FOOTWEAR WITH ZONED INSULATION

• US 20170280821A1
• Filed: 06/20/2017
• Published: 10/05/2017
• Est. Priority Date: 11/11/2015
• Status: Active Grant

• Current Assignee: Cabelas LLC (Bass Pro Group LLC)
• Original Assignee: Cabela's Incorporated (Bass Pro Group LLC)
• Inventors: RIDDLE, Michael Thomas, FORT, Brian Charles, SIRCY, Andrew Donavan, THOMAS, Colton Lee
• Granted Patent: US 10,357,079 B2
• Time in Patent Office: Days
• CPC Class Codes: A43B 23/026 Laminated layers
• CPC Class Codes: A43B 23/07 Linings therefor lining laminated with upper A43B23/026
• CPC Class Codes: A43B 3/02 Boots covering the lower leg
• CPC Class Codes: A43B 5/0405 Linings, paddings or insertions; Inner boots
• CPC Class Codes: A43B 7/12 Special watertight footwear overshoes A43B3/16
• CPC Class Codes: A43B 7/34 with protection against heat or cold
• CPC Class Codes: A43D 999/00 Subject matter not provided for in other groups of this subclass

Abstract

Footwear and a method of manufacture of footwear are presented. The footwear has different insulation zones and each zone has a different level of insulation. For example, an article of footwear includes a first insulation zone, a second insulation zone, and a third insulation zone. The first, second, and third insulation zones each provide a different level of insulation for a specific part of a wearer'"'"'s foot. The first insulation zone may be the heel region of the article of footwear, the second insulation zone may be the main part of the foot region of the article of footwear excluding both the heel region and a toe region of the article of footwear, and the third insulation zone may be the toe region of the article of footwear.

Claims

1. An article of footwear, comprising:

a first insulating material disposed in a first zone of the footwear, the first insulating material being configured to provide a first level of insulation to a first portion of at least one of a foot and a leg of a wearer of the article of footwear; and

a second insulating material disposed in a second zone of the footwear, the second insulating material being configured to provide a second level of insulation to a second portion of at least one of a foot and a leg of the wearer of the article of footwear.

2. The article of footwear of claim 1, wherein the first level of insulation is greater than the second level of insulation and the first insulating material includes a first number of layers of lofted insulation material and the second insulating material includes a second number of layers of lofted insulation material and the first number is greater than the second number.

3. The article of footwear of claim 1, wherein the insulating materials comprise layers of lofted insulation material joined together by stitching.

4. The article of footwear of claim 1, wherein at least one of the first insulating material and the second insulating material includes lofted insulation material.

5. The article of footwear of claim 1, wherein there is a difference of 400 grams between the first level of insulation and the second level of insulation.

6. The article of footwear of claim 1, wherein the article of footwear is a boot including a waterproof outer layer.

7. The article of footwear of claim 1, wherein the first zone of the footwear includes at least one of a toe region zone, a saddle region zone, a heel region zone, and a shaft region zone and the second zone of the footwear includes at least one of a toe region zone, a saddle region zone, a heel region zone, and a shaft region zone, wherein the combination of zones that comprise the first zone and combination of zones that comprise the second zones are mutually exclusive.

8. A method of assembling an article of footwear with multiple insulation zones, comprising the steps of:

providing an outsole for the article of footwear;

forming a first layer of insulation material that covers the entire foot region;

forming a second layer of insulation material that covers the saddle region and toe region;

forming a third layer of insulation material that covers the toe region;

attaching the first, second, and third layers of insulation to the outsole;

attaching rubber panels over the combined first, second, and third insulation layers and to the outsole.

9. The method of claim 8, wherein the first, second, and third insulation layers include a lofted insulation material.

10. The method of claim 8, further comprising the step of combining the first, second, and third layers of insulation before attaching the first, second, and third layers of insulation to the outsole;

wherein combining the first, second, and third layers of insulation comprises sewing the first, second, and third layers of insulation together with a quilted pattern such that the first, second and third layers of insulation remain together as one package during the assembly process.

11. The method of claim 8 wherein the first layer of insulation has a first insulation level of 200 grams, the second layer of insulation has a second insulation level of 200 grams, and the third layer of insulation has a third insulation level of 400 grams.

12. The method of claim 8 wherein the first layer of insulation has a first insulation level of 400 grams, the second layer of insulation has a second insulation level of 400 grams, and the third layer of insulation has a third insulation level of 400 grams.

13. The method of claim 8 wherein the first layer of insulation has a first insulation level of 1,200 grams, the second layer of insulation has a second insulation level of 400 grams, and the third layer of insulation has a third insulation level of 400 grams.

14. A method of assembling an article of footwear, comprising:

providing an outsole for the article of footwear;

forming a first zone of the footwear, the first zone having a first insulating material configured to provide a first level of insulation to a first portion of at least one of a foot and a leg of a wearer of the article of footwear; and

forming a second zone of the footwear, the second zone having a second insulating material configured to provide a second level of insulation to a first portion of at least one of a foot and a leg of a wearer of the article of footwear; and

attaching the first and second zones of the footwear to the outsole; and

attaching rubber panels over the combined first and second zones of the footwear and to the outsole.

15. The method of claim 14, wherein the first level of insulation is greater than the second level of insulation and the first insulating material includes a first number of layers of lofted insulation material and the second insulating material includes a second number of layers of lofted insulation material and the first number is greater than the second number.

16. The method claim 14, wherein the first zone of the footwear includes at least one of a toe region zone, a saddle region zone, a heel region zone, and a shaft region zone and the second zone of the footwear includes at least one of a toe region zone, a saddle region zone, a heel region zone, and a shaft region zone, wherein the zones that comprise the first and second zones are mutually exclusive.

17. The method of claim 14, further comprising the step of combining the first and second zones of the footwear before attaching the first and second zones of the footwear to the outsole;

wherein combining the first and second zones of the footwear comprises sewing the first and second zones of the footwear together with a quilted pattern such that the first and second zones of the footwear remain together as one package during the assembly process.

18. The method of claim 14, wherein at least one of the first insulating material and the second insulating material includes lofted insulation material.

19. The method of claim 14, wherein there is a difference of 400 grams between the first level of insulation and the second level of insulation.

20. The method of claim 14, wherein the article of footwear is a boot including a waterproof outer layer.