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.

1 - 101 . (canceled) 
     
     
         102 . A bootie comprising:
 a seamless conformed expanded polytetrafluoroethylene (ePTFE) membrane having a three dimensional configuration of a symmetrical last or an asymmetrical last or a portion thereof, said seamless conformed expanded polytetrafluoroethylene (ePTFE) membrane being made from a seamless conformable expanded polytetrafluoroethylene (ePTFE) tape having an extensibility of at least 1.5× in at least one direction which is elongated to conform to the shape of the symmetrical last or the asymmetrical last or a portion thereof without fracturing, tearing, or otherwise breaking.   
     
     
         103 . The bootie according to  claim 102 , wherein a first textile is positioned on one side of said seamless conformed ePTFE membrane, wherein said seamless conformed ePTFE membrane and said first textile form a laminate. 
     
     
         104 . The bootie of  claim 103 , wherein said first textile is elastic. 
     
     
         105 . The bootie of  claim 103 , wherein said first textile is selected from the group consisting of a knitted textile tube, a woven textile tube, a tubular sock and a formed sock. 
     
     
         106 . The bootie of  claim 103 , further comprising an adhesive positioned on at least one of said ePTFE membrane or said first textile. 
     
     
         107 . The bootie of  claim 106 , wherein said adhesive is applied in the form of discrete dots or in grid pattern. 
     
     
         108 . The bootie of  claim 106 , wherein said adhesive is a breathable adhesive. 
     
     
         109 . The bootie according to  claim 102 , wherein a first textile is positioned on one side of said seamless conformed ePTFE membrane; and
 a second textile is positioned on an opposing side of said seamless conformed ePTFE membrane opposing said first textile, wherein said seamless conformed ePTFE membrane, said first textile and said second textile form a laminate.   
     
     
         110 . The bootie according to  claim 102 , wherein said seamless conformed ePTFE membrane has at least one additional layer thereon and wherein the additional layer is any of an abrasion resistant coating, an oleophobic coating, and a polymeric overlay. 
     
     
         111 . The bootie of  claim 102 , wherein said seamless conformed 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. 
     
     
         112 . The bootie of  claim 102 , wherein said seamless conformed ePTFE membrane has a density greater than or equal to about 2.0 g/m 2 . 
     
     
         113 . The bootie of  claim 102 , wherein said bootie is breathable. 
     
     
         114 . The bootie of  claim 102 , wherein said bootie is substantially free of wrinkles. 
     
     
         115 . The bootie of  claim 102 , wherein said bootie has a moisture vapor transmission rate of at least 3 g/hr. 
     
     
         116 . The bootie of  claim 102 , wherein said bootie further comprises a toe or heel reinforcement.