Moldable footwear

Abstract

Moldable products which conform to the size and shape of a particular object and methods of forming the same are provided. The products are made from a material selected from the group consisting of natural leathers, synthetic leathers, and mixtures thereof. The products and methods of the invention are particularly useful for manufacturing custom-fit footwear at a reasonable price. Methods in accordance with the invention comprise molding the starting material on and around a foot, wetting the material with a mixture comprising a leather stiffening or hardening agent, and drying the wetted material while still on the foot.

I claim:  
     
         1 . A method of forming leatherwear substantially molded to a body part comprising the steps of: 
 applying a mixture to the surface of a starting material selected from the group consisting of natural leathers, synthetic leathers, and mixtures thereof, said mixture comprising a stiffening agent;    placing said mixture-covered material adjacent at least a portion of said body part to form a shaped material; and    drying said shaped material to at least partially stiffen said shaped material.    
     
     
         2 . The method of    claim 1   , wherein said body part is a foot.  
     
     
         3 . The method of    claim 1   , wherein said starting material is a natural leather.  
     
     
         4 . The method of    claim 3   , wherein said natural leather contains tannin cross-linked polypeptide chains.  
     
     
         5 . The method of    claim 3   , wherein said leather is a vegetable-tanned leather.  
     
     
         6 . The method of    claim 3   , wherein said stiffening agent is an acrylic.  
     
     
         7 . The method of    claim 1   , wherein the product resulting from said drying step has an ASTM D2209-90 tensile strength of at least about 100 psi.  
     
     
         8 . The method of    claim 1   , wherein said drying step comprises subjecting said shaped material to hot air having a temperature of from about 150°-250° F.  
     
     
         9 . The method of    claim 8   , wherein said drying step is carried out for a time period of from about 10-30 minutes.  
     
     
         10 . The method of    claim 1   , wherein said stiffening agent is present in said mixture at a level of from about 10-40% by volume, based on the total volume of the mixture being taken as 100% by volume.  
     
     
         11 . The method of    claim 1   , said mixture further comprising a leather conditioner.  
     
     
         12 . The method of    claim 2   , wherein said placing step further comprises forming said mixture-covered material into substantially the same shape as said foot.  
     
     
         13 . The method of    claim 12   , wherein the product resulting from said drying step substantially retains said foot shape.  
     
     
         14 . The method of    claim 1   , further including the step of compressing said shaped material resulting from said placing step prior to said drying step, said compressing step comprising applying a pressure of from about 8-15 psi to said shaped material.  
     
     
         15 . The method of    claim 1   , wherein the product resulting from said drying step has an ASTM D1815-96 moisture absorption of at least about 62%.  
     
     
         16 . The method of    claim 1   , wherein said placing step comprises placing inner and outer layers of said mixture-covered material adjacent at least a portion of said body part, said inner and outer layers having respective thicknesses and said inner layer being a liner and having a thickness that is less than said outer layer thickness.  
     
     
         17 . A molded leather product in accordance with the method of    claim 1   .  
     
     
         18 . The product of    claim 17   , wherein said starting material is a natural leather.  
     
     
         19 . The product of    claim 18   , wherein said natural leather contains tannin cross-linked polypeptide chains.  
     
     
         20 . The product of    claim 18   , wherein said natural leather is a vegetable-tanned leather.  
     
     
         21 . The product of    claim 17   , said product having an ASTM D2209-90 tensile strength of at least about 1100 psi.  
     
     
         22 . The product of    claim 17   , wherein said product is a shoe molded to the size and shape of a foot.  
     
     
         23 . The product of    claim 17   , said product having an ASTM D1815-96 moisture absorption of at least about 62%.  
     
     
         24 . A molded leather, lined product in accordance with the method of    claim 16   .