Hybrid footwear liner

Abstract

A flexible boot liner ( 100 ) having a flexible upper ( 101 ) and a semi-rigid sole ( 140 ) that provides durability, walkability, and a dimensionally stable fit within a boot ( 90 ). The sole includes a lasting board ( 160 ) that is fixedly attached to the upper and a nonskid outsole ( 142 ). Secondary cushioning devices such as an air cell ( 144 ) may also be incorporated into the sole. The upper is of hybrid construction including a relatively flexible bottom portion ( 120 ) thermoformed from an ethylene vinyl acetate foam that covers the foot and the malleoli of the user, and a semi-rigid upper portion ( 110 ) that wraps about the lower leg of the user. A strap assembly ( 150 ) is provided to secure the liner about the foot of the user.

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:  
     
         1 . A boot liner comprising: 
 an upper having a semi-rigid top portion that is shaped to wrap around part of a user's lower leg and a non-rigid bottom portion, the non-rigid bottom portion being shaped to cover the user's foot and malleoli, the bottom portion having a lower edge; and    a semi-rigid sole attached to the lower edge of the bottom portion of the upper.    
     
     
         2 . The boot liner of  claim 1 , wherein the top portion of the upper is attached to the bottom portion of the upper with stitches.  
     
     
         3 . The boot liner of  claim 1 , wherein the non-rigid bottom portion comprises a thermoformed ethylene vinyl acetate foam.  
     
     
         4 . The boot liner of  claim 3 , wherein the semi-rigid sole comprises a lasting board and an outsole fixedly attached to the lasting board.  
     
     
         5 . The boot liner of  claim 4 , wherein the outsole comprises a second ethylene vinyl acetate material that is more rigid than the ethylene vinyl acetate foam of the bottom portion of the upper.  
     
     
         6 . The boot liner of  claim 4 , wherein the semi-rigid top portion of the upper comprises a protective outer layer, a stiffener bonded to the protective outer layer, a cushioning layer, and an inner lining stitchedly attached to the protective outer layer.  
     
     
         7 . The boot liner of  claim 4 , wherein the lasting board is attached to the circumferential edge of the bottom portion of the upper with stitches.  
     
     
         8 . The boot liner of  claim 4 , wherein the outsole further comprises a secondary cushioning member disposed in a heel portion of the outsole.  
     
     
         9 . The boot liner of  claim 8 , wherein the secondary cushioning member is an air cell.  
     
     
         10 . The boot liner of  claim 3 , wherein the upper defines a vamp opening and further comprising a plurality of lace keepers attached to the semi-rigid top portion of the upper and a lace slidably disposed in the lace keepers.  
     
     
         11 . A boot liner removably insertable into a snowboard boot, the boot liner comprising: 
 an upper having a flexible foot covering portion and a semi-rigid ankle support portion attached to an upper edge of the foot covering portion, the foot covering portion having a lower edge; and    a sole having a semi-rigid lasting board attached to the lower edge of the foot covering portion of the upper, and a nonskid outsole affixed to the lasting board and the foot covering portion of the upper.    
     
     
         12 . The boot liner of  claim 11 , wherein the semi-rigid ankle support portion of the upper is attached to the flexible foot-covering portion of the upper with stitches.  
     
     
         13 . The boot liner of  claim 11 , wherein the flexible foot-covering portion comprises a thermoformed ethylene vinyl acetate foam.  
     
     
         14 . The boot liner of  claim 13 , wherein the outsole comprises a second ethylene vinyl acetate material that is more rigid than the ethylene vinyl acetate foam of the bottom portion of the upper.  
     
     
         15 . The boot liner of  claim 13 , wherein the semi-rigid ankle support portion of the upper comprises a protective outer layer, a stiffener bonded to the protective outer layer, a cushioning layer and an inner lining stitchedly attached to the protective outer layer.  
     
     
         16 . The boot liner of  claim 13 , wherein the lasting board is attached to the circumferential edge of the bottom portion of the upper with stitches.  
     
     
         17 . The boot liner of  claim 11 , wherein the outsole further comprises a secondary cushioning member disposed in a heel portion of the outsole.  
     
     
         18 . The boot liner of  claim 17 , wherein the secondary cushioning member is an air cell.  
     
     
         19 . The boot liner of  claim 13 , wherein the upper defines a vamp opening, and further comprising a plurality of lace keepers attached to the semi-rigid top portion of the upper and a lace slidably disposed in the lace keepers.  
     
     
         20 . A boot liner comprising: 
 a hybrid upper assembly comprising a non-rigid foot portion having a longitudinal slit, and a semi-rigid ankle support portion fixedly attached to the foot portion, the leg portion having a generally vertical slit, wherein the longitudinal slit and the vertical slit cooperatively define a vamp opening in the hybrid upper assembly, the hybrid upper assembly further comprising an elongate tongue that is fixedly attached to the non-rigid foot portion and extends through the length of the vamp opening; and    a semi-rigid sole attached to the upper assembly having a nonskid outsole.    
     
     
         21 . The boot liner of  claim 20 , wherein the non-rigid foot portion comprises a thermoformed ethylene vinyl acetate foam.  
     
     
         22 . The boot liner of  claim 21 , wherein the semi-rigid ankle support portion of the upper comprises a stitched construction having a protective outer layer, a semi-rigid stiffener, a cushioning layer, and an inner lining.  
     
     
         23 . The boot liner of  claim 21 , wherein the outsole comprises a second ethylene vinyl acetate material that is more rigid than the ethylene vinyl acetate foam of the bottom portion of the upper.  
     
     
         24 . The boot liner of  claim 21 , wherein the sole further comprises a lasting board that is fixedly attached to the non-rigid foot portion of the upper.  
     
     
         25 . The boot liner of  claim 24 , wherein the sole further comprises a secondary cushioning member disposed in a heel portion of the outsole.  
     
     
         26 . The boot liner of  claim 25 , wherein the secondary cushioning member is an air cell.