is defined by a single piece. As a result, the one or more textile layers or water-resistant membranes do not have multiple adjacent sections with seams therebetween. In various cases, a textile layer or water-resistant membrane may be attached to itself and/or another layer of the upper portion 110 a using a seam, for example to define a structure of the upper portion 110 a. For example, as shown in FIG. 2C, the textile layers and water-resistant membranes of the upper portion 110 a may be attached at a seam 280. The textile layers and water-resistant membranes may be attached at the seam using any suitable fastening technique, including adhesives, stitching, bonding, and the like.
As discussed above, the upper portion 110 a may include a coating for enhancing the water resistance of the shoe 100 a. The coating(s) and/or water-resistant membrane(s) may improve the water resistance of the shoe 100 a, for example by preventing or reducing water, other liquids, and other contaminants from entering the interior of the shoe through the upper portion. The coating(s) and/or water-resistant membrane(s) may improve the durability of the shoe 100 a. For example, the coating(s) may improve durability characteristics of the shoe 100 a, such as abrasive strength, reduce staining, and the like. Positioning the water-resistant membrane(s) between textile layers may improve durability of the shoe 100 a by protecting the water-resistant membrane(s) from damage from a wearer's foot and/or objects or substances outside the shoe 100 a.
Additionally or alternatively, the coating(s) and/or water-resistant membrane(s) may improve the comfort of the shoe 100 a, for example by providing water resistance while maintaining softness, breathability, and the ability of a wearer to comfortably wear the shoe with or without socks. The water-resistant membrane(s) may provide structural support to the shoe by increasing a stiffness of the upper portion 110 a. Positioning the water-resistant membrane(s) between textile layers may improve the comfort of the shoe 100 by removing seams along the interior surface that may irritate a wearer.
FIG. 2D illustrates a cross-section of the example shoe 100 a showing water- resistant membranes 230 a, 230 b positioned between textile layers 240 a, 240 b of the upper portion 110 a, taken through section line A-A of FIG. 2B. As noted above, in some cases, the textile that forms the upper portion 110 a includes multiple textile layers. In some cases, the upper portion 110 a includes an outer textile layer 240 a and an inner textile layer 240 b. The outer textile layer 240 a may form an exterior surface 250 of the upper portion 110 a, and the inner textile layer 240 b may form an interior surface 252 of the upper portion 110. In some cases, both the outer textile layer 240 a and the inner textile layer 240 b may extend along the entire upper portion 110 a. This may simplify manufacturing and/or improve comfort by reducing the number of seams in the upper portion 110 a.
In various embodiments, the water- resistant membranes 230 a, 230 b may be positioned between the outer textile layer 240 a and the inner textile layer 240 b. The water- resistant membranes 230 a, 230 b may enhance or provide water resistance of the shoe 100 a, for example by preventing or reducing the ingress of water, other liquids, or other contaminants through the textile layers 240 a, 240 b of the upper portion 110 a of the shoe.
The water-resistant membrane 230 a may be positioned in the first membrane region 210 a, and the water-resistant membrane 230 b may be positioned in the second membrane region 210 b shown in FIGS. 2A-2C above. The water-resistant membrane 230 a may extend from a location at or near the lower perimeter 214 of the upper portion 110 a to the boundary 212 a. The water-resistant membrane 230 b may extend from a location at or near the lower perimeter 214 of the upper portion 110 a to the boundary 212 b (not shown in FIG. 2D).
As noted above, the first membrane region 210 a may provide water resistance along the seam 222 between the upper portion 110 a and the sole 120 a. As shown in FIG. 2D, the sole 120 a may overlap part of the upper portion 110 a, such that the lower perimeter of the upper portion is beneath part of the sole 120 a. The sole 120 a and the upper portion 110 a may meet at the seam 222. The first membrane region 210 a may extend around the upper portion 110 a and be positioned at least partially beneath the seam 222.
The water-resistant membranes 230 a and/or 230 b may be formed of any suitable material or combination of materials, including polyamides, polyethylene, polypropylene, polyurethane (e.g., thermoplastic polyurethane), ethyl vinyl acetate, and polyols. In some cases, the water-resistant membranes 230 a and/or 230 b are formed at least partially from a bio-based material, such as corn sugar. The water- resistant membranes 230 a and 230 b include a bio-based thermoplastic polyurethane. The material(s) used to form the water- resistant membranes 230 a, 230 b may be breathable, such that they prevent the ingress of water and other contaminants, but they allow the exchange of air. This may improve the comfort and performance of the shoe 100 a.
The thickness of the water- resistant membranes 230 a, 230 b may be different, and/or may vary at different locations within the membrane regions. The water-resistant membrane 230 b may be thinner than the water-resistant membrane 230 a to allow more flexibility and/or breathability in the first membrane region, because the first membrane region extends higher in the shoe. The water-resistant membrane 230 a may be thicker than the water-resistant membrane 230 b to provide added water resistance near the seam 222. In some cases, the water-resistant membrane 230 a is between 2 and 5 times thicker than the water-resistant membrane 230 b. For example, the water-resistant membrane 230 a have a thickness between 0.1 mm and 0.5 mm, and the water-resistant membrane 230 b may have a thickness between 0.05 and 0.15 mm.
The outer layer 240 a and/or inner layer 240 b may be a knit textile with that includes a yarn with one or more man-made fibers and one or more bio-based fibers. The outer layer 240 a and/or inner layer 240 b may be formed of between 50% and 90% wool, between 1% and 50% nylon, and between 1% and 20% elastane (e.g., SPANDEX). The outer layer 240 a and/or inner layer 240 b may be between 60% and 70% wool, between 25% and 45% nylon, and between 2% and 10% elastane.
The upper portion 110 a may be attached to the sole 120 a using an adhesive or other fastening method. As shown in FIG. 2D, the shoe 100 a may include a strobel 282 that encloses the bottom of the upper portion 110 a. In some cases, the strobel 282 may be attached to the upper portion 110 a at or near the lower perimeter 214 of the upper portion 110 a. For example, a lower perimeter of the strobel 282 may be attached to the lower perimeter 214 of the upper portion 110 a. In some cases, the layers 240 a, 240 b and/or the membranes 230 a, 230 b may wrap under the strobel 282.
An adhesive 284 may be applied between a top surface of the sole 120 a and a bottom surface of the strobel 282 and/or a surface of the upper portion 110 a at or near a lower perimeter of the sole to attach the sole to the upper portion. In some cases the strobel 282 is omitted and the upper portion 110 a is attached directly to the sole 120 a using adhesive or another fastener. In some cases, the strobel 282 may be a part of the upper portion 110 a or the sole 120 a. Following attachment of the upper portion 110 a to the sole 120 a, the insole 220 may be inserted into the cavity 160 a. As noted above, an upper surface of the insole 220 may define a portion of the interior surface of the shoe 100 a. An interior surface of the upper portion 110 a may define an additional portion of the interior surface of the shoe 100 a.
The shoe 100 a described with respect to FIGS. 2A-2D includes two water- resistant membranes 230 a and 230 b and two membrane regions 210 a and 210 b. However, the shoes described herein may include any number of membrane regions and water-resistant membranes. Additionally or alternatively, the locations of the membrane regions along the upper portion may be different than the examples shown in FIGS. 2A-2D. Similarly, the positions of the water-resistant membranes relative to other layers and/or other components of the shoe may be different in various embodiments.
In some cases, the outer layer 240 a and the inner layer 240 b may have different textile characteristics at corresponding locations on the upper portion 110 a. For example, a textile feel or abrasive strength of the outer later 240 a may differ from the inner layer 240 b. The different textile characteristics of the different surfaces may be a result of different textile properties between the outer layer 240 a and the inner layer 240 b, including yarn properties, knit properties, thickness, mechanical effects (e.g., brushing) and the like. In some cases, the outer layer 240 a and the inner layer 240 b may be otherwise attached or affixed to one another, for example using adhesives.
In addition to the textile properties differing among different layers, the textile properties of each layer 240 a, 240 b may differ at different locations of the upper portion 110 a. For example, the outer layer 240 a may be thicker in a first region than the outer layer in a second region, and the inner layer 240 b may be thicker in the first region than the inner layer in the second region. In some cases, textile properties may vary in less than all of the layers. For example, one layer may be thicker in a first region than in a second region, and another layer may be a same thickness in the first region as in the second region.
As noted above, the shoe 100 a may define a cavity 160 a adapted to receive a wearer's foot. In some cases, an insole 220 may be positioned in the cavity, and may define at least a portion of the interior surface of the shoe 100 a that surrounds the cavity 160 a. For example, the insole 220 may define a foot bed configured to receive and contact a bottom surface of a foot of the wearer. The insole 220 may be adapted to be positioned between the wearer's foot and the sole 120 a to cushion the wearer's foot during wear. The insole 220 may cooperate with the upper portion 110 a and one or more additional components of the shoe 100 a to define the interior surface of the shoe 100 a.
The insole 220 may include a top surface 260 a defining a portion of the interior surface of the shoe 100 a and a bottom portion that provides cushioning to the wearer's foot. The top surface 260 a may be formed of any suitable material or combination of materials, including wool, cotton, polyester, nylon, and the like. The bottom portion may be formed of any suitable material or combination of materials, including polyamides, polyethylene, polypropylene, polyurethane (e.g., thermoplastic polyurethane), ethyl vinyl acetate, and polyols. In some cases, the bottom portion is formed at least partially from a bio-based material, such as castor bean oil. As noted above, using bio-based materials may provide environmental benefits, including reduced emissions and ecological sustainability.
As noted above, the sole 120 a may define one or more tread surfaces that are adapted to contact the ground or other surfaces while the shoe is worn. FIG. 2E illustrates a bottom view of the example shoe 100 a showing example tread surfaces 272 a-c on the sole 120 a. As noted above the sole 120 a may include traction pads 270 a, 270 b defining tread surfaces 272 a and 272 b, respectively. The tread surfaces 272 a-c may include one or more patterns or features to improve the traction of the shoe 100 a. In some cases, the tread surfaces 272 a-c include indentations and/or protrusions that define the patterns or features for improving traction.
In various embodiments, the sole 120 a may be formed of any suitable material or combination of materials, including polyamides, polyethylene, polypropylene, polyurethane (e.g., thermoplastic polyurethane), and polyols. In some cases, the sole 120 a is formed at least partially from a natural material, such as castor bean oil. As noted above, using bio-based materials may provide environmental benefits, including reduced emissions and ecological sustainability. The traction pads 270 a, 270 b may be formed of any suitable material or combination of materials, such as polyamides, polyethylene, polypropylene, polyurethane (e.g., thermoplastic polyurethane), polyols, natural and synthetic rubbers, and the like. In some cases, the traction pads 270 a, 270 b may be formed from bio-based material(s).
As noted above, in some cases, one or more regions of an interior surface of the shoe 100 a may have different textile properties than regions of the exterior surface and/or other regions of the interior surface. FIG. 3 illustrates the example shoe 100 a and shows part of the interior surface 252 of the upper portion 110 a, which may be brushed or otherwise treated to soften the interior surface. In some cases, various regions of the upper portion 110 a may have different textile characteristics on an exterior surface than on an interior surface. For example, the tactile feel may be softer on the interior surface 252 than on an exterior surface at the same location of the upper portion 110 a. The interior surface 252 may provide advantages including improving the comfort of the shoe to a wearer, including a wearer wearing the shoe 100 a without a sock. The different textile characteristics of the interior surface 252 may be achieved by processing the textile (e.g., brushing or flocking) differently on each surface and/or using different materials at the different surfaces.
In some cases, different regions of the interior surface 252 may have different textile characteristics, including tactile feel, water resistance, moisture wicking, and odor resistance. FIG. 3 illustrates different regions 352 a and 352 b of the interior surface 252.
The region 352 a may extend around a wearer's heel. The region 352 b may extend around other parts of the wearer's foot. In various embodiments, the region 352 a of the interior surface of the upper portion 110 may be subject to more abrasion and other damage than the region 352 b due to its location near the back of the shoe 100 a. For example, the region 352 a may be rubbed while a wearer puts on or takes off the shoe 100 a. Similarly, the region 352 a may be rubbed by the wearer's heel while the shoe 100 b is worn. In some cases, the shoe 100 may include a heel lining 354 that is attached to the upper portion 110 along the interior surface 252 in the region 352 a. The heel lining 354 may reduce wear of the upper portion 110 a and/or provide friction to retain the wearer's foot in the shoe 100 a during wear.
In some cases, the heel lining 354 is part of the upper portion 110 a and has different textile properties to achieve the desired performance, including durability. In some cases, the heel lining 354 is a separate component that is attached to the upper portion 110 a. For example, the heel lining 354 may be formed from a wear-resistant material (e.g., wool, polyester, or the like) that is attached (e.g., sewn or glued) onto the interior surface 352 of the upper portion 110 a. In some cases, the heel lining is brushed, flocked, or otherwise processed, similar to the interior surface 352. The heel lining 354 may have higher abrasive strength or other improved textile characteristics compared to the upper portion 110 a. In some cases, the heel lining 354 covers the portion of the seam 280 on the interior surface 352 of the upper portion 110 a to improve the comfort of the shoe. For example, the heel lining 354 may prevent the seam 280 from rubbing or otherwise irritating the wearer's foot, including a wearer wearing the shoe 100 a without a sock. In some cases, the shoe 100 a may include heel padding (e.g., a foam padding), for example between the heel lining 354 and the upper portion 110 a to improve the comfort of the shoe.
As noted above, in some cases, the interior surface 252 may be processed (e.g., brushed, flocked, or the like) to achieve different textile characteristics than an exterior surface of the upper portion 110 a. In some cases, one or more regions of the interior surface 252 are brushed to soften the tactile feel of the regions. For example, the region 352 a of the interior surface 252 may be brushed to soften the tactile feel of the region 352 a, for example to improve the comfort of a foot in the shoe 100 a. Additionally or alternatively, the region 352 b may be brushed. In some cases, the regions the region 352 b is not brushed, for example if a separate heel lining 354 is installed in the region 352 b. Additionally or alternatively, one or more regions of the exterior surface of the upper portion 110 a may be brushed. In some cases, the exterior surface of the upper portion 110 a is not brushed.
In some cases, the textile characteristics of one or more regions of the interior surface may extend around a top of the upper portion 110 a and to the exterior surface of the upper portion. For example, a region 356 around the opening 170 a to the cavity 160 a may include the same or similar textile characteristics as the regions 352 a and/or 352 b.
The tongue 130 a may include a wear region 330 that is more prone to abrasion and other damage than other areas of the tongue 130. In some cases, the wear region 330 may be a part of the tongue 130 having different textile characteristics than other areas of the tongue, similar to the reinforcement regions 310 discussed above. In some cases, the wear region 330 of the tongue 130 may include a separate component that is attached to the tongue 130. For example, the wear region 330 may be formed from a wear-resistant material (e.g., wool, polyester, or the like) that is attached (e.g., sewn or glued) to the tongue 130. In some cases, separate component may be attached to an exterior surface and an interior surface of the tongue 130. The wear region 330 may have higher abrasive strength or other improved textile characteristics compared to the tongue 130.
As discussed above, the shoe 100 a may include eyelets 140 a and shoelaces 150 a passing through the eyelets to retain the shoe 100 a to the wearer's foot. Each eyelet 140 a may define an opening through which a shoelace 150 a may extend. In some cases, the upper portion 110 a includes a gap 210 over the tongue 130 a. The tongue 130 a may be configured to be positioned at least partially in the gap 210. As shown in FIG. 2B, a first set of eyelets 140 a may be positioned on a first side of the gap 210 and a second set of eyelets 140 a may be positioned on a second side of the gap 210. The gap 210 may allow the upper portion 110 a to contract or expand to achieve a better fit around a wearer's foot. The shoelace 150 a may extend across the gap 210 and may be coupled to the upper portion 110 a by passing through one or more eyelets 140 a on either side of the gap. As a result, tightening the shoelace 150 a may draw the opposing eyelets 140 a toward each other, thereby reducing a width of the gap 210 and tightening the upper portion 110 a. Similarly, loosening the shoelace 150 a may draw the opposing eyelets 140 a away from each other, thereby increasing a width of the gap 210 and tightening the upper portion 110 a.
In various embodiments, each of the eyelets 140 a may be positioned in an opening extending through the upper portion 110 a. In some cases, the eyelets 140 a include stitches around holes through the upper portion 110 a. Additionally or alternatively, the eyelets 140 a may include one or more components that define holes through the upper portion 110 a. The eyelets 140 a may be formed using any suitable material or combination of materials, including, but not limited to, polyamides, polyethylene, polypropylene, polyurethane (e.g., thermoplastic polyurethane), and polyols. In some cases, the eyelets 140 a may be formed at least partially from bio-based materials, including plant-based polymers, natural oil polyols, and the like. In some cases, the eyelets 140 a may include a bio-based plastic made using corn sugar. As noted above, using bio-based materials may provide environmental benefits, including reduced emissions and ecological sustainability.
As noted above, the shoelace 150 a may extend through the eyelets 140 a to secure the shoe 100 a to a wearer's foot. In some cases, the shoelace 150 a includes a tubular outer portion and an inner fill. The shoelace 150 a may be formed using any suitable material or combination of materials, including polyester, nylon, cotton, and the like. In some cases, the outer portion and/or the inner fill are formed from recycled materials, such as recycled polyester from plastic bottles. As noted above, using recycled materials instead of new materials reduces waste sent to landfills and incinerators and conserves natural resources, prevents pollution, and saves energy related to the collection and processing of new raw materials. In some cases, the shoelace 150 a includes a coating for water resistance, stain resistance, durability, and the like, similar to the coatings applied to the upper portion 110 a.
In some cases, the shoelace 150 a includes a dome-tipped aglet at each end. The dome-tipped aglet may be formed from a thermoplastic material (e.g., thermoplastic polyurethane). The thermoplastic material may include a bio-based material, such as a polyol derived from corn sugar. In some cases, bio-based materials may make up 20% or more of the thermoplastic material.
As noted above, many embodiments described herein reference a shoe having water-resistant membranes. It may be appreciated, however, that this is merely one example; other configurations, implementations, and constructions are contemplated in view of the various principles and methods of operations—and reasonable alternatives thereto—described in reference to the embodiments described above.
One may appreciate that although many embodiments are disclosed above, that the operations and steps presented with respect to methods and techniques described herein are meant as exemplary and accordingly are not exhaustive. One may further appreciate that alternate step order or fewer or additional operations may be required or desired for particular embodiments.
Although the disclosure above is described in terms of various exemplary embodiments and implementations, it should be understood that the various features, aspects and functionality described in one or more of the individual embodiments are not limited in their applicability to the particular embodiment with which they are described, but instead can be applied, alone or in various combinations, to one or more of the embodiments of the invention, whether or not such embodiments are described and whether or not such features are presented as being a part of a described embodiment. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments but is instead defined by the claims herein presented.

Claims

What is claimed is:

1. A shoe, comprising:

a sole defining a tread surface and a top surface opposite the tread surface; and

an upper portion attached to the top surface of the sole and comprising:

an outer textile layer comprising wool;

an inner textile layer comprising wool;

a first water-resistant membrane positioned between the outer textile layer and the inner textile layer and extending from a lower perimeter of the upper portion to a first boundary a first distance from the lower perimeter; and

a second water-resistant membrane positioned between the outer textile layer and the inner textile layer and extending from the lower perimeter of the upper portion to a second boundary a second distance greater than the first distance from the lower perimeter.

2. The shoe of claim 1, wherein:

the outer textile layer defines at least part of an exterior surface of the upper portion and comprises a durable water repellant coating disposed on the exterior surface;

the first water-resistant membrane comprises bio-based thermoplastic polyurethane; and

the second water-resistant membrane comprises bio-based thermoplastic polyurethane.

3. The shoe of claim 2, wherein the durable water repellant coating is not disposed on a second surface of the outer textile layer opposite the exterior surface.

4. The shoe of claim 1, wherein:

the outer textile layer is formed from a first single piece of textile that extends along an entirety of the upper portion; and

the inner textile layer defines at least part of an interior surface of the upper portion and is formed from a second single piece of textile that extends along the entirety of the upper portion.

5. The shoe of claim 1, wherein:

the first water-resistant membrane has a first thickness; and

the second water-resistant membrane has a second thickness greater than the first thickness.

6. The shoe of claim 1, wherein:

the shoe further comprises an eyelet configured to receive a shoelace; and

the second distance is substantially equal to a third distance between the eyelet and a surface when the tread surface is placed on the surface.

7. The shoe of claim 1, wherein the sole comprises first and second traction pads defining at least a portion of the tread surface.

8. The shoe of claim 1, wherein the sole comprises a bio-based material.

9. A shoe, comprising:

an upper portion defining a gap and comprising:

a first membrane region comprising a first water-resistant membrane positioned between an outer textile layer and an inner textile layer; and

a second membrane region comprising a second water-resistant membrane positioned between the outer textile layer and the inner textile layer; and

a tongue comprising a third water-resistant membrane and configured to be positioned at least partially in the gap defined by the upper portion.

10. The shoe of claim 9, wherein at least part of the first membrane region overlaps the second membrane region.

11. The shoe of claim 9, wherein the first water-resistant membrane and the second water-resistant membrane comprise bio-based thermoplastic polyurethane.

12. The shoe of claim 9, wherein:

the shoe further comprises a sole attached to the upper portion; and

the first membrane region and the second membrane region extend across a seam between the upper portion and the sole.

13. The shoe of claim 9, wherein:

the upper portion further defines an interior surface and an exterior surface opposite the interior surface; and

a first region of the interior surface is brushed to soften the first region.

14. The shoe of claim 13, wherein the shoe further comprises a heel lining attached to the upper portion and positioned along a second region of the interior surface.

15. The shoe of claim 9, wherein:

the upper portion defines a cavity configured to receive a foot of a wearer; and

the shoe further comprises an insole positioned within the cavity and defining a top surface configured to contact a bottom of the foot.

16. The shoe of claim 9, wherein:

the shoe further comprises:

an eyelet attached to the upper portion; and

a shoelace extending through the eyelet; and

the first membrane region extends from a lower perimeter of the upper portion to the eyelet.

17. An upper portion for a shoe, comprising:

a first membrane region comprising:

a first part of an outer textile layer, the outer textile layer;

a first part of an inner textile layer; and

a first water-resistant membrane comprising bio-based thermoplastic polyurethane and positioned between the first part of the outer textile layer and the first part of the inner textile layer; and

a second membrane region adjacent to the first membrane region and comprising:

a second part of the outer textile layer;

a second part of the inner textile layer; and

a second water-resistant membrane comprising bio-based thermoplastic polyurethane and positioned between the second part of the outer textile layer and the second part of the inner textile layer; wherein:

the outer textile layer is knit as a single, unitary piece comprising wool; and

at least a part of the first membrane region overlaps the second membrane region.

18. The upper portion of claim 17, wherein:

the outer textile layer defines an exterior surface of the upper portion; and

the inner textile layer defines an interior surface of the upper portion opposite the exterior surface.

19. The upper portion of claim 18, further comprising a durable water repellant coating disposed on the exterior surface of the upper portion.

20. The upper portion of claim 17, wherein a thickness of the first water-resistant membrane is greater than a thickness of the second water-resistant membrane.