Waterproof shoe with size and shape-adjustable bootie

Abstract

A footwear system is disclosed for protecting a user's foot from water or other liquid substances. In one embodiment, the footwear comprises a shoe having an upper, a seamless sock-shaped bootie, an inner lining, and a sole engaged to the upper. The seamless bootie may be composed of waterproof material and include at least one ribbed portion adapted to expand to allow the bootie to conform to the size of the inner lining. The bootie may be arranged between the upper and inner lining. Methods of manufacturing the aforementioned footwear system are also disclosed.

1 . A shoe comprising:
 an upper having an exterior surface and an interior surface;   a sole having an exterior surface for contacting the ground and an interior surface, the sole being secured to the upper, wherein the interior surface of the upper and the interior surface of the sole define a cavity for receiving a wearer's foot;   an inner lining arranged within the cavity; and   a seamless bootie formed of waterproof material in a sock shape, the seamless bootie overlying the inner lining within the cavity and including one or more ribbed portions adapted to expand to allow the bootie to conform to the size of the inner lining, the seamless bootie being configured to shield a wearer's foot from contact with water or another liquid.   
     
     
         2 . The shoe according to  claim 1 , wherein the seamless bootie entirely covers the inner lining. 
     
     
         3 . The shoe according to  claim 1 , wherein the inner lining is composed of pieces of fabric that are stitched together. 
     
     
         4 . The shoe according to  claim 1 , wherein the waterproof material of the seamless bootie is selected from the group consisting of latex, polyurethane, rubber, Ethyl Vinyl Acetate, or any combination of thereof. 
     
     
         5 . The shoe according to  claim 1 , wherein the bootie includes multiple ribbed portions configured to expand so that the bootie conforms to the size of the inner lining, at least some of the ribbed portions being arranged transverse to a longitudinal axis of the bootie. 
     
     
         6 . The shoe according to  claim 1 , wherein the bootie includes a toe region with a perimeter, and the one or more ribbed portions extend along a portion of the perimeter of the toe region. 
     
     
         7 . A method of manufacturing a shoe, the method comprising:
 providing an upper, an inner lining, and a foot-shaped mold having an outer surface, the foot-shaped mold including at least one ribbed portion on its outer surface;   applying a waterproof material to the outer surface of the foot-shaped mold, thereby creating a seamless functional layer with at least one ribbed portion corresponding to the at least one ribbed portion on the outer surface of the foot-shaped mold, the seamless functional layer being in the form a seamless, sock-shaped bootie;   placing the seamless functional layer over the inner lining, such that the at least one rib expands to conform the seamless bootie to the size of the inner lining;   placing the upper over the seamless functional layer; and   affixing a sole to the upper.   
     
     
         8 . The method according to  claim 7 , wherein the upper is stitched to a foot bed that is interposed between the sole and the upper. 
     
     
         9 . The method according to  claim 7 , wherein the foot-shaped mold includes multiple ribbed portions on its outer surface, at least some of the ribbed portions being arranged transverse to a longitudinal axis of the mold. 
     
     
         10 . The method according to  claim 9 , wherein the foot-shaped mold includes a toe region with a perimeter, and at least one of the ribbed portions extends along a portion of the perimeter of the toe region. 
     
     
         12 . The method according to  claim 7 , further comprising the step of immersing the foot-shaped mold in a body of waterproof material to cover a substantial amount of the mold's outer surface with the waterproof material. 
     
     
         13 . The method according to  claim 12 , further comprising the steps of removing the foot-shaped mold from the body of waterproof material, and heating the foot-shaped mold and waterproof material to cure the waterproof material. 
     
     
         14 . The method according to  claim 7 , wherein foot-shaped mold includes one or more ribs at a heel portion of the mold. 
     
     
         15 . An article for waterproofing footwear comprising a seamless, sock-shaped bootie formed of waterproof material, the seamless bootie having at least one rib extending transversely from a surface of the bootie and being configured for insertion over an inner lining of a shoe, wherein the bootie is adapted to conform to the size of the inner lining via the at least one rib. 
     
     
         16 . The article according to  claim 15 , wherein the seamless bootie includes multiple ribs. 
     
     
         17 . The article according to  claim 16 , wherein the seamless bootie includes a toe region with a perimeter, and at least one of the ribs extends along a portion of the perimeter of the toe region. 
     
     
         18 . The article according to  claim 15 , wherein at least one rib is placed vertically along an instep area of the bootie. 
     
     
         19 . The article according to  claim 18 , wherein at least one rib is placed transverse in relation to the vertical rib on the bootie. 
     
     
         20 . The article according to  claim 15 , wherein the waterproof material of the seamless bootie is selected from the group consisting of latex, polyurethane, rubber, Ethyl Vinyl Acetate, or any combination of thereof.