WO2012044907A1

WO2012044907A1 - Waterproof breathable material

Info

Publication number: WO2012044907A1
Application number: PCT/US2011/054172
Authority: WO
Inventors: Glen E. Dawson; Venkat S.P. Dixit; Richard Olmsted; Ilona S. Moszkiewicz
Original assignee: Higher Dimension Materials, Inc.
Priority date: 2010-09-30
Filing date: 2011-09-30
Publication date: 2012-04-05

Abstract

In some aspects, the disclosure relates to multilayer composite constructions including a waterproof/breathable membrane layer attached to another layer formed of a breathable material. In some examples, the disclosure relates to footwear comprising a sole and an upper attached to the sole and including an outer surface. The upper may comprise a first layer including a top surface defining at least a portion of the outer surface of the upper, and a second layer including a top surface directly attached to a bottom surface of first layer, wherein the second layer is substantially waterproof and breathable.

Description

WATERPROOF BREATHABLE MATERIAL

TECHNICAL FIELD

[0001 ] In some examples, the disclosure relates to a multiple layer fabric construction that may be used, e.g., for the upper portion of waterproof footwear.

BACKGROUND

[0002] None.

SUMMARY

[0003] In some examples, the disclosure relates to multilayer construction including a waterproof/breathable membrane layer attached to another layer formed of a breathable material. Such multilayer construction may be used to form all or portions of, e.g., footwear, headwear, handwear, and/or outerwear. In examples in which the multilayer construction is used to form all or portions of footwear, the multilayer construction may provide the functions of a

waterproof/breathable footwear bootie and also form the outer, upper layer of the footwear.

[0004] In some examples, the disclosure relates to footwear comprising a sole, and an upper attached to the sole and including an outer surface, wherein the upper comprises a first l ayer including a top surface defining at least a portion of the outer surface of the upper, and a second layer including a. top surface directly attached to a bottom surface of first layer, wherein the second layer is substantially waterproof and breathable.

[0005] In another example, the disclosure relates to an article of handwear comprising a first layer including a top surface defining at least a portion of an outer surface of the handwear; and a second layer including a top surface directly attached to a bottom surface of first layer, wherein the second layer is substantially waterproof and breathable.

[0006] In another example, the disclosure relates to an article of headwear comprising a first layer including a top surface defining at least a portion of an outer surface of the headwear; and a. second layer including a top surface directly attached to a bottom surface of first layer, wherein the second layer is substantially waterproof and breathable.

[0007] In another example, the disclosure relates to an article of outerwear comprising a first layer including a top surface defining at least a portion of an outer surface of the outerwear; and a second layer including a top surface directly attached to a bottom surface of first layer, wherein the second layer is substantially waterproof and breathable

BRIEF DESCRIPTION OF THE DRAWINGS

[0808] FIG. 1 is a conceptual diagram illustrating an example footwear in the form of an example boot including a sole and upper.

[0009] FIG. 2 is a conceptual diagram illustrating an example boot upper construction including a waterproof bootie.

[0010] FIG. 3 is a conceptual diagram illustrating an example multilayer construction including an example outer layer and example waterproof/breathable layer.

[0011] FIG. 4 is a conceptual diagram illustrating an example multilayer construction including an example outer layer and example waterproof/breathable layer bond via a web adhesive.

[0012] FIG. 5 is a conceptual diagram illustrating an example multilayer construction including an example outer layer, example waterproof/breathable layer and an example inner layer.

[0013] FIG. 6 is a conceptual diagram illustrating an example multilayer construction including an example outer layer bonded to an example

waterproof/breathable layer via an example web adhesive layer, an example inner layer bonded to the waterproof/breathable layer via another example web adhesive layer,

[0014] FIG. 7 is a conceptual diagram illustrating the example multilayer construction of FIG. 6, where the outer layer includes an example fabric substrate layer and example cured polymer guard plates deposited on the surface of the substrate layer. [0015] FIG. 8 is a conceptual diagram illustrating the example outer layer of FIG . 7 with a water droplet.

DETAILED DESCRIPTION

[0016] As described above, in some examples, the multilayer construction described herein may be used as waterproof cons truction that may be used to form at least a portion of an upper of footwear. Waterproofing footwear has been a goal of footwear users since water and footwear first came in contact with each other. In some examples, attempts at such waterproofing included the application of waxes (beeswax, candle wax), tallow and various oils both animal and mineral in origin. Such attempts can be marginally successful but generally work if applied correctly and frequently renewed.

[0017] With the advent of rubber materials, footwear users can have a completely sealed environment for the foot within footwear. The downside to such examples rubber construction relate to breathability, e.g., as rubber may be impervious to water and air. In such case, a user feet may stray dry from exterior water but soon get wet from interior water, e.g., resulting from sweat.

[0018] In another example, footwear may include an inserted liner 'bootie' made with a multi layer fabric material. Some examples include Goriex® and

SympaTex®. Such fabrics may be characterized by a thin film (for example, a non-woven waterproof/breathable material) sandwiched between protective layers of fabric. The thin film may include polymer films, such as, e.g., PTFE in the case of Gortex® and a polyether-ester copolymer in the case of SympaTex®. Such films may be constructed to allow^r water vapor and air to pass through but not liquid water, and may be referred to as "waterproof/breathable" constructions.

[0019] In some examples, such a construction is made as a stitched bootie with waterproof tape sealing all stitched seams. The bootie may be an internal component of the shoe or boot, and may be stitched at the upper collar area of the boot or shoe and is "free floating" inside the shoe or may be adhered to the inner surface of the sole. The outer component of the boot or shoe may be a

combination of leather, synthetic feather, nylon, rubber, etc. Such outer materials can still allow water to enter the boot or shoe but the waterproof bootie may keep the foot within the boot or shoe dry.

[0020] Thus, in some examples, waterproof/breathable footwear may be formed of a first layer (the outside of the footwear upper) that is not impervious to water, e.g., due to stitch seams, properties of the materials itself (open weaves, pores etc) and the like. Water can enter such a boot or shoe, which may cause undesirable side effects if not allowed to dry adequately, e.g., bacterial growth, dry-rot, and the like. The waterproof/breathable bootie inserted into the shoe or boot may the wearer's feet dry and comfortable.

[0021] As described above, examples of the disclosure relate to a multilayer construction including a first layer defining an outer surface of the construction and a substantially waterproof and breathable inner layer directly attached to the first layer. The first layer may be formed of a breathable material. In some examples, such a construction may be used to form all or a portion of the upper of footwear. In such cases, such a design may prevent or substantially decrease the transport of moisture into all or parts of the upper, unlike designs that incorporate booties, as described above. In this manner, manufacturing efficiencies may be increased by eliminating the need for an inner bootie, which also reduces costs, weight, and the like.

[0022] In some examples, such waterproofTbreathable footwear combine the inner bootie structure with the outer upper material of the boot or shoe in a single, composite multilayer structure. By applying a separate waterproofing process to the seams of the boot, the boot can retain its waterproof integrity. On the other hand, by using a breathable outer material, such as a SuperFabric® material (described below) or other abrasion resistant, breathable and flexible material, the whole boot upper may remain breathable as well as waterproof. As will be described below, in some examples, it may also be desirable to add additional layers for thermal insulation, water wicking and/or cushioning to the multilayer structure of the invention. In some examples, such a multiple layer offers the possibility of making lighter weight boots where desirable, since the outer bootie layer is combined with the upper outer boot material. [0023] FIG. 1 is a conceptual diagram illustrating an example footwear 100 including sole 101 attached to upper 102. In some examples, footwear 100 may- take the form of a waterproof boot or waterproof shoe. Depending on the desired application, footwear may be insulated or not insulated. As will be described below , in some examples, all or a portion of upper 102 may be formed of an example multilayer construction described herein. In this manner, upper 102 may^¬ be substantially waterproof and breathable, and may not include an inner bootie.

[0024] Aithough examples of the multilayer constructions are primarily described with regard to the formation of the upper of footwear, applications are not limited as such. In some examples, the described multilayer constructions may be used to form all or portion of other waterproof and breathable articles. For example, the multilayer constructions may be used to form ail or portions of handwear (e.g., glove and/or mittens), headwear (e.g., stocking cap, tuque and/or baseball cap), outerwear (e.g., jacket and/or pants), and the like. In each application, it may be desirable for such an article to be substantially waterproof and breathable.

[0025] FIG. 2 is a conceptual diagram illustrating a cross sectional view of one example of a waterproof/breathable upper 200. As shown, upper 200 includes outer layer 201 and bootie 205. Outer layer 201 is not directly attached to bootie 205, which may be "free floating" within upper 200. Bootie 205 is constructed of three layers, an outer bootie layer 202, a waterproof/breathable layer 203 and a bootie inner layer 204. As described above, in some examples, water can penetrate outer layer 201 and enter upper 200, which may cause undesirable side effects if not allowed to dry adequately, e.g., bacterial growth, dry-rot, and the like,

[0026] FIG. 3 conceptual diagram illustrating a side view of example upper 300. Upper 300 includes outside layer 301, which may be formed of an abrasion resistant and breathable material, and inner layer 302, which may be substantially waterproof and breathable. The top surface of outer layer 301 (the surface opposite that of inner layer 302) may form the outer surface of all or a portion of upper 300. In some examples, the bottom surface of inner layer (the surface opposite that of outer lay er 301 ) may form the inner surface of upper 300 as well as a portion of the inner surface of footwear including upper 300. In this manner, when such a construction is used to form all or a portion of upper 300 of footwear, such portions of upper 300 may be substantially waterproof and breathable.

[0027] As shown in FIG. 3, outer layer 301 may be directly attached to inner layer 302 over substantially the entire area of adjacent surfaces. In this manner, inner layer 302 may not be "free floating" within upper 300 but instead attached to the surface of outer layer 301 .

[0028] As described above, inner layer 302 may be formed of a substantially breathable and waterproof material. A material layer can be said to be substantially waterproof and breathable if water contacting its surface does not penetrate it, while at the same time, it is permeable to water vapor. Examples of waterproof/breathable layer material include Skyair® from Skymark Performance Films, Ltd., Mannaberg Way , Scunthorpe, North Lincolnshire, DN15 8XF, U.K., Gore-Tex® from W. L. Gore and Associates, 295 Blue Bail Road, Elkton, MD 21921, and SympaTex® from SYMPATEX TECHNOLOGIES GMBH,

FeringastraBe 7 A, 85744 Unterfohring, Germany. It is recognized that the waterproof/breathable layer materials described in this specification may themselves comprise multiple layers.

[0029 ] The breathability or water permeability of a material can be characterized by its permeance or Moisture Vapor Transmission Rate (MVTR). MVTR can be measured per ASTM E96. Water permeance is essential to comfortable footwear and clothing. Water permeance allows sweat generated by the body to escape maintaining a cool feeling for the wearer.

[0030] Outer layer 301 may be formed of any suitably breathable material. In some examples, the material of outer layer 301 may also be flexible, and/or wear resistant. Suitable outer layer material may be abrasion resistant providing, for example, a Taber abrasion resistance as measured per ASTM D 3884 with a total 2 kg weight and HI 8 abrasive wheels of greater than 100 cycles. Suitable outer layers may also be breathable is the sense of water permeance (MVTR) as measured per ASTM E-96BW (38°C/50%RH) with an M VTR greater than 200 grams per meter² per day.

[0031] As will be described further below with regard to FIG. 7, outer layer 301 can consist of SuperFabric® available from HDM, Inc., 570 Hale Avenue, Oakdale, MN, 55128. SuperFabric® may offer an abrasion resistant outer surface that is water repeliarst and breathable. SuperFabric® may be a locally hard, globally flexible fabric. SuperFabric© consists of cured polymer plates printed on a flexible base fabric. The plates may be separated from one another by gaps. The plates may provide resistance to wear, cut and puncture and the gap regions provide the flexibility of the base fabric in areas between the plates and air and water vapor permeability. In some examples, SuperFabric® materials can provide abrasion resistances of more than 1000 cycles per the test defined above.

[0032] FIG. 4 is a conceptual diagram illustrating a cross-sectional view of another example upper 400. Upper 400 may be substantially the same or similar to upper 300. As shown, upper 400 includes outer layer 401 and inner layer 402 directly attached to each other. However, unlike upper 300, upper 400 include a bonding layer 403 that adheres upper layer 401 to inner layer 402. In some examples, bonding layer 403 may be formed of a suitable web adhesive. In some examples, inner layer 402 is bonded to upper layer 401 via a lamination process by using a web adhesive. The web adhesive must maintain the breathable nature of the finished multilayer structure. An example web adhesive is Spunfab® from Spunfab, Ltd, 175 Muffin Lane, Cuyahoga Fails, OH, 44223. Spunfab® comes in a web form. When placed between material layers and heated under pressure, Spunfab® melts and bonds the layers together.

[0033] FIG. 5 is a conceptual diagram illustrating a cross-sectional view of another example upper 500. Upper 500 may be substantially the same or similar to that of uppers 300 and 400, For example, upper 500 includes outer layer 501 and intermediary layer 502, which may generally correspond to inner layers 302 and 402. However, upper 500 includes third layer 504, which may form the inner surface of upper 500.

[0034] In some examples, third layer 504 may be formed of a material that provides desired cushioning, thermal insulation and/or moisture wieking.

Cushioning may reduce the effect of impacts to the body by absorbing the energy of the impact over a longer time, reducing the force applied to the body. Thermal insulation may provide a barrier to body heat losses in cold climates. For example, an inner layer may be chosen to have a thermal insulation value of greater than 1 Clo (1 Go = 0.88 R, where R=l is 1 ft².°F.h/Btu) for a cool environment and a value of greater than 2 Clo for a cold environment or a value of 5 Clo for extreme cold conditions where there will be minimal physical activity. Moisture wicking materials may allow water or moisture generated by the body to be removed from the layer next to the body so that it can be evaporatively transported through the breathable layers. 4DG™ specialty fibers from Fiber Innovation Technology, Johnson City, TN, for example, provides much better wicking than cotton.

[0035] In some examples, the inner layer material can be a felt material, Chamude from Kolon Industries, Inc., Korea, or other microsuede materials, or other nonwoven materials. Acceptable nonwovens are made by Kem-Wove, 10530 Westlake Drive, Charlotte, NC 28273, and by National Nonwovens, P.O. Box 150, Easthampton, MA 01027.

[0036] FIG. 6 is a conceptual diagram illustrating a cross-sectional view of another example upper 600. Upper 600 may be substantially the same or similar to that of upper 500. For example, upper 600 includes outer layer 601, intermediary layer 602, and third layer 604. However, upper 600 includes bond layers 603 which adhere outer layer 601 to intermediary layer 602, and intermediary layer 602 to third layer 604. Bond layer 603 may be substantially the same or similar to that of bond layer 403 (FIG. 4).

[0037] FIG. 7 is a conceptual diagram illustrating a cross-sectional view of another example upper 700. Upper 700 may be substantially the same or similar to that of upper 600. Upper 700 includes outer layer 701, intermediary layer 702, and third layer 704. Bond layers 703 adhere outer layer 701 to intermediary layer 702, and intermediary layer 702, to third layer 704. In the example of FIG. 7, outer layer 701 includes base fabric 705 with a. plurality of cured polymer guard plates 706 attached to the top surface of base fabric 705.

[0038] As describe above, some examples of the disclosure, the breathable material forming the outer surface of an article, such as, e.g., upper 700 of footwear, may be formed of an advanced fabric material. One example advanced fabric material for forming outer layer 701 of upper 700 (or other outer layer of the example article described herein) may include SuperFabric®. SuperFabric® (commercially available from Higher Dimension Materials, Oakdale, MN) may be a family of fabric assemblies with a variety of unique features. In some examples, SuperFabric® may comprise a woven or non-woven base fabric material, e.g., base 705, onto which cured polymer guard plates, e.g., plates 706, have been attached, e.g., due to the partial penetration of the guard plates into the surface of the substrate before being fully cured. Examples of articles including a woven or non- woven base fabric material may include one or more examples described in United States Patent No. 6,962,739, entitled "Supple Penetration Resistant Fabric and Method of Making;" United States Patent No. 7,018,692, entitled "Penetration Resistant Fabric with Multiple Layer Guard Plate Assemblies and Method of Making the Same;" published United States Patent Application No. 2004/0192133, entitled "Abrasion and Heat Resistant Fabrics;" and published United States Patent Application No. 2009/014253, entitled "Supple Penetration Resistant Fabric and Method of Making." In some examples, SuperFabric© can be fabricated to resist water penetration, oil and other stains and remain flexible and breathable.

[0039] In some examples, SuperFabric!® may include guard plates 706 ranging in size and shape, and in overall geometrical arrangement. Guard plate sizes may range from approximately 20 to approximately 200 mils (approximately 0.508 mm to approximately 5.08 mm) with gap areas between guard plates ranging from approximately 5 to approximately 50 mils (approximately 0.127 mm to approximately 1 .27 mm), although sizes outside these ranges may be used in other examples. Guard plates 706 may range in thickness from approximately 5 to approximately 40 mils (approximately 0, 127 mm to approximately 1.02 mm), although thicknesses outside of this range may be used in other examples. In some examples, the guard plate material partially penetrates into the base fabric material and is therefore bonded or otherwise attached to the base fabric substrate. In some examples, the net result of the SuperFabric¹?) construction may be to provide a fabric with local hardness and abrasion resistance while maintaining other useful aspects of fabric such as flexibility, i.e., its ability to conform to arbitrary shapes, and vapor permeability of the base fabric material.

[0040] For a plurality of guard plates on the surface of a fabric substrate, the guard plates are separated from each other by gaps. The gaps may generally correspond to the portions of the fabric substrate that are not covered by guard plates, e.g., the uncovered surface of a fabric substrate between adjacent guard plates. When the guard plates are made of relatively hard abrasion protective materials that are substantially unflexible, a fabric substrate covered by guard plates with no gaps cannot be flexible. Accordingly, the gaps between guard plates may allow for flexibility and also, in many applications, for air and moisture permeability of a fabric substrate with guard plates. In some embodiments, the gap width between adjacent guard plates may be in the range of about 0, 1 mm to about 2,5mm.

[0041] In some examples, the size of guard plates may range from about 1 mm to about 5 mm (e.g., about 0.04 inches to about 0,2 inches), preferably from about I mm to about 3 mm (e.g., about 0.04 inches to about 0.1 inches) and thickness of guard plates may range from about 0.1 mm about 1 mm (e.g., about 0.004 inches to about 0.04 inches).

[0042] In some examples, guard plates may be constructed of a variety of composite materials, such as cured epoxies, polyurethanes, hybrid of cured epoxy-- poiyureihane, etc. composited with wear and strength enhancing materials such as silicon dioxide, aluminum oxide, titanium oxide and other filler materials such as pigments.

[0043] Suitable polymeric compositions for forming guard plates 14, 18 may include epoxy resin(s). In one embodiment, plates 14, 18 may be formed of heat- cured epoxy resin. Another example of an appropriate resin may be ultra-violet CUV) cured acrylate. Depending on the particular application, plates 14, 18 of fabric assembly 10, 16 may have a hardness between about 70 and about 100 Shore D, such as, e.g., between about 80 and about 95 Shore D. The hardness of plates 14, 18 may depend on a number of factors including, but not limited to, the polymeric resin composition used to form the plates and/or the process used to cure the polymeric resin composition after being deposited on the surface of flexible layer 12. In some embodiments the guard plates may comprise a thermoset epoxy. In some embodiments the guard plates may comprise inorganic filler particles. Thermally cured polymeric materials used for guard plates may be relatively hard and crack-resistant.

[0044] In some example, the polymer resin selected for use to form guard plates may ensure a strong bond between the guard plate and the fabric substrate base material. In some examples, a suitable polymer resin for construction of guard plates is a one-part heat-curable epoxy resin formulated to (i) provide abrasion resistance, (ii) be screen printable, (iii) be resistant to fracture, (iv) be bondable to the base material, and (v) have good shape definition during printing and curing of the guard plate material. Such resins may be readily formulated to meet these criteria and are available from, for example, Fielco Industries, Inc., Huntingdon Valley, PA, 19006, which has formulated resins that may meet the characteristics set forth in this paragraph and has given them the designations: TR21 and TR84. Other examples of suitable resin formulations are available from Hexion Specialty Chemicals, Columbus, OH 43215. For example, Hexion Starting Formulation 4019 may be a suitable thermosetting heat curable epoxy base resin formulation. In some examples, abrasion resistance provided by guard plates can be increased by adding small particles (e.g., 1 to 100 micrometers) of silica, alumina, silicon carbide, titanium oxide and the like to the resin.

[0045] In some embodiments, the use of low-wicking resin compositions to form guard plates. In some examples, a low-wicking polymeric resin composition may include one or more of an epoxy resin, phenolic resin, e.g., bakelite, polyester resin, polyurefhane resin, polyimide resin, aliyl resin, and the like. The polymeric resin may be a polymeric resin that irreversibly cross-links via a radiative process, such as, e.g., a thermal and/or UV process. In some examples, the polymeric resin formulation may include thermosetting resins and/or light turbo resins such as acrlyates, aryiate copolymers, styrenes, and hybrids. Example epoxy resins may include Epon 828, a di-functional glycidyl ether based on bisphenol A, (obtained from Hexion Corporation, Columbus, OH), Epon 161 , which is mulit-functional gyicidyl epoxy of a novolac oligomer (also available from Hexion), and/or Epon 160, which is a higher molecular weight analog of Epon 161 (also available from Hexion).

[0046] In some examples, the resin composition may include one or more additives. Additives may include one or more suitable curing agents, rheoiogy modifiers, such as, e.g., one or more thixotropes, surfactants, dispersants, diluents, air release agents, fillers, colorants (dyes), glass beads, and/or the like. In some examples, a rheological modifier may impart yield stress on the resin composition, and may cause the resin composition to exhibit gel-like properties. In some examples, the resin composition may include one or more appropriate rheological modifiers from available from Hexion Corp, Columbus, OH 43215, such as, e.g., Heioxy Modifier 67. In some examples, the resin composition may include BYK 525, 555, which are bubble releasing materials from BYK USA, Waliingford, CT; BYK-9010, which is a wetting/dispersing aid also from BYK; and/or A-187, which is an epoxy functional silane available from GE Silicones. Examples colorants may include TiO₂, burnt umber, FD&C blue #2, cardinal pthalo blue, and BK 5099. In some examples, appropriate fillers may be included in the resin composition, such as, e.g., Imsil A30 available from Unimin Specialty Minerals, Inc, New Canaan, CT 06840.

[0047] Example fabric types for a fabric substrate, such as outside layer 301 (FIG. 3) may include, but are not limited to, woven, non-woven, or knit fabrics having the ability to permit at least partial penetration of uncured resin used to form polymeric guard plates after deposition of the uncured polymer on fabric substrate. Fabric materials include without limitations cotton and cotton-polyester blends and other natural and man-made fabrics having similar properties. In one example, the flexible fabric substrate may include a tightly woven cotton-polyester blend. In such an example, this type of fabric may be used because resin compositions including heat-cured epoxy resins used to form guard plates have been found to seep into and bond well with this substrate fabric.

[0048] In some examples, an outer layer material may provide for at least some degree of water repellency. FIG, 8 is a conceptual diagram illustrating a cross sectional view of a water droplet 807 on the surface of an example outer layer 801. Outer layer 801 may be used to form one or more of the outer layers described herein (e.g., layers 301, 401, 501, 601, and 701). As shown, outer layer 801 includes base fabric 804 and cured, epoxy based guard plates 806 on the top surface of base fabric. As shown in the magnified view, water drop 807, with a surface energy of approximately 73 dynes/cm, cannot penetrate to the base fabric 804 due to the difference in the surface tension of the water compared to that of the epoxy, e.g., with a surface energy of about 45 to 50 dynes/cm. [0049] In some examples, the water repellency of outer layer 801 is due to epoxy guard plates printed on a fabric surface with narrow guard plates. Since the surface energy of the epoxy is lower than that of water, water does not penetrate into narrow gap area between the plates unless it is forced in by high pressure. The gap width can be selected to optimize the water repellency.

[0050] In addition, the base fabric 804 may be treated with water repellent materials. In this case, since the guard plates protrude above the fabric surface, the water repellent treatment material is not readily worn away during use.

[0051] An example of the behavior of a water drop on the surface of outer layer 801 is shown in FIG. 8. This figure shows the drop sitting on the tops of several neighboring guard plates but because of the contact angle of the water with the epoxy of the guard plates it does not penetrate the gap regions to contact the base fabric,

[0052] The multilayer constructions of described in this disclosure may be made using any suitable technique. In one example, the following process may be used. Rolls of the two materials to be joined together are placed such that a roll of thermoplastic non-woven material is provided to fit between them. The resulting sandwich of top layer, thermoplastic layer and bottom layer is then fed through a laminator which heats the results sufficiently to melt the thermoplastic material and compresses the layers together. If a third layer is to be bonded to the first two layers, the process can be repeated. In the case of adding a third layer, it may be desirable to process the first two layers at a somewhat lower temperature and/or pressure.

Claims

CLAIMS:

1. Footwear comprising:

a sole; and

an upper attached to the sole and including an outer surface, wherein the upper comprises a first layer including a top surface defining at least a portion of the outer surface of the upper, and a second layer including a top surface directly attached to a bottom surface of first layer, wherein the second layer is substantially waterproof and breathable,

2. The footwear of claim 1 , wherein the upper further comprises a third layer including a top surface direc tly attached to a bottom surface of the second layer, wherein a bottom surface of the third layer defines an inner surface of the upper.

3. The footwear of claim 2, wherein the inner surface of the upper defines the inner surface of at least a portion of the footwear,

4. The footwear of claim 2, wherein the third layer comprises at least one of a water wicking layer, a thermally insulating layer, and a comfort layer.

5. The footwear of claim 2, wherein the third layer comprises at least one of felt, wool fleece, synthetic fleece or other non-woven material.

6. The footwear of claim 1, further comprising a plurality of non-overlapping, cured polymer guard plates attached to the top surface of the first layer.

7. The footwear of claim 1, further comprising a thermoplastic web adhesive attaching the first layer to the second layer.

8. The footwear of claim 1 , wherein the first layer comprises at least one of a woven fabric with printed plates each surrounded by a gap area, a non-woven fabric with printed guard plates each surrounded by a gap area, a woven nylon fabric, a woven ultra-high molecular weight polyethylene fabric.

9. The footwear of claim 1, wherein the second layer comprises at least one of polytetrafluoroethylene based waterproof/breathable material, a polyether-ester based waterproof material, a non- woven hydrophobic fiber yarn material

10. The footwear of claim 1 , wherein the footwear comprises a boot or a shoe.

11. An article of handwear comprising:

a first layer including a top surface defining at least a portion of an outer surface of the handwear; and

a second layer including a top surface directly attached to a bottom surface of first layer, wherein the second layer is substantially waterproof and breathable.

12. The handwear of claim 11 , further comprising a third layer including a top surface directly attached to a bottom surface of the second layer, wherein a bottom surface of the third layers defines an inner surface of the handwear.

13. The handwear of claim 12, wherein the third layer comprises at least one of a water wicking lay er, a thermally insulating layer, and a comfort layer.

14. The handwear of claim 12, wherein the third layer comprises felt, woof fleece, synthetic fleece or other non-woven material.

15. The handwear of claim 11 , further comprising a plurality of non- overlapping, cured polymer guard plates attached to the top surface of the first layer.

16. The handwear of claim 1 1 , further comprising a thermoplastic web adhesive attaching the first layer to the second layer.

17. The handwear of claim 11 , wherein the first layer comprises at least one of a woven fabric with printed plates each surrounded by a gap area, a non-woven fabric with printed guard plates each surrounded by a gap area, a woven nylon fabric, a woven ultra-high molecular weight polyethylene fabric.

18. The handwear of claim 1 1 , wherein the second layer comprises at least one of polytetrafiuoroethylene based waterproof/breathable material, a poly ether-ester based waterproof material, a non- woven hydrophobic fiber yarn material.

19. The handwear of claim 1 1, wherein the handwear comprises a glove or a mitten.

20. An article of headwear comprising:

a first layer including a top surface defining at least a portion of an outer surface of the headwear; and

21 . The headwear of claim 20, further comprising a third layer including a top surface directly attached to a bottom surface of the second layer, wherein a bottom surface of the third layers defines an inner surface of the headwear.

22. The headwear of claim 21, wherein the third layer comprises at least one of a water wicking layer, a thermally insulating layer, and a comfort layer.

23. The headwear of claim 21 , wherein the third layer comprises felt, wool fleece, synthetic fleece or other non-woven material

24. The headwear of claim 20, further comprising a plurality of non- overlapping, cured polymer guard plates attached to the top surface of the first layer.

25. The headwear of claim 20, further comprising a thermoplastic web adhesive attaching the first layer to the second layer.

26. The headwear of claim 20, wherein the firs t layer comprises at least one of a woven fabric with printed plates each surrounded by a gap area, a non-woven fabric with printed guard plates each surrounded by a gap area, a woven nylon fabric, a woven ultra-high molecular weight polyethylene fabric.

27. The headwear of claim 20, wherein the second layer comprises at least one of polyteirafluoroethylene based waterproof/breathable material, a polyether-ester based waterproof material, a non-woven hydrophobic fiber yam material,

28. The headwear of claim 20, wherein the headwear comprises stocking cap.

29. An article of outerwear comprising:

a first layer including a top surface defining at least a portion of an outer surface of the outerwear; and

30. The outerwear of claim 29, further comprising a third layer including a top surface directly attached to a bottom surface of the second layer, wherein a bottom surface of the third layers defines an inner surface of the headwear.

.

31 . The outerwear of claim .30, wherein the third layer comprises at least one of a water wicking layer, a thermally insulating layer, and a comfort layer.

32. The outerwear of claim 30, wherein the third layer comprises felt, wool fleece, synthetic fleece or other non-woven material.

33. The outeiwear of claim 29, further comprising a plurality of non- overlapping, cured polymer guard plates attached to the top surface of the first layer.

34. The outerwear of claim 29, further comprising a thermoplastic web adhesive attaching the first layer to the second layer.

35. The outerwear of claim 29, wherein the first layer comprises at least one of a woven fabric with printed plates each surrounded by a gap area, a non-woven fabric with printed guard plates each surrounded by a gap area, a woven nylon fabric, a woven ultra-high molecular weight polyethylene fabric.

.

36. The outerwear of claim 29, wherein the second layer comprises at least one of polytetrafluoroethylene based waterproo£/breathable material, a poly ether-ester based waterproof material, a non- woven hydrophobic fiber yarn material

37. The outerwear of claim 29, wherein the headwear comprises a jacket.