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 shoe insert comprising:
 a seamless shaped ePTFE membrane.   
     
     
         2 . The shoe insert of  claim 1 , wherein said ePTFE membrane has at least one additional layer thereon. 
     
     
         3 . The shoe insert of  claim 2 , wherein said at least one additional layer is an abrasion resistant coating. 
     
     
         4 . The shoe insert of  claim 3 , wherein said abrasion resistant coating is present on at least one of an inner surface of said shoe insert and an outer surface of said shoe insert. 
     
     
         5 . The shoe insert of  claim 1 , wherein said ePTFE membrane has a thickness variation from a first location in said shoe insert to a second location in said shoe insert of at least 1.2:1. 
     
     
         6 . The shoe insert of  claim 1 , wherein said ePTFE membrane is amorphously locked. 
     
     
         7 . The shoe insert of  claim 1 , wherein said ePTFE membrane has a density greater than or equal to about 2.0 g/m 2 . 
     
     
         8 . The shoe insert of  claim 1 , wherein said shoe insert is breathable over its entirety. 
     
     
         9 . The shoe insert of  claim 1 , wherein said shoe insert has a generally symmetrical shape. 
     
     
         10 . The shoe insert of  claim 1 , wherein said shoe insert is breathable. 
     
     
         11 . The shoe insert of  claim 1 , wherein said shoe insert is waterproof and breathable. 
     
     
         12 . The shoe insert of  claim 1 , further comprising at least one second component attached to said ePTFE membrane or a portion thereof. 
     
     
         13 . The shoe insert of  claim 12 , wherein said at least one second component creates regions in said shoe insert, at least one of said regions possessing a function or feature different from another said region. 
     
     
         14 . The shoe insert of  claim 12 , 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. 
     
     
         15 . The shoe insert of  claim 14 , wherein said laminate and said textile laminate include a polymer membrane. 
     
     
         16 . The shoe insert of  claim 15 , wherein said polymer membrane is a fluoropolymer membrane. 
     
     
         17 . The shoe insert of  claim 16 , wherein said fluoropolymer membrane is a polytetrafluoroethylene membrane or an expanded polytetrafluoroethylene membrane. 
     
     
         18 . A shoe insert comprising:
 a seamless shaped ePTFE membrane having a first side and a second side; and   a textile positioned on one of said first side and said second side of said ePTFE membrane,   wherein said seamless shaped ePTFE membrane and said textile form a laminate.   
     
     
         19 . The shoe insert of  claim 18 , wherein said textile has at least some elastic properties. 
     
     
         20 . The shoe insert of  claim 18 , wherein said textile is elastic. 
     
     
         21 . The shoe insert of  claim 18 , 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. 
     
     
         22 . The shoe insert of  claim 21 , 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.   
     
     
         23 . The shoe insert of  claim 22 , wherein said sock is at least partially elastic. 
     
     
         24 . The shoe insert of  claim 18 , wherein said shoe insert is self-supporting. 
     
     
         25 . The shoe insert of  claim 18 , wherein said ePTFE membrane has a thickness variation from a first location in said shoe insert to a second location in said shoe insert of at least 1.2:1. 
     
     
         26 . The shoe insert of  claim 18 , wherein at least one of said ePTFE membrane and said textile has at least one additional layer thereon. 
     
     
         27 . The shoe insert of  claim 26 , wherein said at least one additional layer is an abrasion resistant coating. 
     
     
         28 . The shoe insert of  claim 27 , wherein said abrasion resistant coating is present on at least one of said first side and said second side of said ePTFE membrane. 
     
     
         29 . The shoe insert of  claim 26 , wherein said at least one additional layer is an oleophobic coating. 
     
     
         30 . The shoe insert of  claim 18 , further comprising an adhesive positioned on at least one of said ePTFE membrane and said textile. 
     
     
         31 . The shoe insert of  claim 18 , wherein said textile is affixed to said ePTFE membrane with a discontinuous adhesive. 
     
     
         32 . The shoe insert of  claim 18 , wherein said textile is affixed to said ePTFE membrane with a continuous breathable adhesive. 
     
     
         33 . The shoe insert of  claim 18 , wherein said ePTFE membrane is amorphously locked. 
     
     
         34 . The shoe insert of  claim 18 , wherein said ePTFE membrane has a density greater than or equal to about 2.0 g/m 2 . 
     
     
         35 . The shoe insert of  claim 18 , wherein said shoe insert has a moisture vapor transmission rate of at least 3 g/hr. 
     
     
         36 . The shoe insert of  claim 18 , wherein said shoe insert has a moisture vapor transmission rate of at least 5 g/hr. 
     
     
         37 . The shoe insert of  claim 18 , wherein said shoe insert has a moisture vapor transmission rate of at least 10 g/hr. 
     
     
         38 . The shoe insert of  claim 18 , wherein said shoe insert has a moisture vapor transmission rate of at least 20 g/hr. 
     
     
         39 . The shoe insert of  claim 18 , wherein said shoe insert has a moisture vapor transmission rate of at least 30 g/hr. 
     
     
         40 . The shoe insert of  claim 18 , wherein said shoe insert is waterproof. 
     
     
         41 . The shoe insert of  claim 18 , wherein said shoe insert is breathable. 
     
     
         42 . The shoe insert of  claim 18 , wherein said shoe insert is waterproof and breathable. 
     
     
         43 . The shoe insert of  claim 18 , wherein said shoe insert is breathable over its entirety. 
     
     
         44 . The shoe insert of  claim 18 , wherein said shoe insert does not demonstrate leaking when a shoe containing said shoe insert is subjected to the Centrifuge Waterproofness Test. 
     
     
         45 . The shoe insert of  claim 18 , wherein said shoe insert has a generally asymmetrical shape. 
     
     
         46 . The shoe insert of  claim 18 , further comprising at least one polymeric overlay on said shoe insert. 
     
     
         47 . The shoe insert of  claim 18 , wherein a portion of said laminate is removed and said portion is affixed to at least one second component. 
     
     
         48 . The shoe insert of  claim 18 , wherein a portion of said laminate is removed and at least one second component replaces said removed portion. 
     
     
         49 . The shoe insert of  claim 18 , further comprising at least one second component attached to said laminate or a portion thereof. 
     
     
         50 . The shoe insert of  claim 49 , wherein said at least one second component creates regions in said shoe insert, at least one of said regions possessing a function or feature different from another said region. 
     
     
         51 . The bootie of  claim 49 , 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. 
     
     
         52 . The shoe insert of  claim 51 , wherein said laminate and said textile laminate include a polymer membrane. 
     
     
         53 . The shoe insert of  claim 52 , wherein said polymer membrane is a fluoropolymer membrane. 
     
     
         54 . The shoe insert of  claim 53 , wherein said fluoropolymer membrane is a polytetrafluoroethylene membrane or an expanded polytetrafluoroethylene membrane. 
     
     
         55 . A shoe comprising the shoe insert of  claim 18 . 
     
     
         56 . A boot comprising the shoe insert of  claim 18 . 
     
     
         57 . A shoe insert comprising:
 a seamless shaped ePTFE membrane having a first side and a second side;   a first textile positioned on said first side said ePTFE membrane of a shoe insert; and   a second textile positioned on a second side of said ePTFE membrane opposing said first textile,   wherein said seamless shaped ePTFE membrane, said first textile, and said second textile form a laminate.   
     
     
         58 . The shoe insert of  claim 57 , wherein said first textile and said second textile are affixed to said ePTFE membrane with a discontinuous adhesive. 
     
     
         59 . The shoe insert of  claim 57 , wherein said first and second textiles are affixed to said ePTFE membrane with a continuous breathable adhesive. 
     
     
         60 . The shoe insert of  claim 57 , wherein at least one of said ePTFE membrane, said first textile, and said second textile has thereon a discontinuous adhesive; and
 wherein at least one of said ePTFE membrane, said first textile, and said second textile has thereon a continuous breathable adhesive.   
     
     
         61 . The shoe insert of  claim 57 , wherein said first textile and said second textile have at least some elastic properties. 
     
     
         62 . The shoe insert of  claim 57 , wherein said first textile and said second textile are elastic. 
     
     
         63 . The shoe insert of  claim 57 , 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. 
     
     
         64 . The shoe insert of  claim 57 , 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.   
     
     
         65 . The shoe insert of  claim 57 , wherein said sock is elastic. 
     
     
         66 . The shoe insert of  claim 57 , wherein said shoe insert is self-supporting. 
     
     
         67 . The shoe insert of  claim 57 , wherein said ePTFE membrane has a thickness variation from a first location in said shoe insert to a second location in said shoe insert of at least 1.2:1. 
     
     
         68 . The shoe insert of  claim 57 , wherein at least one of said ePTFE membrane, said first textile, and said second textile has at least one additional layer thereon. 
     
     
         69 . The shoe insert of  claim 68 , wherein said at least one additional layer is an abrasion resistant coating. 
     
     
         70 . The shoe insert of  claim 68 , wherein said at least one additional layer is an oleophobic coating. 
     
     
         71 . The shoe insert of  claim 57 , wherein said ePTFE membrane is amorphously locked. 
     
     
         72 . The shoe insert of  claim 57 , wherein said ePTFE membrane has a density greater than or equal to 2.0 g/m 2 . 
     
     
         73 . The shoe insert of  claim 57 , wherein said shoe insert has a generally asymmetrical shape. 
     
     
         74 . The shoe insert of  claim 57 , wherein said shoe insert is breathable. 
     
     
         75 . The shoe insert of  claim 74 , wherein said shoe insert is breathable over its entirety. 
     
     
         76 . The shoe insert of  claim 57 , wherein said shoe insert is waterproof. 
     
     
         77 . The shoe insert of  claim 57 , wherein said shoe insert of waterproof and breathable. 
     
     
         78 . The shoe insert of  claim 57 , wherein said shoe insert has a moisture vapor transmission rate of at least 3 g/hr. 
     
     
         79 . The shoe insert of  claim 57 , wherein said shoe insert has a moisture vapor transmission rate of at least 5 g/hr. 
     
     
         80 . The shoe insert of  claim 57 , wherein said shoe insert has a moisture vapor transmission rate of at least 10 g/hr. 
     
     
         81 . The shoe insert of  claim 57 , wherein said shoe insert has a moisture vapor transmission rate of at least 20 g/hr. 
     
     
         82 . The shoe insert of  claim 57 , wherein said shoe insert has a moisture vapor transmission rate of at least 30 g/hr. 
     
     
         83 . The shoe insert of  claim 57 , further comprising at least one polymeric overlay on said shoe insert. 
     
     
         84 . The shoe insert of  claim 57 , wherein said shoe insert does not demonstrate leaking when a shoe containing said shoe insert is subjected to the Centrifuge Waterproofness Test. 
     
     
         85 . The shoe insert of  claim 57 , further comprising at least one second component attached to said laminate or a portion thereof. 
     
     
         86 . The shoe insert of  claim 85 , wherein said at least one second component creates regions in said shoe insert, at least one of said regions possessing a function or feature different from another said region. 
     
     
         87 . The shoe insert of  claim 85 , wherein said at least 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. 
     
     
         88 . The shoe insert of  claim 87 , wherein said laminate and said textile laminate include a polymer. 
     
     
         89 . The shoe insert of  claim 88 , wherein said polymer is a fluoropolymer. 
     
     
         90 . The shoe insert of  claim 89 , wherein said fluoropolymer is polytetrafluoroethylene or expanded polytetrafluoroethylene. 
     
     
         91 . The shoe insert of  claim 57 , wherein a portion of said laminate is removed and said portion is affixed to at least one second component. 
     
     
         92 . The shoe insert of  claim 57 , wherein a portion of said laminate is removed and at least one second component replaces said removed portion. 
     
     
         93 . A shoe comprising the shoe insert of  claim 57 . 
     
     
         94 . A boot comprising the shoe insert of  claim 57 . 
     
     
         95 . A shoe insert comprising:
 a seamless, conformed ePTFE membrane.   
     
     
         96 . The shoe insert of  claim 95 , wherein said shoe insert has a generally symmetrical shape. 
     
     
         97 . The shoe insert of  claim 95 , wherein said shoe insert has a generally asymmetrical shape. 
     
     
         98 . The shoe insert of  claim 95 , wherein said ePTFE membrane has at least one additional layer thereon. 
     
     
         99 . The shoe insert of  claim 95 , wherein said at least one additional layer is an abrasion resistant coating. 
     
     
         100 . The shoe insert of  claim 99 , wherein said abrasion resistant coating is present on at least one of an inner surface of said shoe insert and an outer surface of said shoe insert. 
     
     
         101 . The shoe insert of  claim 95 , wherein said ePTFE membrane has a thickness variation from a first location in said shoe insert to a second location in said shoe insert of at least 1.2:1. 
     
     
         102 . The shoe insert of  claim 95 , wherein said ePTFE membrane is amorphously locked. 
     
     
         103 . The shoe insert of  claim 95 , wherein said ePTFE membrane has a density greater than or equal to about 2.0 g/m 2 . 
     
     
         104 . The shoe insert of  claim 95 , wherein said shoe insert is breathable over its entirety. 
     
     
         105 . The shoe insert of  claim 95 , wherein said shoe insert is breathable. 
     
     
         106 . The shoe insert of  claim 95 , wherein said shoe insert is waterproof and breathable. 
     
     
         107 . The shoe insert of  claim 95 , further comprising at least one second component attached to said conformed ePTFE membrane or a portion thereof. 
     
     
         108 . The shoe insert of  claim 107 , wherein said at least one second component creates regions in said shoe insert, at least one of said regions possessing a function or feature different from another said region. 
     
     
         109 . The shoe insert of  claim 107 , 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. 
     
     
         110 . The shoe insert of  claim 109 , wherein said laminate and said textile laminate include a polymer. 
     
     
         111 . The shoe insert of  claim 110 , wherein said polymer is a fluoropolymer. 
     
     
         112 . The shoe insert of  claim 111 , wherein said fluoropolymer is polytetrafluoroethylene or expanded polytetrafluoroethylene. 
     
     
         113 . A shoe last comprising:
 a first portion; and   a second portion, said first and second portions being substantial mirror images of each other across a generally central axis.