Waterproof footwear gasket and related method of manufacture

Abstract

A footwear construction is provided including a waterproof gasket formed between components of the footwear. The footwear can include an upper including a first layer and a waterproof functional second layer adjacent the first layer. A waterproof functional insole includes a perimeter that is disposed adjacent the first layer and/or the second layer. A thread extends through the first layer, sewn through it, and is located between the insole and the second layer, and adjacent the perimeter. The thread is melted to form a waterproof gasket between the second layer and the insole, along the perimeter. Alternatively, the first layer is surrounded with a hot melt flange stitched to an insole. A waterproof functional second layer seals the first layer and flange. A gasket panel can be disposed over the hot melt flange and insole, which can include insole stitching joining the same. Related methods also are provided.

What is claimed is: 
     
         1 . An article of footwear comprising:
 an upper including a first layer having an interior surface and an exterior surface, with a first layer disposed between the interior surface and the exterior surface, the first layer having a first edge;   a waterproof functional second layer adjacent at least one of the interior surface and the exterior surface of the first layer, the second layer having a second edge;   a waterproof functional insole having a perimeter, approximating an outline of a human foot, the perimeter terminating at a third edge, the third edge adjacent at least one of the second edge and the first edge; and   a polymeric thread extending over the interior surface, through the first layer body and the exterior surface, the polymeric thread engaging the second layer and the perimeter,   wherein the polymeric thread is in a melted form and fused to the second layer and the perimeter to form a waterproof gasket between the second layer and the waterproof functional insole.   
     
     
         2 . The article of footwear of  claim 1 , comprising:
 a structural stitch extending through the first layer, the second layer and the insole.   
     
     
         3 . The article of footwear of  claim 2 ,
 wherein the polymeric thread forms the waterproof gasket along at least one of the first edge, the second edge and the third edge,   wherein the structural stitch extends transversely through the gasket.   
     
     
         4 . The article of footwear of  claim 3 ,
 wherein the gasket is disposed adjacent the first edge and the second edge,   wherein the gasket has a width,   wherein the width is less than 20 mm.   
     
     
         5 . The article of footwear of  claim 1 ,
 wherein the insole is in the form of a waterproof Strobel board,   wherein the Strobel board includes the third edge,   wherein the third edge is abutted against the first edge to form a butt seam, and   wherein the polymeric thread is in melted form and fused to the third edge and to the first edge.   
     
     
         6 . The article of footwear of  claim 1 ,
 wherein the first layer and the second layer form a laminate,   wherein the first layer is a textile layer including a plurality of textile strands with interstitial spaces therebetween,   wherein the polymeric thread extends adjacent the textile strands and through the interstitial spaces, and   wherein the polymeric thread is melted to entrap the textile strands and to at least partially fill the interstitial spaces.   
     
     
         7 . The article of footwear of  claim 6 ,
 wherein the first layer and the second layer are bent outward from a longitudinal axis,   wherein the first edge and the second edge are aligned one above the other.   
     
     
         8 . The article of footwear of  claim 1 , comprising:
 a liner joined with an interior surface of the waterproof functional second layer and facing inward to form a footwear void,   wherein the structural stitch penetrates the liner.   
     
     
         9 . The article of footwear of  claim 1 ,
 wherein the waterproof functional insole includes an insole interior surface and a waterproof functional fourth layer adjacent the insole interior surface,   wherein the polymeric thread is melted and fused to the waterproof functional second layer and to the waterproof functional fourth layer.   
     
     
         10 . The article of footwear of  claim 9 ,
 wherein the polymeric thread is melted to form a continuous gasket between the insole and the waterproof functional second layer around the perimeter,   wherein the polymeric thread is melted inside the first layer between the interior surface and the exterior surface of the first layer, and encapsulates strands inside the first layer.   
     
     
         11 . An article of footwear comprising:
 an upper including a first layer and a waterproof functional second layer adjacent the first layer,   a waterproof functional insole having a perimeter, the perimeter being positioned adjacent at least one of the first layer and the second layer,   a thread extending between the waterproof functional insole and the waterproof functional second layer, and   wherein the thread is in melted form to provide waterproof gasket between the waterproof functional second layer and the waterproof functional insole.   
     
     
         12 . The article of footwear of  claim 11 , comprising:
 a structural stitch extending through the waterproof functional second layer and the waterproof functional insole,   wherein the structural stitch extends transversely through the gasket,   wherein a first segment of the structural stitch is parallel to a first segment of the thread extending through the first layer,   wherein a second segment of the structural stitch is parallel to a second segment of the thread extending along the first layer,   wherein the first and second segment of the structural stitch are transverse to one another, and   wherein the first and second segment of the thread are transverse to one another.   
     
     
         13 . The article of footwear of  claim 11 ,
 wherein the waterproof functional insole has a longitudinal axis and an insole width perpendicular to the longitudinal axis,   wherein the gasket has a gasket width, and   wherein a ratio of the gasket width to the insole width is less than  1 : 4 .   
     
     
         14 . The article of footwear of  claim 11 , comprising:
 an outsole disposed below the first layer and the waterproof functional insole,   wherein the thread is not fused to the outsole.   
     
     
         15 . The article of footwear of  claim 14 ,
 wherein the structural stitch is a zig zag stitch passing back and forth between a first edge of the first layer and a perimeter of the waterproof functional insole.   
     
     
         16 . The article of footwear of  claim 15 ,
 wherein the insole is in the form of a Strobel board including a third edge adjacent the perimeter,   wherein the third edge is abutted against the first edge to form a butt seam, and   wherein the thread is melted and fused to the third edge and to the first edge.   
     
     
         17 . The article of foot wear of  claim 11 ,
 wherein the first layer is a textile layer including a plurality of textile strands with interstitial spaces therebetween,   wherein the thread extends adjacent the textile strands and through the interstitial spaces, and   wherein the thread is melted to entrap the textile strands and to at least partially fill the interstitial spaces.   
     
     
         18 . A method of making an article of footwear, the method comprising:
 providing an upper having a U-shaped outer perimeter, the upper including a first layer and a waterproof functional second layer adjacent the first layer;   sewing a thread repeatedly through the first layer around the outer perimeter;   positioning a waterproof functional insole having an insole perimeter adjacent at least one of the first layer and the second layer; and   melting the thread to form a waterproof gasket between the waterproof functional second layer and the waterproof functional insole with the melted thread.   
     
     
         19 . The method of  claim 18  comprising:
 sewing a structural stitch through the first layer, the waterproof functional second layer and the waterproof functional insole, 
 wherein the structural stitch extends transversely through the gasket, 
 wherein a first segment of the structural stitch is parallel to a first segment of the thread extending through the first layer, 
 wherein a second segment of the structural stitch is parallel to a second segment of the thread extending along the first layer, 
 wherein the first and second segment of the structural stitch are transverse to one another, and 
 wherein the first and second segment of the thread are transverse to one another. 
 
     
     
         20 . The method of  claim 19  comprising:
 heating the thread to at least 150 degrees Fahrenheit so that the thread melts and encapsulates adjacent strands in the first layer, and adheres to a surface of the waterproof functional second layer.