Conformable Booties, Shoe Inserts, and Waterproof Breathable Socks Containing an Integrally Joined Interface

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 shaped ePTFE membrane having at least one integrally joined interface attaching said shaped ePTFE membrane to itself.   
     
     
         2 . The shoe insert of  claim 1 , wherein said integrally joined interface comprises a patch, stitches, an adhesive, staples, waterproof tape, or one or more folds. 
     
     
         3 . The shoe insert of  claim 1 , wherein said ePTFE membrane has at least one additional layer thereon. 
     
     
         4 . The shoe insert of  claim 3 , wherein said at least one additional layer is an abrasion resistant coating. 
     
     
         5 . The shoe insert of  claim 4 , 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. 
     
     
         6 . 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. 
     
     
         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 , further comprising at least one second component attached to said ePTFE membrane or a portion thereof. 
     
     
         9 . The shoe insert of  claim 1 , 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. 
     
     
         10 . The shoe insert of  claim 8 , 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. 
     
     
         11 . The shoe insert of  claim 1 , wherein said shaped ePTFE membrane is seamless. 
     
     
         12 . A shoe insert comprising:
 a shaped ePTFE membrane having at least one integrally joined interface attaching said shaped ePTFE membrane to itself, said 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 ePTFE membrane and said textile form a laminate.   
     
     
         13 . The shoe insert of  claim 12 , wherein said integrally joined interface comprises a patch, stitches, an adhesive, staples, waterproof tape, or one or more folds. 
     
     
         14 . The shoe insert of  claim 12 , wherein said textile has at least some elastic properties. 
     
     
         15 . The shoe insert of  claim 12 , 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. 
     
     
         16 . The shoe insert of  claim 12 , 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. 
     
     
         17 . The shoe insert of  claim 12 , wherein at least one of said ePTFE membrane and said textile has at least one additional layer thereon. 
     
     
         18 . The shoe insert of  claim 17 , wherein said at least one additional layer is an abrasion resistant coating. 
     
     
         19 . The shoe insert of  claim 12 , wherein said textile is affixed to said ePTFE membrane with a discontinuous adhesive. 
     
     
         20 . The shoe insert of  claim 12 , wherein said textile is affixed to said ePTFE membrane with a continuous breathable adhesive. 
     
     
         21 . The shoe insert of  claim 12 , wherein said ePTFE membrane has a density greater than or equal to about 2.0 g/m 2 . 
     
     
         22 . The shoe insert of  claim 12 , further comprising at least one polymeric overlay on said shoe insert. 
     
     
         23 . The shoe insert of  claim 12 , further comprising at least one second component attached to said laminate or a portion thereof. 
     
     
         24 . The shoe insert of  claim 23 , 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. 
     
     
         25 . The shoe insert of  claim 23 , 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. 
     
     
         26 . The shoe insert of  claim 12 , wherein said shaped ePTFE membrane is seamless. 
     
     
         27 . A shoe insert comprising:
 a shaped ePTFE membrane having at least one integrally joined interface attaching said shaped ePTFE membrane to itself, said ePTFE membrane having a first side and a second side;   a first textile positioned on said first side of said ePTFE membrane; and   a second textile positioned on a second side of said ePTFE membrane opposing said first textile,   wherein said ePTFE membrane, said first textile, and said second textile form a laminate.   
     
     
         28 . The shoe insert of  claim 27 , wherein said integrally joined interface comprises a patch, stitches, an adhesive, staples, waterproof tape, or one or more folds. 
     
     
         29 . The shoe insert of  claim 27 , wherein said first textile and said second textile are affixed to said ePTFE membrane with a discontinuous adhesive. 
     
     
         30 . The shoe insert of  claim 27 , wherein said first and second textiles are affixed to said ePTFE membrane with a continuous breathable adhesive. 
     
     
         31 . The shoe insert of  claim 27 , wherein said first textile and said second textile have at least some elastic properties. 
     
     
         32 . The shoe insert of  claim 30 , 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. 
     
     
         33 . The shoe insert of  claim 27 , 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. 
     
     
         34 . The shoe insert of  claim 27 , wherein at least one of said ePTFE membrane, said first textile, and said second textile has at least one additional layer thereon. 
     
     
         35 . The shoe insert of  claim 34 , wherein said at least one additional layer is an abrasion resistant coating. 
     
     
         36 . The shoe insert of  claim 27 , wherein said ePTFE membrane has a density greater than or equal to 2.0 g/m 2 . 
     
     
         37 . The shoe insert of  claim 27 , further comprising at least one second component attached to said laminate or a portion thereof. 
     
     
         38 . The shoe insert of  claim 37 , 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. 
     
     
         39 . The shoe insert of  claim 37 , 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. 
     
     
         40 . The shoe insert of  claim 27 , wherein said shaped ePTFE membrane is seamless. 
     
     
         41 . A shoe insert comprising:
 a conformed ePTFE membrane having at least one integrally joined interface attaching said conformed ePTFE membrane to itself, said 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 ePTFE membrane and said textile form a laminate.   
     
     
         42 . The shoe insert of  claim 41 , wherein said shoe insert has a symmetrical shape. 
     
     
         43 . The shoe insert of  claim 41 , wherein said shoe insert has an asymmetrical shape. 
     
     
         44 . The shoe insert of  claim 41 , wherein said integrally joined interface comprises a patch, stitches, an adhesive, staples, waterproof tape, or one or more folds. 
     
     
         45 . The shoe insert of  claim 41 , 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. 
     
     
         46 . The shoe insert of  claim 41 , 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. 
     
     
         47 . The shoe insert of  claim 41 , further comprising at least one second component attached to said laminate or a portion thereof. 
     
     
         48 . The shoe insert of  claim 47 , 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. 
     
     
         49 . The shoe insert of  claim 47 , 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. 
     
     
         50 . The shoe insert of  claim 41 , wherein said conformed ePTFE membrane is seamless. 
     
     
         51 . A shoe insert comprising:
 a conformed ePTFE membrane having at least one integrally joined interface attaching said conformed ePTFE membrane to itself, said ePTFE membrane having a first side and a second side;   a first textile positioned on said first side of said ePTFE membrane; and   a second textile positioned on a second side of said ePTFE membrane opposing said first textile,   wherein said ePTFE membrane, said first textile, and said second textile form a laminate.   
     
     
         52 . Theshoe insert of  claim 51 , wherein said shoe insert has a symmetrical shape. 
     
     
         53 . The shoe insert of  claim 51 , wherein said shoe insert has an asymmetrical shape. 
     
     
         54 . The shoe insert of  claim 51 , wherein said integrally joined interface comprises a patch, stitches, an adhesive, staples, waterproof tape, or one or more folds. 
     
     
         55 . The shoe insert of  claim 51 , 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. 
     
     
         56 . The shoe insert of  claim 51 , 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. 
     
     
         57 . The shoe insert of  claim 51 , further comprising at least one second component attached to said laminate or a portion thereof. 
     
     
         58 . The shoe insert of  claim 57 , 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. 
     
     
         59 . The shoe insert of  claim 57 , 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. 
     
     
         60 . The shoe insert of  claim 51 , wherein said conformed ePTFE membrane is seamless.