Conformable Booties, Shoe Inserts, and Footwear Assemblies Made Therewith, and Waterproof Breathable Socks

Abstract

Waterproof, breathable socks, booties, shoe inserts, and footwear assemblies containing the shoe inserts are provided. The booties and shoe inserts include a laminate of a seamless ePTFE membrane and at least one textile. The bootie is conformable over a range of sizes and shoe shapes, and may be shaped to fit numerous sizes and shapes of asymmetrical shoe lasts. The bootie may shrink to fit, or, alternatively, be stretched to fit, an asymmetrical last having a desired size to form a shoe insert. Such a conformable bootie eliminates the need to have multiple sizes of shoe inserts correlating to particular shoe sizes. In embodiments where the ePTFE is seamless and continuous, the shoe insert eliminates the need for a waterproof seam tape, which is conventionally used to make shoe inserts waterproof. Methods of forming the socks, booties, and shoe inserts are also provided.

1 - 83 . (canceled) 
     
     
         84 . A method of forming a bootie comprising:
 placing a first textile layer over a last;   setting an expanded polytetrafluoroethylene (ePTFE) tape in a frame, the expanded polytetrafluoroethylene (ePTFE) tape having an extensibility of at least 1.5× in at least one direction;   applying an adhesive on (1) a side of said first textile layer or (2) a side of said ePTFE tape;   rotating the last having the first textile layer through the ePTFE tape to deform the ePTFE tape to the shape of the last; and   bonding the adhesive to adhere the first textile layer to the ePTFE tape to form said bootie comprising a seamless ePTFE layer and a first textile layer.   
     
     
         85 . The method of  claim 84 , wherein at least two sides of said ePTFE tape are set into said frame. 
     
     
         86 . The method of  claim 84 , further comprising removing said ePTFE tape from said frame once said ePTFE tape is deformed to the shape of said last. 
     
     
         87 . The method of  claim 84 , further comprising heating said ePTFE tape when fixed in said frame to a temperature from 50 to 200° C. 
     
     
         88 . The method of  claim 84 , wherein said last is an asymmetrical last. 
     
     
         89 . The method of  claim 84 , wherein the said ePTFE layer has a thickness variation from a first location in said bootie to a second location in said bootie of at least 1.2:1. 
     
     
         90 . The method of  claim 84 , wherein said ePTFE layer has a density greater than 2.0 g/m 2 . 
     
     
         91 . The method of  claim 84 , wherein said first textile layer comprises a knitted textile tube, a woven textile tube, a tubular sock or a formed sock. 
     
     
         92 . The method of  claim 84 , further comprising heating said bootie to a temperature from 50 to 200° C. 
     
     
         93 . The method of  claim 84 , wherein the deforming of said ePTFE tape to the shape of the last is done under vacuum. 
     
     
         94 . The method of  claim 84 , further comprising placing a second textile layer over the seamless ePTFE layer. 
     
     
         95 . The method of  claim 94 , wherein applying a second adhesive on a side of said second textile layer. 
     
     
         96 . The method of  claim 94 , wherein said second textile layer comprises a knitted textile tube, a woven textile tube, a tubular sock or a formed sock. 
     
     
         97 . The method of  claim 84 , wherein the last is rotated upward at an angle of 90°. 
     
     
         98 . The method of  claim 84 , wherein said bootie has a moisture vapor transmission rate of at least 3 g/hr. 
     
     
         99 . The method of  claim 84 , further comprising applying at least one polymeric overlay on said bootie. 
     
     
         100 . The method of  claim 84 , further comprising applying an abrasion resistant coating on said ePTFE layer. 
     
     
         101 . The method of  claim 84 , further comprising applying an oleophobic coating on said ePTFE layer. 
     
     
         102 . The method of  claim 84 , wherein said first textile layer possesses at least some elastic properties.