BACKGROUND

[0001] People engaging in physical or outdoor activities must be prepared for contrasting climates and weather. Certain articles, such as footwear, may include some type of waterproofing or durable water-repellant (DWR) treatment. Currently, waterproof footwear may include a waterproof liner or bootie. However, the conventional processes for manufacturing waterproof booties need improvement.

SUMMARY

[0002] A method of manufacturing a waterproof bootie comprises applying heat- activated adhesive (e.g., heat-activated adhesive , microwave absorptive cement) onto a surface of the membrane to generate a printed membrane; cutting the printed membrane to result in at least a first bootie portion and a second bootie portion; coupling the first bootie portion to the second bootie portion to form a bootie; arranging a knit upper adjacent the bootie; and activating the heat-activated adhesive to couple the knit upper to the bootie.

[0003] A method comprises applying heat-activated adhesive (e.g., heat-activated adhesive , microwave absorptive cement) onto a surface of the membrane to generate a printed membrane; cutting the printed membrane to result in at least a first bootie portion and a second bootie portion; coupling the first bootie portion to the second bootie portion to form a bootie; arrange the bootie on a planar rigid member; arrange a knit upper adjacent the bootie on the planar rigid member; and coupling, using the heat- activated adhesive , the knit upper to the bootie.

[0004] A method comprises preparing a membrane consisting essentially of a lateral lining pattern and a medial lining pattern; applying heat-activated adhesive (e.g., heat-activated adhesive , microwave absorptive cement) onto a surface of the membrane; applying heat to the surface of the membrane to activate the heat-activated adhesive and to generate a printed membrane; cutting the printed membrane to result in at least a first bootie portion and a second bootie portion; coupling the first bootie portion to the second bootie portion to form a bootie; sealing one or more seams of the bootie; arrange the bootie on a planar rigid member; arrange a knit upper adjacent the bootie on the planar rigid member; and coupling the knit upper to the bootie by applying heat and pressure to the stack of the knit upper and the bootie.

BRIEF DESCRIPTION OF THE DRAWINGS

[0005] The following drawings illustrate generally, by way of example, but not by way of limitation, various examples discussed in the present disclosure. In the drawings:

[0006] FIG. 1 shows an example set of five bootie patterns in accordance with the prior art.

[0007] FIGS. 2A-2B show an example bootie in accordance with the prior art.

[0008] FIGS. 3A-3B show an example cement sealing process in accordance with the prior art.

[0009] FIG. 4A-4B show an example gasket application in accordance with the prior art.

[0010] FIG. 5 shows an example waterproof bootie in accordance with the prior art.

[0011] FIG. 6 shows an example method of making a waterproof bootie in accordance with the present disclosure.

[0012] FIG. 7 shows an example set of two bootie patterns in accordance with the present disclosure.

[0013] FIGS. 8A-8B show an example application of heat-activated adhesive, for example using screen printing. Other application methods may be used.

[0014] FIG. 9 shows an example material with heat- activated adhesive disposed thereon.

[0015] FIG. 10 shows an example cutting procedure.

[0016] FIG. 11 shows an example coupling procedure.

[0017] FIG. 12 shows an example bootie in accordance with the present disclosure.

[0018] FIG. 13 shows an example upper.

[0019] FIG. 14 an example knit upper.

[0020] FIGS. 15A-15D show a process of arranging a bootie and knit upper over a rigid member.

[0021] FIG. 16 shows a bootie and knitted upper disposed over a rigid member. [0022] FIGS. 17A-17D show the arrangement of a toe box and heel counter relative to the bootie.

[0023] FIG. 18 shows a bootie and upper in accordance with the present disclosure.

[0024] FIG. 19 shows a bootie and upper on a last.

[0025] FIG. 20 shows an example cutting process of a bootie material.

[0026] FIG. 21 shows example cut portion of a bootie.

[0027] FIG. 22 shows removal of release paper of a heat-activated adhesive (e.g., hot melt film).

[0028] FIG. 23 shows the coupling of bootie portions to form a bootie.

[0029] FIG. 24 shows an example bootie in accordance with the present disclosure.

[0030] FIG. 25 shows sealing (e.g., taping) of a seam on a bootie.

[0031] FIG. 26 shows an example sealed bootie in accordance with the present disclosure.

[0032] FIG. 27 shows material preparation for an upper.

[0033] FIG. 28 shows an example heat pressing for markings such as logos.

[0034] FIG. 29 shows an example heel stitching of an upper.

[0035] FIG. 30 shows an example toe box and heel counter arranged with an upper.

[0036] FIG. 31-32 show an example coupling process for a toe box and heel counter.

[0037] FIG. 33-34 show example heel back molding and toe shaping of an upper.

[0038] FIG. 35 shows an example Strobel arranged with an insole for an upper.

[0039] FIG. 36 shows an example steaming operation.

[0040] FIG. 37 shows an example lasting process.

[0041] FIG. 38 shows an example cooling process for a lasted upper.

[0042] FIG. 39 shows an example lasting process for a bootie in accordance with the present disclosure.

[0043] FIG. 40 shows an arrangement of an upper and a bootie in accordance with the present disclosure.

[0044] FIG. 41 shows a last upper and bootie combination.

[0045] FIG. 42 shows an example heat activation process (e.g., microwave).

[0046] FIG. 43 shows a de-lasting operation. [0047] FIG. 44 shows an example of an upper and bootie in accordance with the present disclosure.

DETAILED DESCRIPTION

[0048] A waterproof bootie may be used to provide waterproofing to footwear. As an example, waterproofing may be provided to a knit upper my coupling a waterproof bootie to the knit upper and then completing the footwear article. Waterproofing may be based on one or more tests or standards. For example, whole shoe flex - waterproof testing may be based on SATRA TM 77-1992. However, other tests may be used including in-house testing such as immersion tank. As a further example, a waterproof test may comprise removing all tags, laces, and inserts, placing a weight inside the footwear, inserting the footwear into tank, fill tank and then remove footwear and inspect for leaks. Fill line may be 60% of the lowest point on a topline of the footwear or may be set at a predefined level (e.g., 120mm). A show flexing waterproof test may be used, such as by incorporating a show flexing waterproof tester/machine. Other tests may be used.

[0049] Conventional waterproof booties are complex and are not stretchable or breathable. FIG. 1 illustrates an example set of five patterns for a conventional bootie. The patterns may be cut from a material and may be stitched together to form a liner, as shown in FIG. 2A. In conventional process, the stitching seams are taped, as shown in FIG. 2B. The taped lining then goes through a multi-step sealing process including lasting, the application of cement on the liner, as shown in FIGS. 3A-3B, and drying of the cement. A waterproof gasket may be pressed onto the liner, as shown in FIGS. 4A-4B, resulting a waterproof bootie, shown in FIG. 5.

[0050] In accordance with the present disclosure, article and methods may result in a simplified waterproof bootie construction (as compared to the conventional process) and may require less labor. The bootie may be lightweight and comfortable to a wearer. The bootie may be formed with stretchable/breathable materials. Breathable materials may be defined in accordance with ASTM D737-2018. Breathable materials may comprise materials having cfm of .023 or higher, in accordance with ASTM D737-2018 (e.g., using Textest FX3300 Air

Permeability Tester III, with test pressure 125 Pa, and test area 38 sq.cm. Other thresholds or ranges may be used. Stretchable material may be defined by elongation. Elongation in accordance with VF-B01 test, may define a stretchable material as having elongation in length of greater than 131% under peak tension of from about 39.15 kgf to about 36.87 kgf at test speed on 300mm/min using a sample width of 25.4mm sample. Additional definition of stretachble may be derived from the follow data:

[0051] FIG. 6 illustrates an example method in accordance with the present disclosure.

[0052] At operation 602, a membrane may be prepared. The membrane may comprise a lateral lining pattern and a medial lining pattern, as shown in FIG. 7. The membrane may consist essentially of a lateral lining pattern and a medial lining pattern. The membrane may consist of a lateral lining pattern and a medial lining pattern. Various patterns may be formed on the membrane. The membrane may be formed from a stretchable or breathable material such as one or more of PTFE or TPU/PU.

[0053] At operation 604, a heat- activated adhesive may be disposed (e.g., applied) onto a surface of the membrane. The membrane may be cut pieces or roll material, for example. The heat-activated adhesive may be applied using screen printing, such as a shown in FIG. 8A. Other applications may be used such as a spraying application. Heat- activated adhesives, may be or comprise hot melt or a microwave absorptive cement.

[0054] At operation 606, heat may be applied to the surface of the membrane to activate the heat-activated adhesive and to generate a printed membrane, as shown in FIG. 8B.

As an example, applying heat to the surface of the membrane to activate the heat-activated adhesive and to generate a printed membrane may comprise heat drying the heat-activated adhesive.

[0055] At operation 608, the printed membrane may be cut. The printed membrane may be cut to result in at least a first bootie portion and a second bootie portion, as shown in FIG. 10. The cutting may be laser cutting. The cutting may be die cutting. The die cutting may use the same die for each of the first bootie portion and a second bootie portion.

[0056] At operation 610, the first bootie portion may be coupled to the second bootie portion to form a bootie, as shown in FIGS. 11-12. Such coupling may be stitching. The coupling the first bootie portion to the second bootie portion may comprise arranging the first bootie portion to the second bootie portion in a mirrored configuration and wherein the bootie comprises an ankle opening defined between the coupled first bootie portion to the second bootie portion. At operation 612, one or more seams of the bootie may be sealed, for example using tape. Tape condition, for example, may be:

[0057] The bootie may be coupled to a knit upper, such as the one shown in FIGS. 13- 14. At operation 614, the bootie may be arranged on a planar rigid member (e.g., board), as shown in FIGS. 15A-15C. At operation 616, a knit upper may be disposed adjacent the bootie on the planar rigid member, as shown in FIG. 15D.

[0058] At operation 618, the knit upper may be coupled to the bootie. As an example, since the bootie has heat-activated adhesive disposed thereon, heat and pressure may be applied to the stack of the knit upper and the bootie to cause the knit upper to be coupled to the bootie. The stack may me heat pressed using a conventional heat pressing machine to activate the adhesive (hot melt). Example conditions may be:

[0059] The bootie with the upper may be removed from the rigid member and the article (footwear) may be completed. Alternatively, the knit upper and liner may be formed around a last and may traverse a heat tunnel (e.g., 120-250C for 2~8 minutes). Alternatively, the knit upper and liner may be formed around a last and may undergo a steam and vacuum process (e.g., 120-250C for 2~8 minutes). Alternatively, the knit upper and liner may be formed around a last and may undergo a microwave energy process to activate a microwave absorbent cement as the adhesive.

[0060] As an example, a toe box may be coupled to the upper, as shown in FIG. 17B. A heel counter may be coupled to the upper, as shown in FIG. 17C. An insole board may be coupled to one or more of the upper or the bootie, as shown in FIG. 18. The bootie may then be positioned on a last for additional construction, as shown in FIG. 19.

[0061] FIGS. 20-26 show an example assembly process for a bootie in accordance with the present disclosure. As shown, a material may be cut based on a form of a desired bootie. An example material may comprise a membrane. Various patterns may be formed on the membrane. The membrane may be formed from a stretchable or breathable material such as one or more of PTFE or TPU/PU. The material may comprise a heat- activated adhesive such as a hot melt film. In certain aspects, a release paper may be removed from a hot melt film prior to assembly of the bootie, as shown in FIG. 22. Various patterns may be coupled together to form the bootie. As an example, two portions may be coupled together to form the bootie, as shown in FIG. 23. Coupling may comprise a sewn seam such as a zigzag along a center of the bootie.

Other coupling mechanisms may be used. The seam of the bootie may be sealed, for example using waterproof seam tape, such as shown in FIG. 25. A collar of the bootie portions may be bound using a binding technique. An end of the bootie may be stich bonded.

[0062] FIGS. 27-35 show an example assembly process for an upper, such as a knitted upper. A material for the upper may be prepared, for example based on one or more patterns, as shown in FIG. 27. In certain aspects, markings such as logos may be disposed on the upper material, for example using heat pressing, as shown in FIG. 28. A heel of the upper may be coupled using a stitching technique such as a zigzag stitch with cement. Other processes may be used. As shown in FIGS. 30-32, a toe box and/or heel counter may be arranged with the upper and may be coupled thereto, for example using cement for reinforcement. The heel may be molded and the toe may be shaped, as shown in FIGS. 33-34. A Strobel may be arranged with the insole of the upper, as shown in FIG. 35 to form an example upper.

[0063] The example upper may be subjected to a steam operation, such as shown in FIG. 36. Once steamed, the upper may be lasted, as shown in FIG. 37, and then cooled, as shown in FIG. 38. Once cooled, the upper may be de-lasted. An example bootie may be lasted, as shown in FIG. 39. The upper may be disposed on or about the lasted bootie, as shown in FIGS. 40-41.

[0064] The upper with the bootie may be subjected to a heat activation step such as a microwave chamber, as shown in FIG. 42. The heat activation process activates the adhesive to couple the bootie to the upper. The upper and bootie combination may be de-lasted (FIG. 43) to result in a coupled bootie/upper combination (FIG. 44). The combination provides waterproofing to the upper via the bootie.

[0065] The present disclosure comprises at least the following aspects:

[0066] Aspect 1 : A method of manufacturing a waterproof bootie, the method comprising: preparing a membrane consisting essentially of a lateral lining pattern and a medial lining pattern; applying heat-activated adhesive onto a surface of the membrane; applying heat to the surface of the membrane to activate the heat-activated adhesive and to generate a printed membrane; cutting the printed membrane to result in at least a first bootie portion and a second bootie portion; coupling the first bootie portion to the second bootie portion to form a bootie; sealing one or more seams of the bootie; arranging the bootie on a planar rigid member;

arranging a knit upper adjacent the bootie on the planar rigid member; and coupling the knit upper to the bootie by applying heat and pressure to the stack of the knit upper and the bootie.

[0067] Aspect 2: The method of aspect 1, wherein the membrane consists of the lateral lining pattern and the medial lining pattern.

[0068] Aspect 3 : The method of aspect 1 , wherein the membrane is formed from one or more of PTFE or TPU/PU.

[0069] Aspect 4: The method of aspect 1, wherein the membrane is formed from a stretchable material.

[0070] Aspect 5: The method of aspect 1, wherein the membrane is formed from a breathable material.

[0071] Aspect 6: The method of aspect 1, wherein the applying heat-activated adhesive comprises screen printing. [0072] Aspect 7: The method of aspect 1, wherein the applying heat-activated adhesive comprises spraying.

[0073] Aspect 8: The method of aspect 1, wherein the applying heat to the surface of the membrane to activate the heat-activated adhesive and to generate a printed membrane comprises heat drying the heat- activated adhesive.

[0074] Aspect 9: The method of aspect 1, wherein the cutting comprises laser cutting.

[0075] Aspect 10: The method of aspect 1, wherein the cutting comprises die cutting.

[0076] Aspect 11: The method of aspect 10, wherein the die cutting uses the same die for each of the first bootie portion and a second bootie portion.

[0077] Aspect 12: The method of aspect 1, wherein the coupling the first bootie portion to the second bootie portion comprises stitching.

[0078] Aspect 13: The method of aspect 1, wherein the coupling the first bootie portion to the second bootie portion comprises arranging the first bootie portion to the second bootie portion in a mirrored configuration and wherein the bootie comprises an ankle opening defined between the coupled first bootie portion to the second bootie portion.

[0079] Aspect 14: The method of aspect 1, wherein the sealing comprises taping.

[0080] Aspect 15: The method of aspect 1, further comprising coupling a toe box to the upper.

[0081] Aspect 16: The method of aspect 1, further comprising coupling a heel counter to the upper.

[0082] Aspect 17: The method of aspect 1, further comprising coupling an insole board to one or more of the upper or the bootie.

[0083] Aspect 18: An article formed using the methods of any one of aspects 1-17.

[0084] Aspect 19: The article of aspect 18, wherein the article comprises footwear.

[0085] Aspect 20: A waterproof bootie formed by a process comprising: preparing a membrane consisting essentially of a lateral lining pattern and a medial lining pattern; applying heat-activated adhesive onto a surface of the membrane; applying heat to the surface of the membrane to activate the heat-activated adhesive and to generate a printed membrane; cutting the printed membrane to result in at least a first bootie portion and a second bootie portion; coupling the first bootie portion to the second bootie portion to form a bootie; sealing one or more seams of the bootie; arranging the bootie on a planar rigid member; arranging a knit upper adjacent the bootie on the planar rigid member; and coupling the knit upper to the bootie by applying heat and pressure to the stack of the knit upper and the bootie.

[0086] Aspect 21 : The waterproof bootie of aspect 20, wherein the membrane consists of the lateral lining pattern and the medial lining pattern.

[0087] Aspect 22: The waterproof bootie of aspect 20, wherein the membrane is formed from one or more of PTFE or TPU/PU.

[0088] Aspect 23: The waterproof bootie of aspect 20, wherein the membrane is formed from a stretchable material.

[0089] Aspect 24: The waterproof bootie of aspect 20, wherein the membrane is formed from a breathable material.

[0090] Aspect 25: The waterproof bootie of aspect 20, wherein the applying heat- activated adhesive comprises screen printing.

[0091] Aspect 26: The waterproof bootie of aspect 20, wherein the applying heat- activated adhesive comprises spraying.

[0092] Aspect 27 : The waterproof bootie of aspect 20, wherein the applying heat to the surface of the membrane to activate the heat-activated adhesive and to generate a printed membrane comprises heat drying the heat-activated adhesive.

[0093] Aspect 28: The waterproof bootie of aspect 20, wherein the cutting comprises laser cutting.

[0094] Aspect 29: The waterproof bootie of aspect 20, wherein the cutting comprises die cutting.

[0095] Aspect 30: The waterproof bootie of aspect 29, wherein the die cutting uses the same die for each of the first bootie portion and a second bootie portion.

[0096] Aspect 31 : The waterproof bootie of aspect 20, wherein the coupling the first bootie portion to the second bootie portion comprises stitching.

[0097] Aspect 32: The waterproof bootie of aspect 20, wherein the coupling the first bootie portion to the second bootie portion comprises arranging the first bootie portion to the second bootie portion in a mirrored configuration and wherein the bootie comprises an ankle opening defined between the coupled first bootie portion to the second bootie portion.

[0098] Aspect 33: The waterproof bootie of aspect 20, wherein the sealing comprises taping. [0099] Aspect 34: The waterproof bootie of aspect 20, further comprising coupling a toe box to the upper.

[00100] Aspect 35: The waterproof bootie of aspect 20, further comprising coupling a heel counter to the upper.

[00101] Aspect 36: The waterproof bootie of aspect 20, further comprising coupling an insole board to one or more of the upper or the bootie.

[00102] Aspect 37: A method of manufacturing a waterproof bootie, the method comprising: applying heat-activated adhesive onto a surface of the membrane to generate a printed membrane; cutting the printed membrane to result in at least a first bootie portion and a second bootie portion; coupling the first bootie portion to the second bootie portion to form a bootie; arranging the bootie on a planar rigid member; arranging a knit upper adjacent the bootie on the planar rigid member; and coupling, using the heat- activated adhesive , the knit upper to the bootie.

[00103] Aspect 38: The method of aspect 37, wherein the membrane comprises a lateral lining pattern and a medial lining pattern.

[00104] Aspect 39: The method of aspect 37, wherein the membrane consists of the lateral lining pattern and the medial lining pattern.

[00105] Aspect 40: The method of aspect 37, wherein the membrane consists of the lateral lining pattern and the medial lining pattern.

[00106] Aspect 41: The method of aspect 37, wherein the membrane is formed from one or more of PTFE or TPU/PU.

[00107] Aspect 42: The method of aspect 37, wherein the membrane is formed from a stretchable material.

[00108] Aspect 43: The method of aspect 37, wherein the membrane is formed from a breathable material.

[00109] Aspect 44: The method of aspect 37, wherein the applying heat-activated adhesive comprises screen printing.

[00110] Aspect 45: The method of aspect 37, wherein the applying heat-activated adhesive comprises spraying. [00111] Aspect 46: The method of aspect 37, further comprising applying heat to the surface of the membrane to activate the heat-activated adhesive and to generate the printed membrane

[00112] Aspect 47: The method of aspect 37, wherein the cutting comprises laser cutting.

[00113] Aspect 48: The method of aspect 37, wherein the cutting comprises die cutting.

[00114] Aspect 49: The method of aspect 48, wherein the die cutting uses the same die for each of the first bootie portion and a second bootie portion.

[00115] Aspect 50: The method of aspect 37, wherein the coupling the first bootie portion to the second bootie portion comprises stitching.

[00116] Aspect 51: The method of aspect 37, wherein the coupling the first bootie portion to the second bootie portion comprises arranging the first bootie portion to the second bootie portion in a mirrored configuration and wherein the bootie comprises an ankle opening defined between the coupled first bootie portion to the second bootie portion.

[00117] Aspect 52: The method of aspect 37, further comprising coupling a toe box to the upper.

[00118] Aspect 53: The method of aspect 37, further comprising coupling a heel counter to the upper.

[00119] Aspect 54: The method of aspect 37, further comprising coupling an insole board to one or more of the upper or the bootie.

[00120] Aspect 55: An article formed using the methods of any one of aspects 37-54.

[00121] Aspect 56: The article of aspect 55, wherein the article comprises footwear.

[00122] Aspect 57: A method of manufacturing a waterproof bootie, the method comprising: applying heat-activated adhesive onto a surface of the membrane to generate a printed membrane; cutting the printed membrane to result in at least a first bootie portion and a second bootie portion; coupling the first bootie portion to the second bootie portion to form a bootie; arranging a knit upper adjacent the bootie; and activating the heat-activated adhesive to couple the knit upper to the bootie.

[00123] Aspect 58: The method of aspect 57, wherein the membrane comprises a lateral lining pattern and a medial lining pattern. [00124] Aspect 59: The method of aspect 57, wherein the membrane consists of the lateral lining pattern and the medial lining pattern.

[00125] Aspect 60: The method of aspect 57, wherein the membrane consists of the lateral lining pattern and the medial lining pattern.

[00126] Aspect 61: The method of aspect 57, wherein the membrane is formed from one or more of PTFE or TPU/PU.

[00127] Aspect 62: The method of aspect 57, wherein the membrane is formed from a stretchable material.

[00128] Aspect 63: The method of aspect 57, wherein the membrane is formed from a breathable material.

[00129] Aspect 64: The method of aspect 57, wherein the applying heat-activated adhesive comprises screen printing.

[00130] Aspect 65: The method of aspect 57, wherein the applying heat-activated adhesive comprises spraying.

[00131] Aspect 66: The method of aspect 57, further comprising applying heat to the surface of the membrane to activate the heat-activated adhesive and to generate the printed membrane

[00132] Aspect 67: The method of aspect 57, wherein the cutting comprises laser cutting.

[00133] Aspect 68: The method of aspect 57, wherein the cutting comprises die cutting.

[00134] Aspect 69: The method of aspect 68, wherein the die cutting uses the same die for each of the first bootie portion and a second bootie portion.

[00135] Aspect 70: The method of aspect 57, wherein the coupling the first bootie portion to the second bootie portion comprises stitching.

[00136] Aspect 71: The method of aspect 57, wherein the coupling the first bootie portion to the second bootie portion comprises arranging the first bootie portion to the second bootie portion in a mirrored configuration and wherein the bootie comprises an ankle opening defined between the coupled first bootie portion to the second bootie portion.

[00137] Aspect 72: The method of aspect 57, further comprising coupling a toe box to the upper. [00138] Aspect 73: The method of aspect 57, further comprising coupling a heel counter to the upper.

[00139] Aspect 74: The method of aspect 57, further comprising coupling an insole board to one or more of the upper or the bootie.

[00140] Aspect 75: The method of aspect 57, wherein the activation comprises one or more of heat pressing, steam and vacuum, microwaving, or us of a heat tunnel, or a combination of the same.

[00141] Aspect 76: An article formed using the methods of any one of aspects 57-75.

[00142] Aspect 77: The article of aspect 75, wherein the article comprises footwear.