Method and apparatus for one piece footwear construction

Abstract

A bootie for use in a footwear item, a method of making the bootie, and a footwear item including the bootie are provided. The bootie provides the upper of the footwear item that will surround the wearer's foot. The bootie includes a body formed from a single air permeable, moisture vapor permeable, and waterproof sheet formed from a plurality of layers of material laminated together. The body has a bottom portion that is located under a wearer's foot in use. The body defines an opening through which a wearer's foot will extend when in use. A single bottom seam extends substantially an entire length of the bottom portion of the body between a toe-end and a heal-end of the body.

What is claimed is: 
     
         1 . A method of fabricating a footwear item, said method comprising:
 providing a single air permeable, moisture vapor permeable, and waterproof sheet formed from a plurality of layers of material laminated together;   forming a bootie from the single air permeable, moisture vapor permeable, and waterproof sheet, the bootie having a bottom portion that is located under a wearer's foot in use, wherein forming the bootie includes:
 stitching only a single bottom seam extending substantially an entire length of the bottom portion of the bootie between a toe-end and a heal-end of the bootie; and 
   attaching the bootie to an outsole such that an outside surface of the single air permeable, moisture vapor permeable, and waterproof sheet is directly exposed to the outside surrounding environment when in use on the wearer's foot.   
     
     
         2 . The method of  claim 1 , wherein forming the bootie further comprises stitching at least one cross-stitching seam that extends transverse to the bottom seam. 
     
     
         3 . The method of  claim 2 , wherein the bottom seam extends at least 80% of the length of the bottom portion between the toe-end and heal-end of the bootie. 
     
     
         4 . The method of  claim 1 , wherein forming the bootie further comprises applying sealing material across the bottom seam. 
     
     
         5 . The method of  claim 4 , wherein the sealing material is applied on an inside surface of the single air permeable, moisture vapor permeable, and waterproof sheet. 
     
     
         6 . The method of  claim 1 , wherein forming the bootie further includes stitching a rear assembly stitching seam proximate the heal-end of the bootie, the rear assembly stitching seam forming at least in part, an opening into the bootie through which a wearer's foot will extend when in use. 
     
     
         7 . The method of  claim 6 , wherein forming the bootie further includes stitching a front toe stitching seam over a curved portion of the toe-end of the bootie. 
     
     
         8 . The method of  claim 7 , wherein the bottom seam, rear assembly stitching seam and front toe stitching seams are substantially aligned with one another. 
     
     
         9 . The method of  claim 8 , wherein the bottom seam and front toe stitching seam are formed as a continuous seam. 
     
     
         10 . The method of  claim 1 , wherein the single air permeable, moisture vapor permeable, and waterproof sheet comprises:
 a first layer comprising an air permeable, moisture vapor permeable, and waterproof membrane material, having a first side and a second side; and   a second layer comprising a padding material, having a first side and a second side, the second layer positioned between the first layer and an outside environment when the footwear item is completed, the second layer configured to facilitate protecting the first layer from the outside surrounding environment.   
     
     
         11 . The method of  claim 1 , wherein attaching the bootie to an outsole covers at least a majority of the single bottom seam with the outsole. 
     
     
         12 . The method of  claim 1 , further comprising
 attaching an external support frame comprising a strengthening material to the outer surface of the single air permeable, moisture vapor permeable, and waterproof sheet by one or more of the following: molding, stitching, adhesive bonding, heat welding (e.g. using a hot press), and high frequency welding.   
     
     
         13 . The method of  claim 1 , wherein at least ten percent of a surface area of the outer surface of the single air permeable, moisture vapor permeable, and waterproof sheet is directly exposed to the outside surrounding environment. 
     
     
         14 . A footwear item comprising:
 a bootie including:
 a body formed from a single air permeable, moisture vapor permeable, and waterproof sheet formed from a plurality of layers of material laminated together, the body having a bottom portion that is located under a wearer's foot in use, the body defining an opening through which a wearer's foot will extend when in use; 
 a single bottom seam that extends substantially an entire length of the bottom portion of the body between a toe-end and a heal-end of the body; and 
   an outsole attached to the bootie such that an outside surface of the single air permeable, moisture vapor permeable, and waterproof sheet is directly exposed to an outside surrounding environment when in use on the wearer's foot.   
     
     
         15 . The footwear item of  claim 14 , further comprising at least one cross-stitching seam formed in the bottom portion that extends transverse to the bottom seam. 
     
     
         16 . The footwear item of  claim 15 , wherein the bottom seam extends at least 80% of the length of the bottom portion between the toe-end and heal-end. 
     
     
         17 . The footwear item of  claim 14 , further comprising a sealing material across the bottom seam to make the bottom seam waterproof, the sealing material is applied on an inside surface of the single air permeable, moisture vapor permeable, and waterproof sheet. 
     
     
         18 . The footwear item of  claim 14 , further comprising a rear assembly stitching seam proximate the heal-end of the bootie, the rear assembly stitching seam forming at least in part, the opening into the bootie. 
     
     
         19 . The footwear item of  claim 18 , further comprising a front toe stitching seam over a curved portion of the toe-end of the bootie. 
     
     
         20 . The footwear item of  claim 19 , wherein the bottom seam, rear assembly stitching seam and front toe stitching seams are substantially aligned with one another. 
     
     
         21 . The footwear item of  claim 20 , wherein the bottom seam and front toe stitching seam are formed as a continuous seam. 
     
     
         22 . The footwear item of  claim 14 , wherein the single air permeable, moisture vapor permeable, and waterproof sheet comprises:
 a first layer comprising an air permeable, moisture vapor permeable, and waterproof membrane material, having a first side and a second side;   a second layer having a first side and a second side, the second layer positioned between the first layer and an outside environment when the footwear item is completed, the second layer configured to facilitate protecting the first layer from the outside surrounding environment.   
     
     
         23 . The footwear item of  claim 14  further comprising an external support frame comprising a strengthening material coupled to the outer surface of the single air permeable, moisture vapor permeable, and waterproof sheet by one or more of the following: molding, stitching, adhesive bonding, heat welding (e.g. using a hot press), and high frequency welding. 
     
     
         24 . The footwear item of  claim 14 , wherein at least ten percent of a surface area of the outer surface of the single air permeable, moisture vapor permeable, and waterproof sheet is directly exposed to the outside surrounding environment.