Self sealing system for waterproof coupling of uppers to outsoles

Abstract

Disclosed herein are waterproof footwear, footwear that include a waterproofed stitch line, and methods of waterproofing a stitch line in footwear. Methods are provided for waterproofing a seam in an article of footwear by positioning co-extruded top-welt/rubber tape comprising a rubber tape layer and a top-welt layer between the layers to be stitched, and stitching the seam so that it passes through the co-extruded top-welt/rubber tape.

What is claimed is: 
     
         1 . A waterproof footwear seam comprising:
 a shell outsole;   an upper;   a co-extruded top-welt/rubber tape comprising a rubber tape layer and a top-welt layer, wherein the co-extruded top-welt/rubber tape is positioned between the shell outsole and the upper such that the rubber tape layer of the co-extruded top-welt/rubber tape is positioned between the shell outsole and the top-welt layer of the co-extruded top-welt/rubber tape; and   at least one line of stitching passing through the shell outsole, the co-extruded top-welt/rubber tape, and the upper.   
     
     
         2 . The waterproof footwear seam of claim of  claim 1 , wherein the rubber tape layer comprises synthetic rubber, natural rubber, or a rubber composite. 
     
     
         3 . The waterproof footwear seam of claim of  claim 1 , wherein the rubber tape layer comprises a polymer. 
     
     
         4 . The waterproof footwear seam of  claim 1 , wherein the upper comprises leather. 
     
     
         5 . An article of footwear comprising the waterproof footwear seam of  claim 1 . 
     
     
         6 . A method of waterproofing a footwear seam comprising:
 positioning a co-extruded top-welt/rubber tape comprising a rubber tape layer and a top-welt layer along an upper edge of a shell outsole, such that the rubber tape layer is positioned between the top-welt layer and an outer surface of the upper shell;   positioning a footwear upper such that the shell outsole and the footwear upper overlap with the co-extruded top-welt/rubber tape positioned therebetween;   forming a seam between the shell outsole and the footwear upper, wherein the seam passes through the co-extruded top-welt/rubber tape; and   at least partially curing the rubber tape layer.   
     
     
         7 . The method of  claim 6 , further comprising forming the co-extruded top-welt/rubber tape. 
     
     
         8 . The method of  claim 6 , further comprising partially vulcanizing the rubber tape layer. 
     
     
         9 . The method of  claim 8 , wherein the rubber tape layer is partially vulcanized prior to positioning the co-extruded top-welt/rubber tape along the upper edge of the shell outsole. 
     
     
         10 . The method of  claim 8 , wherein the rubber tape layer is partially vulcanized after the co-extruded top-welt/rubber tape is positioned along the upper edge of the shell outsole. 
     
     
         11 . The method of  claim 6 , wherein the rubber tape layer comprises synthetic rubber, natural rubber, or a rubber composite. 
     
     
         12 . The method of  claim 6 , wherein the rubber tape layer comprises a polymer. 
     
     
         13 . The method of  claim 6 , wherein forming the seam comprises stitching the seam. 
     
     
         14 . The method of  claim 6 , wherein positioning the co-extruded top-welt/rubber tape along the upper edge of the shell outsole comprises coupling the co-extruded top-welt/rubber tape to the shell outsole with adhesive. 
     
     
         15 . The method of  claim 6 , wherein the footwear upper comprises leather. 
     
     
         16 . The method of  claim 6 , wherein at least partially curing the rubber tape layer comprises heating the rubber tape layer. 
     
     
         17 . The method of  claim 16 , wherein heating the rubber tape layer comprises heating the rubber tape layer to a temperature of about 50-100° C. 
     
     
         18 . The method of  claim 16 , wherein heating the rubber tape layer comprises heating the rubber tape layer to a temperature of about 70-85° C. for about 5-10 minutes. 
     
     
         19 . An article of footwear made by the method of  claim 6 .