Sock with shoe-like properties and method for making the sock

Abstract

A footwear article may include a layer coupled to the sock in the sole area of the sock, a heel cushion coupled to the layer in the heel area of the sock, and a polymer material added to the sole area, the lower sides, the lower front side, and the lower rear side of the sock. The polymer material may encompass the layer in the sole area of the sock and the heel cushion. A method for manufacturing a footwear article may include steps of placing a sock on a last; coupling a layer to the sock in the sole area; coupling a heel cushion to the layer in the heel area; placing a heel-area piece and a ball-area piece in a bottom portion of a mold; introducing the last and the sock into the mold; closing the mold; and injecting a polymer material into the bottom portion of the mold, so that the polymer material flows to the sole area, and the lower sides of the sock.

1 . An article for footwear, the article comprising:
 a. a sock defining a sole area, a pair of lower sides, and a lower front side and a lower rear side;   b. a layer coupled to the sock in the sole area of the sock, the layer defining a heel area;   c. a heel cushion coupled to the layer in the heel area of the sock;   d. a polymer material added to the sole area, the pair of lower sides, the lower front side, and the lower rear side of the sock, wherein the polymer material encompasses the layer in the sole area of the sock and encompasses the heel cushion.   
     
     
         2 . The article for footwear of  claim 1  further comprising a heel-area piece that is coupled to the sock by the polymer material. 
     
     
         3 . The article for footwear of  claim 1  further comprising a ball-area piece that is coupled to the sock by the polymer material. 
     
     
         4 . The article for footwear of  claim 1  wherein the sock is waterproof. 
     
     
         5 . The article for footwear of  claim 4  wherein the sock include a waterproof membrane between two knit layers. 
     
     
         6 . The article for footwear of  claim 5  wherein the waterproof membrane is breathable. 
     
     
         7 . The article for footwear of  claim 1  wherein the layer in the sole area is coupled to the sock by a self-adhesive surface on the layer. 
     
     
         8 . The article for footwear of  claim 1  wherein the heel cushion is attached to the layer by a self-adhesive surface on the heel cushion. 
     
     
         9 . The article for footwear of  claim 1  wherein the polymer material is polyurethane. 
     
     
         10 . The article for footwear of  claim 1  further comprising a rubber heel-area piece and a rubber ball-area piece, wherein the rubber pieces are coupled to the sock by the polymer material. 
     
     
         11 . The article for footwear of  claim 1  wherein the layer coupled to the sock in the sole area of the sock is substantially made of a nonwoven fabric. 
     
     
         12 . A method for manufacturing an article for footwear, the method comprising steps of:
 a. placing a sock on a last, wherein the sock defines a sole area, a pair of lower sides, and a lower front side and a lower rear side;   b. coupling a layer to the sock in the sole area of the sock, the layer defining a heel area;   c. coupling a heel cushion to the layer in the heel area of the sock;   d. providing a mold configured to receive the last and the sock, the mold defining an upper portion and a bottom portion;   e. placing a heel-area piece and a ball-area piece in the bottom portion of the mold;   f. introducing the last and the sock, with the layer in the sole area and the heel cushion, into the mold;   g. closing the mold; and   h. injecting a polymer material into the bottom portion of the mold, the polymer material flowing to the sole area, the pair of lower sides, the lower front side, and the lower rear side of the sock.   
     
     
         13 . The method of  claim 12  further comprising a step of removing the article from the mold and trimming any excess polymer material. 
     
     
         14 . The method of  claim 12  wherein the step of coupling the layer in the sole area to the sock uses a self-adhesive surface on the layer. 
     
     
         15 . The method of  claim 12  wherein the step of coupling the heel cushion to the layer uses a self-adhesive surface on the heel cushion. 
     
     
         16 . The method of  claim 12  wherein the polymer material is polyurethane. 
     
     
         17 . The method of  claim 12  wherein the heel-area piece and the ball-area piece are formed substantially of rubber. 
     
     
         18 . The method of  claim 12  wherein the layer coupled in the sole area of the sock is formed substantially of a non-woven fabric. 
     
     
         19 . The method of  claim 12  wherein the heel cushion is formed substantially of ethylene-vinyl acetate (EVA).