Conformable Booties, Shoe Inserts, and Footwear Assemblies Made Therewith, and Waterproof Breathable Socks

Abstract

Waterproof, breathable socks, booties, shoe inserts, and footwear assemblies containing the shoe inserts are provided. The booties and shoe inserts include a laminate of a seamless ePTFE membrane and at least one textile. The bootie is conformable over a range of sizes and shoe shapes, and may be shaped to fit numerous sizes and shapes of asymmetrical shoe lasts. The bootie may shrink to fit, or, alternatively, be stretched to fit, an asymmetrical last having a desired size to form a shoe insert. Such a conformable bootie eliminates the need to have multiple sizes of shoe inserts correlating to particular shoe sizes. In embodiments where the ePTFE is seamless and continuous, the shoe insert eliminates the need for a waterproof seam tape, which is conventionally used to make shoe inserts waterproof. Methods of forming the socks, booties, and shoe inserts are also provided.

What is claimed is: 
     
         1 . A bootie comprising:
 a seamless conformed expanded polytetrafluoroethylene (ePTFE) membrane.   
     
     
         2 . The bootie of  claim 1 , wherein said ePTFE membrane has at least one additional layer thereon. 
     
     
         3 . The bootie of  claim 2 , wherein said at least one additional layer is an abrasion resistant coating. 
     
     
         4 . The bootie of  claim 3 , wherein said abrasion resistant coating is present on at least one of a first side of said ePTFE membrane and a second side of said ePTFE membrane. 
     
     
         5 . The bootie of  claim 1 , wherein said ePTFE membrane has a thickness variation from a first location in said bootie to a second location in said bootie of at least 1,2:1. 
     
     
         6 . The bootie of  claim 1 , wherein said ePTFE membrane is amorphously locked. 
     
     
         7 . The bootie of  claim 1 , wherein said ePTFE membrane has a density greater than or equal to about 2.0 g/m 2 . 
     
     
         8 . The bootie of  claim 1 , wherein said bootie is breathable over its entirety. 
     
     
         9 . The bootie of  claim 1 , wherein said bootie has a generally symmetrical shape. 
     
     
         10 . The bootie of  claim 1 , wherein said bootie is breathable. 
     
     
         11 . The bootie of  claim 1 , wherein said bootie is waterproof and breathable. 
     
     
         12 . The bootie of  claim 1 , further comprising a polymeric overlay on said ePTFE membrane. 
     
     
         13 . The bootie of  claim 1 , further comprising at least one second component attached to said ePTFE membrane or a portion thereof. 
     
     
         14 . The bootie of  claim 13 , wherein said at least one second component creates regions in said bootie, at least one of said regions possessing a function or feature different from another said region. 
     
     
         15 . The bootie of  claim 13 , wherein said at least one second component is selected from the group consisting of a textile, a laminate, a textile laminate, a polymer membrane and a second ePTFE membrane different from said conformed ePTFE membrane. 
     
     
         16 . The bootie of  claim 15 , wherein said laminate and said textile laminate include a polymer membrane. 
     
     
         17 . The bootie of  claim 16 , wherein said polymer membrane is a fluoropolymer membrane. 
     
     
         18 . The bootie of  claim 17 , wherein said fluoropolymer membrane is a polytetrafluoroethylene membrane or an expanded polytetrafluoroethylene membrane. 
     
     
         19 . The bootie of  claim 1 , wherein said ePTFE membrane has at least one additional layer thereon. 
     
     
         20 . The bootie of  claim 19 , wherein said at least one additional layer is an abrasion resistant coating. 
     
     
         21 . The bootie of  claim 20 , wherein said abrasion resistant coating is present on at least one of a first side and a second side of said ePTFE membrane. 
     
     
         22 . The bootie of  claim 18 , wherein said at least one additional layer is an oleophobic coating. 
     
     
         23 . A bootie comprising:
 a seamless conformed expanded polytetrafluoroethylene (ePTFE) membrane having a first side and a second side; and   a textile joined to said first side of said ePTFE membrane,   wherein said seamless conformed ePTFE membrane and said textile form a laminate.   
     
     
         24 . The bootie of  claim 23 , wherein said textile has at least some elastic properties. 
     
     
         25 . The bootie of  claim 23 , wherein said textile is elastic. 
     
     
         26 . The bootie of  claim 23 , wherein said textile is selected from the group consisting of a knitted textile tube, a woven textile tube, a tubular sock and a formed sock. 
     
     
         27 . The bootie of  claim 26  wherein said textile is a sock having a heel portion, a toe portion, and a body portion positioned therebetween, and
 wherein at least one of said heel portion and said toe portion is reinforced. 
 
     
     
         28 . The bootie of  claim 27 , wherein said sock is at least partially elastic. 
     
     
         29 . The bootie of  claim 23 , wherein said bootie is self-supporting. 
     
     
         30 . The bootie of  claim 23 , wherein said ePTFE membrane has a thickness variation from a first location in said bootie to a second location in said bootie of at least 1.2:1. 
     
     
         31 . The bootie of  claim 23 , wherein at least one of said ePTFE membrane and said textile has at least one additional layer thereon. 
     
     
         32 . The bootie of  claim 31 , wherein said at least one additional layer is an abrasion resistant coating. 
     
     
         33 . The bootie of  claim 32 , wherein said abrasion resistant coating is present on at least one of said first side and said second side of said ePTFE membrane. 
     
     
         34 . The bootie of  claim 31 , wherein said at least one additional layer is an oleophobic coating. 
     
     
         35 . The bootie of  claim 23 , further comprising an adhesive positioned on at least one of said ePTFE membrane and said textile. 
     
     
         36 . The bootie of  claim 35 , wherein said adhesive is a discontinuous adhesive. 
     
     
         37 . The bootie of  claim 35 , wherein said adhesive is a continuous breathable adhesive. 
     
     
         38 . The bootie of  claim 23 , wherein one of said ePTFE membrane and said textile has thereon a discontinuous adhesive; and
 wherein one of said ePTFE membrane and said textile has thereon a continuous breathable adhesive.   
     
     
         39 . The bootie of  claim 23 , wherein said ePTFE membrane is amorphously locked. 
     
     
         40 . The bootie of  claim 23 , wherein said ePTFE membrane has a density greater than or equal to about 2.0 g/m 2 . 
     
     
         41 . The bootie of  claim 23 , wherein said bootie is waterproof. 
     
     
         42 . The bootie of  claim 23 , wherein said bootie is breathable. 
     
     
         43 . The bootie of  claim 23 , wherein said bootie has a moisture vapor transmission rate of at least 3 g/hr. 
     
     
         44 . The bootie of  claim 23 , wherein said bootie has a moisture vapor transmission rate of at least 5 g/hr. 
     
     
         45 . The bootie of  claim 23 , wherein said bootie has a moisture vapor transmission rate of at least 10 g/hr. 
     
     
         46 . The bootie of  claim 23 , wherein said bootie has a moisture vapor transmission rate of at least 20 g/hr. 
     
     
         47 . The bootie of  claim 23 , wherein said bootie has a moisture vapor transmission rate of at least 30 g/hr. 
     
     
         48 . The bootie of  claim 23 , wherein said bootie is waterproof and breathable. 
     
     
         49 . The bootie of  claim 23 , wherein said bootie is breathable over its entirety. 
     
     
         50 . The bootie of  claim 23 , wherein said bootie does not demonstrate leaking when said bootie is subjected to the Sock Centrifuge Waterproofness Test. 
     
     
         51 . The bootie of  claim 23 , wherein said bootie has a generally symmetrical shape. 
     
     
         52 . The bootie of  claim 23 , wherein said bootie has a generally asymmetrical shape. 
     
     
         53 . The bootie of  claim 23 , further comprising at least one second component attached to said laminate or a portion thereof. 
     
     
         54 . The bootie of  claim 53  wherein said at least one second component creates regions in said bootie, at least one of said regions possessing a function or feature different from another said region. 
     
     
         55 . The bootie of  claim 54 , wherein said at least one second component is selected from the group consisting of a textile, a laminate, a textile laminate, a polymer membrane and a second ePTFE membrane different from said conformed ePTFE membrane. 
     
     
         56 . The bootie of  claim 55 , wherein said laminate and said textile laminate include a polymer membrane. 
     
     
         57 . The bootie of  claim 56 , wherein said polymer membrane is a fluoropolymer membrane. 
     
     
         58 . The bootie of  claim 57 , wherein said fluoropolymer membrane is a polytetrafluoroethylene membrane or an expanded polytetrafluoroethylene membrane. 
     
     
         59 . The bootie of  claim 23 , wherein a portion of said laminate is removed and said portion is affixed to at least one second component. 
     
     
         60 . The bootie of  claim 23 , wherein a portion of said laminate is removed and at least one second component replaces said removed portion. 
     
     
         61 . A method of forming a shoe insert comprising:
 placing the bootie of  claim 23  on an asymmetrical last; and   heating said bootie and said asymmetrical last to a temperature from about 50° C. to about 200° C. to form a shoe insert.   
     
     
         62 . A bootie comprising:
 a seamless conformed ePTFE membrane having a first side and a second side;   a first textile forming an interior portion of a bootie; and   a second textile forming an exterior portion of said bootie,   wherein said second textile is positioned adjacent said ePTFE membrane opposing said first textile, and   wherein said seamless conformed ePTFE membrane, said first textile, and said second form a laminate.   
     
     
         63 . The bootie of  claim 62 , wherein said first textile and said second textile are affixed to said ePTFE membrane with a discontinuous adhesive. 
     
     
         64 . The bootie of  claim 62 , wherein said first and second textiles are affixed to said ePTFE membrane with a continuous breathable adhesive. 
     
     
         65 . The bootie of  claim 62 , wherein at least one of said ePTFE membrane and said first and second textiles has thereon a discontinuous adhesive; and
 wherein at least one of said ePTFE membrane and said first and second textiles has thereon a continuous breathable adhesive.   
     
     
         66 . The bootie of  claim 62 , wherein at least one of said first textile and said second textile have at least some elastic properties. 
     
     
         67 . The bootie of  claim 62 , wherein said first textile and said second textile are elastic. 
     
     
         68 . The bootie of  claim 62 , wherein said first textile and said second textile are selected from the group consisting of a knitted textile tube, a woven textile tube, a tubular sock and a formed sock. 
     
     
         69 . The bootie of  claim 62 , wherein at least one of said first textile and said second textile is a sock having a heel portion, a toe portion, and a body portion positioned therebetween, and
 wherein at least one of said heel portion and said toe portion is reinforced.   
     
     
         70 . The bootie of  claim 62 , wherein said sock is at least partially elastic. 
     
     
         71 . The bootie of  claim 62 , wherein said bootie is self-supporting. 
     
     
         72 . The bootie of  claim 62 , wherein said ePTFE membrane has a thickness variation from a first location in said bootie to a second location in said bootie of at least 1.2:1. 
     
     
         73 . The bootie of  claim 62 , wherein at least one of said ePTFE membrane, said first textile, and said second textile has at least one additional layer thereon. 
     
     
         74 . The bootie of  claim 73 , wherein said at least one additional layer is an abrasion resistant coating. 
     
     
         75 . The bootie of  claim 73 , wherein said at least one additional layer is an oleophobic coating. 
     
     
         76 . The bootie of  claim 62 , wherein said ePTFE membrane is amorphously locked. 
     
     
         77 . The bootie of  claim 62 , wherein said ePTFE membrane is densified and has a density greater than or equal to about 2.0 g/m 2 . 
     
     
         78 . The bootie of  claim 62 , wherein said bootie has a generally symmetrical shape. 
     
     
         79 . The bootie of  claim 62 , wherein said bootie has a generally asymmetrical shape. 
     
     
         80 . The bootie of  claim 62 , wherein said bootie has a moisture vapor transmission rate of at least 3 g/hr. 
     
     
         81 . The bootie of  claim 62 , wherein said bootie has a moisture vapor transmission rate of at least 5 g/hr. 
     
     
         82 . The bootie of  claim 62 , wherein said bootie has a moisture vapor transmission rate of at least 10 g/hr. 
     
     
         83 . The bootie of  claim 62 , wherein said bootie has a moisture vapor transmission rate of at least 20 g/hr. 
     
     
         84 . The bootie of  claim 62 , wherein said bootie has a moisture vapor transmission rate of at least 30 g/hr. 
     
     
         85 . The bootie of  claim 62 , wherein said bootie is waterproof. 
     
     
         86 . The bootie of  claim 62 , wherein said bootie of waterproof and breathable. 
     
     
         87 . The bootie of  claim 62 , wherein said bootie is breathable. 
     
     
         88 . The bootie of  claim 62 , wherein said bootie is breathable over its entirety. 
     
     
         89 . The bootie of  claim 62 , further comprising at least one polymeric overlay on said bootie. 
     
     
         90 . The bootie of  claim 62 , further comprising at least one second component attached to said laminate or a portion thereof. 
     
     
         91 . The bootie of  claim 90 , wherein said at least one second component creates regions in said bootie, at least one of said regions possessing a function or feature different from another said region. 
     
     
         92 . The bootie of  claim 90 , wherein said at least one second component is selected from a textile, a laminate, a textile laminate, a polymer membrane, or a second ePTFE membrane different from said conformed ePTFE membrane. 
     
     
         93 . The bootie of  claim 92 , wherein said laminate and said textile laminate include a polymer membrane. 
     
     
         94 . The bootie of  claim 93 , wherein said polymer membrane is a fluoropolymer membrane. 
     
     
         95 . The bootie of  claim 94 , wherein said fluoropolymer membrane is a polytetrafluoroethylene membrane or an expanded polytetrafluoroethylene membrane. 
     
     
         96 . The bootie of  claim 62 , further comprising an adhesive positioned on at least one of said ePTFE membrane, said first textile, and said second textile. 
     
     
         97 . The bootie of  claim 96 , wherein said adhesive is a discontinuous adhesive. 
     
     
         98 . The bootie of  claim 96 , wherein said adhesive is a continuous breathable adhesive. 
     
     
         99 . The bootie of  claim 62 , wherein a portion of said laminate is removed and said portion is affixed to at least one second component. 
     
     
         100 . The bootie of  claim 62 , wherein a portion of said laminate is removed and at least one second component replaces said removed portion. 
     
     
         101 . A method of forming a shoe insert comprising:
 placing the bootie of  claim 64  on an asymmetrical last; and   heating said bootie and said asymmetrical last to a temperature from about 50° C. to about 200° C. to form a shoe insert.