Foot covering

Abstract

A foot covering comprising a three dimensional molded portion formed of an elastomeric material molded onto a fabric material, wherein the molded portion is molded seamlessly 360° about the foot covering. The molded portion also preferably includes openings or perforations within the area of the molded portion for breathability The foot covering is manufactured by placing a sock comprising a fabric material in the form of at least a portion of a sock over a first mold part in the form of at least a portion of a foot and bringing at least one second mold part into molding engagement with the first mold part to create a cavity with the fabric material on the first mold part within the cavity. The elastomeric material is then injected into the cavity to form a molded portion, wherein the elastomeric material is injected on the side of the fabric material opposite the first mold part. Once the molded portion is formed, the second mold part is disengaged from the first mold part and the fully formed foot covering is removed from the first mold part.

1 . A foot covering comprising a three dimensional molded portion formed of an elastomeric material formed on a fabric material, wherein the foot covering includes a sole and a top with the molded portion formed continuously about the foot covering, 360° from the sole to the top, without a seam. 
     
     
         2 . The foot covering of  claim 1  wherein elastomeric material comprises a material is taken from the group consisting of a thermoplastic vulcanite (TPV) and a thermoplastic rubber (TPR) having a shore durometer of from about 15 to about 35 
     
     
         3 . The foot covering of  claim 2  wherein the elastomeric material is a TPR having a shore durometer of about 25. 
     
     
         4 . The foot covering of  claim 1  wherein the molded portion has a thickness of from about 0.8 to about 10.8 mm with the elastomeric material including two or more areas of differing thicknesses within the range of from about 0.4 to about 10.0 mm. 
     
     
         5 . The foot covering of  claim 4  wherein the fabric material is a knit hydrophilic material having a thickness of from about 0.4 to about 1.8 mm. 
     
     
         6 . The foot covering of  claim 5  wherein the knit hydrophilic material comprises a nylon material and has a thickness of from about 0.5 to about 0.8 mm. 
     
     
         7 . The foot covering of  claim 4  wherein the molded portion has a first area in which the elastomeric material has a thickness of from about 0.4 to about 3.0 mm. 
     
     
         8 . The foot covering of  claim 7  wherein the molded portion has a raised area in which the elastomeric material has a thickness of from about 1.0 to about 5.0 mm 
     
     
         9 . The foot covering of  claim 8  wherein the raised area includes at least one of a heel area, a ball of the foot area and a toe area. 
     
     
         10 . The foot covering of  claim 1  wherein different portions of the molded portion are formed with elastomeric materials having different physical characteristics. 
     
     
         11 . The foot covering of  claim 1  wherein the fabric material extends beyond the molded portion. 
     
     
         12 . The foot covering of  claim 1  wherein the molded portion surrounds one or more open fabric portions. 
     
     
         13 . The foot covering of  claim 12  wherein the molded portion surrounds open fabric portions in an area between an arch on the top of the foot and a toe area. 
     
     
         14 . A method of manufacturing a foot covering having a three dimensional molded portion for surrounding at least a portion of a foot comprising the steps of:
 a. placing a fabric material in the form of at least a portion of a sock over a three dimensional first mold part in the form of at least a portion of a foot;   b. bringing a second mold part into molding engagement with the first mold part to create a cavity between the first mold part and the second mold part with at least a portion of the sock on the first mold part within the cavity; and   c. injecting an elastomeric material into the cavity to form a molded portion, wherein the elastomeric material is injected on the side of the fabric material opposite the first mold part.   
     
     
         15 . The method of  claim 14  further comprising the steps of:
 d. disengaging the second mold part from the first mold part; and 
 e. removing a fully formed foot covering from the first mold part. 
 
     
     
         16 . The method of  claim 14  wherein the second mold part includes elements for forming a molded portion with two or more adjacent elastomeric areas of differing thicknesses. 
     
     
         17 . The method of  claim 14  wherein the second mold part includes elements for forming a molded portion with one or more textured gripping portions taken from the group consisting of gnarled portions, dimples, bumps, w-shaped members, v-shaped members, textured loops, perforations and embossed gripping details. 
     
     
         18 . The method of  claim 14  wherein the mold parts create a cavity that extends 360° about at least a portion of the foot covering between the ankle and the toes without a seam. 
     
     
         19 . The method of  claim 14  wherein the molded portion includes open areas or perforations through the elastomeric material. 
     
     
         20 . The method of  claim 14  wherein step (b) further comprises bringing a third mold part into molding engagement with the first and second mold parts to create a cavity with the fabric in the form of at least a portion of a sock on the first mold part. 
     
     
         21 . The method of  claim 20  wherein the second mold part is adapted to mold onto at least a portion of one side of the fabric in the form of at least a portion of a sock and the third mold part is adapted to mold onto at least a portion of the other side of the fabric in the form of at least a portion of a sock.