Waterproof footwear and method of making the same

Abstract

A waterproof footwear assembly comprises a sole assembly and an upper. The upper has an outer layer with a plurality of panels stitched together. A continuous layer of waterproof material is fixed to the outer layer's inner surface and extends over the stitched seams. The waterproof material defines a seamless waterproof barrier covering substantially the entire outer layer. The waterproof material's peripheral shape substantially matches the outer layer's peripheral shape. The layer of waterproof material is joined to the outer layer when in the outer layer is flat. The upper has a second configuration wherein the waterproof laminate is formed from the first configuration to a three-dimensional shape that defines the interior area configured to receive the foot of the wearer.

1 . A waterproof footwear assembly, comprising:
 a sole assembly; and   an upper fixed to the sole assembly, the upper comprising an outer layer having a plurality of panels stitched together, wherein stitched interconnections between the panels define water-permeable, stitched seams, the upper having a continuous layer of waterproof material fixed to an inner surface of the outer layer and extending over the stitched seams, wherein the waterproof material defines a seamless waterproof barrier covering substantially the entire outer layer, and the upper having an interior liner positioned so the seamless waterproof barrier is intermediate the interior liner and the outer layer.   
     
     
         2 . The footwear assembly of  claim 1  wherein the panels are made of at least one of leather and a fabric material. 
     
     
         3 . The footwear assembly of  claim 1  wherein the waterproof material is impermeable to liquid water and is permeable to water vapor. 
     
     
         4 . The footwear assembly of  claim 1  wherein the outer layer is an outermost exterior layer of the upper. 
     
     
         5 . The footwear assembly of  claim 1  wherein the outer layer has a first peripheral shape, and the waterproof material has a second peripheral shape that substantially matches the first peripheral shape. 
     
     
         6 . A waterproof upper for footwear having a sole assembly and having an interior area that receives a foot of a wearer, comprising:
 an upper having a plurality of panels stitched together to define an outer layer, wherein stitched interconnections between adjacent panels are water-permeable stitched seams, the upper having a continuous layer of waterproof material fixed to an inner surface of the outer layer and extending over the stitched seams, wherein the layer of waterproof material defines a seamless waterproof barrier covering substantially the entire outer layer to form a substantially waterproof laminate;   wherein the upper has a first configuration with the outer layer being substantially flat defining a two-dimensional plane, and wherein the layer of waterproof material is joined to the outer layer when in the first configuration to form the waterproof laminate; and   wherein the upper has a second configuration wherein the waterproof laminate is formed from the first configuration to a three-dimensional shape that defines the interior area configured to receive the foot of the wearer.   
     
     
         7 . The waterproof upper of  claim 6  wherein the panels are made of at least one of leather and a fabric material. 
     
     
         8 . The waterproof upper of  claim 6  wherein the layer of waterproof material is impermeable to liquid water and is permeable to water vapor. 
     
     
         9 . The waterproof upper of  claim 6  wherein the outer layer is an outermost exterior layer of the upper. 
     
     
         10 . The waterproof upper of  claim 6  wherein the outer layer has a first peripheral shape, and the layer of waterproof material has a second peripheral shape that substantially matches the first peripheral shape. 
     
     
         11 . The waterproof upper of  claim 6 , further comprising an interior liner positioned so the seamless waterproof barrier is intermediate the interior liner and the outer layer. 
     
     
         12 . A method of making a footwear assembly for a foot of a wearer, comprising:
 stitching together a plurality of panels in a substantially flat planar arrangement to define an outer layer for an upper, wherein stitched interconnections between panels define stitched seams, the outer layer having a first peripheral shape;   attaching a substantially continuous layer of waterproof material to an inner surface of the outer layer when the outer layer is in the substantially flat planar arrangement, wherein the continuous layer of waterproof material extends over the stitched seams and defines a seamless waterproof barrier covering substantially the entire outer layer to form a substantially waterproof laminate in a flat configuration;   shaping the waterproof upper laminate from the flat configuration to a three-dimensional configuration that defines an interior area shaped to receive the foot of the wearer; and   attaching the waterproof upper laminate when in the three-dimensional configuration to a sole assembly.   
     
     
         13 . The method of  claim 12  wherein the stitching together a plurality of panels comprises stitching together a plurality of panels made of at least one of leather and a fabric material. 
     
     
         14 . The method of  claim 12  wherein attaching a substantially continuous layer of waterproof material comprises attaching a substantially continuous layer of waterproof material that is impermeable to liquid water and is permeable to water vapor. 
     
     
         15 . The method of  claim 12 , further comprising altering the layer of waterproof material to form the second peripheral shape before the layer of waterproof material is attached to the outer layer. 
     
     
         16 . The method of  claim 12 , further comprising cutting the layer of waterproof material into the second peripheral shape before the layer of waterproof material is attached to the outer layer. 
     
     
         17 . The method of  claim 12 , further comprising attaching the layer of waterproof material to the outer layer and then altering the layer of waterproof material to form the second peripheral shape to match first peripheral shape. 
     
     
         18 . The method of  claim 12 , further comprising attaching the layer of waterproof material to the outer layer and then trimming the outer layer and the layer of waterproof material substantially simultaneously to the first and second peripheral shapes. 
     
     
         19 . The method of  claim 12  wherein shaping the waterproof upper laminate comprises shaping the waterproof upper laminate into a substantially finished shape of the upper for the footwear assembly. 
     
     
         20 . The method of  claim 12 , further comprising attaching an interior liner to the waterproof upper laminate, wherein the interior liner is positioned with the layer of waterproof material intermediate the interior liner and the outer layer.