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 bootie comprising:
 a conformed expanded polytetrafluoroethylene (ePTFE) membrane containing at least one integrally joined interface attaching said conformed ePTFE membrane to itself.   
     
     
         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 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 integrally joined interface comprises a patch, stitches, an adhesive, staples, waterproof tape, or one or more folds. 
     
     
         7 . The bootie of  claim 1 , wherein said bootie further comprises at least one second component. 
     
     
         8 . The bootie of  claim 7 , 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. 
     
     
         9 . The bootie of  claim 7 , 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. 
     
     
         10 . The bootie of  claim 1 , wherein said conformed ePTFE membrane is seamless 
     
     
         11 . A bootie comprising:
 a conformed ePTFE membrane containing 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 said first side of said ePTFE membrane,   wherein said ePTFE membrane and said textile form a laminate.   
     
     
         12 . The bootie of  claim 11 , wherein said integrally joined interface comprises a patch, stitches, an adhesive, staples, waterproof tape, or one or more folds. 
     
     
         13 . The bootie of  claim 11 , wherein said textile is selected from a knitted textile tube, a woven textile tube, a tubular sock and a formed sock. 
     
     
         14 . The bootie of  claim 11 , 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. 
     
     
         15 . The bootie of  claim 11 , wherein at least one of said ePTFE membrane and said textile has at least one additional layer thereon. 
     
     
         16 . The bootie of  claim 15 , wherein said one additional layer is an abrasion resistant coating. 
     
     
         17 . The bootie of  claim 11 , further comprising an adhesive positioned on at least one of said ePTFE membrane and said textile. 
     
     
         18 . The bootie of  claim 17 , wherein said adhesive is a discontinuous adhesive. 
     
     
         19 . The bootie of  claim 17 , wherein said adhesive is a continuous breathable adhesive. 
     
     
         20 . The bootie of  claim 11 , wherein said cPTFE membrane has a density greater than or equal to about 2.0 g/m 2 . 
     
     
         21 . The bootie of  claim 11 , wherein said bootie has a generally symmetrical shape. 
     
     
         22 . The bootie of  claim 11 , further comprising at least one second component attached to said laminate or a portion thereof. 
     
     
         23 . The bootie of  claim 22 , 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. 
     
     
         24 . The bootie of  claim 22 , 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. 
     
     
         25 . The bootie of  claim 11 , wherein said conformed ePTFE membrane is seamless. 
     
     
         26 . A bootie comprising:
 a conformed expanded polytetrafluoroethylene (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 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 ePTFE membrane, said first textile, and said second textile form a laminate.   
     
     
         27 . The bootie of  claim 26 , wherein said integrally joined interface comprises a patch, stitches, an adhesive, staples, waterproof tape, or one or more folds. 
     
     
         28 . The bootie of  claim 26 , wherein said first textile and said second textile are affixed to said ePTFE membrane with a discontinuous adhesive. 
     
     
         29 . The bootie of  claim 26 , wherein said first and second textiles are affixed to said ePTFE membrane with a continuous breathable adhesive. 
     
     
         30 . The bootie of  claim 26 , 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.   
     
     
         31 . The bootie of  claim 26 , wherein said first textile and said second textile are selected from a knitted textile tube, a woven textile tube, a tubular sock and a formed sock. 
     
     
         32 . The bootie of  claim 26 , 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. 
     
     
         33 . The bootie of  claim 26 , wherein at least one of said ePTFE membrane, said first textile, and said second textile has at least one additional layer thereon. 
     
     
         34 . The bootie of  claim 33 , wherein said at least one additional layer is an abrasion resistant coating. 
     
     
         35 . The bootie of  claim 26 , wherein said ePTFE membrane has a density greater than or equal to about 2.0 g/m 2 . 
     
     
         36 . The bootie of  claim 26 , wherein said bootie has a generally symmetrical shape. 
     
     
         37 . The bootie of  claim 26 , further comprising at least one polymeric overlay on said bootie. 
     
     
         38 . The bootie of  claim 26 , further comprising at least one second component attached to said laminate or a portion thereof. 
     
     
         39 . The bootie of  claim 38 , 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. 
     
     
         40 . The bootie of  claim 38 , 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. 
     
     
         41 . The bootie of  claim 26 , wherein said conformed ePTFE is seamless. 
     
     
         42 . A sock comprising:
 a conformed expanded polytetrafluoroethylene (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 first elastic textile affixed to said first side of said ePTFE membrane, said first elastic textile having an elasticity of at least 50%   wherein said first elastic textile and said ePTFE membrane form a first laminate.   
     
     
         43 . The sock of  claim 42 , wherein said first textile is selected from a knitted textile tube, a woven textile tube, and a tubular sock. 
     
     
         44 . The sock of  claim 42  wherein said first textile is affixed to said ePTFE membrane with a discontinuous adhesive. 
     
     
         45 . The sock of  claim 42 , wherein said first textile is affixed to said ePTFE membrane with a continuous breathable adhesive. 
     
     
         46 . The sock of  claim 42 , wherein said ePTFE membrane has a thickness variation from a first location in said sock to a second location in said sock of at least 1.2:1. 
     
     
         47 . The sock of  claim 42 , wherein at least one of said ePTFE membrane and said first elastic textile has at least one additional layer thereon. 
     
     
         48 . The sock of  claim 47 , wherein said at least one additional layer is an abrasion resistant coating. 
     
     
         49 . The sock of  claim 42 , further comprising a second elastic textile affixed to said second side of said ePTFE membrane, said second elastic textile having an elasticity of at least 50%, wherein said ePTFE membrane, said first textile, and said second textile form a second laminate. 
     
     
         50 . The sock of  claim 49 , wherein said first and second elastic textiles are selected from a knitted textile tube, a woven textile tube, a tubular sock and a formed sock. 
     
     
         51 . The sock of  claim 49 , further comprising at least one second component attached to said second laminate or a portion thereof. 
     
     
         52 . The sock of  claim 51 , wherein said at least one second component creates regions in said sock, at least one of said regions possessing a function or feature different from another said region. 
     
     
         53 . The sock of  claim 51 , 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. 
     
     
         54 . The sock of  claim 49 , wherein said first elastic textile and said second elastic textile are affixed to said ePTFE membrane with a discontinuous adhesive. 
     
     
         55 . The sock of  claim 49 , wherein at least one of said ePTFE membrane and said first and second elastic textile has thereon a discontinuous adhesive; and
 wherein at least one of said ePTFE membrane and said first and second elastic textiles has thereon a continuous breathable adhesive.   
     
     
         56 . The sock of  claim 49 , wherein said first and second elastic textiles are affixed to said ePTFE membrane with a continuous breathable adhesive. 
     
     
         57 . The sock of  claim 49 , further comprising at least one polymeric overlay on said sock. 
     
     
         58 . The sock of  claim 49 , wherein at least one of said ePTFE membrane, said first elastic textile, and said second elastic textile has at least one additional layer thereon. 
     
     
         59 . The sock of  claim 59 , wherein said at least one additional layer is an abrasion resistant coating. 
     
     
         60 . The sock of  claim 49 , wherein said sock has a generally symmetrical shape. 
     
     
         61 . The sock of  claim 49 , wherein said ePTFE membrane has a density greater than or equal to about 2.0 g/m 2 . 
     
     
         62 . The sock of  claim 42 , further comprising at least one second component attached to said first laminate or a portion thereof. 
     
     
         63 . The sock of  claim 63 , wherein said at least one second component divides said sock into regions, at least one of said regions possessing a function or feature different from another said region. 
     
     
         64 . The sock of  claim 63 , 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. 
     
     
         65 . The sock of  claim 63 , wherein said conformed ePTFE membrane is seamless. 
     
     
         66 . The sock of  claim 42 , wherein said conformed ePTFE membrane is seamless.