Slip-resistant, moisture absorbent sheet material

• US 5,714,229 A
• Filed: 12/18/1995
• Issued: 02/03/1998
• Est. Priority Date: 01/31/1992
• Status: Expired due to Fees

• Current Assignee: The Cadle Company II, Inc.
• Original Assignee: Ogden, Inc.
• Inventors: Ogden, John M.
• Primary Examiner(s): WATKINS III, WILLIAM P
• Application Number:
  US08/573,628
• Time in Patent Office: 778 Days
• Field of Search: 428/116, 428/138, 428/483, 428/338, 428/318.4, 428/424.4, 428/907, 36/43, 36/44, 36/3 B, 442/35, 442/57
• US Class Current: 428/138
• CPC Class Codes: A43B 1/0045 made at least partially of deodorant means
• CPC Class Codes: A43B 13/38 Built-in insoles joined to uppers during the manufacturing process, e.g. structural insoles; Insoles glued to shoes during the manufacturing process
• CPC Class Codes: A43B 17/14 made of sponge, rubber, or plastic materials
• CPC Class Codes: A63B 49/08 with special construction of the handle
• CPC Class Codes: A63B 60/14 Coverings specially adapted for handles, e.g. sleeves or ribbons
• CPC Class Codes: A63B 60/18 with means for cooling, ventilating or sweat-reduction, e.g. holes or powder dispensers
• CPC Class Codes: B32B 2262/0276 Polyester fibres
• CPC Class Codes: B32B 2262/062 Cellulose fibres, e.g. cotton
• CPC Class Codes: B32B 2307/304 Insulating
• CPC Class Codes: B32B 2307/7145 Rot proof, resistant to bacteria, mildew, mould, fungi
• CPC Class Codes: B32B 2307/7265 Non-permeable
• CPC Class Codes: B32B 2307/744 Non-slip, anti-slip
• CPC Class Codes: B32B 2437/02 Gloves, shoes
• CPC Class Codes: B32B 2471/02 Carpets
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/306 comprising vinyl acetate or vinyl alcohol (co)polymers
• CPC Class Codes: B32B 3/266 characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
• CPC Class Codes: B32B 5/022 Non-woven fabric
• CPC Class Codes: B32B 5/08 the fibres or filaments of a layer being of different substances , e.g. conjugate fibres, mixture of different fibres
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/26 : another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: Y10S 428/907 : Resistant against plant or animal attack
• CPC Class Codes: Y10T 428/24149 : Honeycomb-like
• CPC Class Codes: Y10T 428/24331 : including nonapertured component
• CPC Class Codes: Y10T 428/249987 : With nonvoid component of specified composition
• CPC Class Codes: Y10T 428/268 : Monolayer with structurally defined element
• CPC Class Codes: Y10T 428/31576 : Ester monomer type [polyvinylacetate, etc.]
• CPC Class Codes: Y10T 428/31797 : Next to addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 442/159 : Including a nonwoven fabric which is not a scrim
• CPC Class Codes: Y10T 442/197 : Including a nonwoven fabric which is not a scrim
• CPC Class Codes: Y10T 442/674 : Nonwoven fabric with a preformed polymeric film or sheet

Abstract

A sheet material which includes an apertured top layer formed of a non-absorbant, thermally non-conductive thermoplastic material, a non-woven layer having a first portion formed of a mixture of moisture-wicking and moisture-absorbent fibers affixed to the top layer, and, optionally, a second portion including fibers which are non-adsorbent and non-absorbent, and, in various embodiments, a barrier layer and/or cushioning layer forming a laminate in which the non-woven layer is sandwiched between the top layer and such other layers. The chemical formulation of the top layer of thermoplastic material can be varied to alter its coefficient of friction or degree of slip resistance depending upon the requirements of a particular application.

Claims

1. A sheet material, comprising:

a first layer formed of a slip-resistent, non-absorbent and thermally non-conductive thermoplastic material, said first layer being formed with a plurality of apertures having wall sections therebetween, said first layer having an outer, exposed surface and an inner surface;

a second layer affixed to said wall sections of said first layer, said second layer being formed of a non-woven material consisting of fibers which are intertwined with one another throughout the thickness of said second layer, said non-woven material having a basis weight in the range of about 2 ounces per square yard to about 5 ounces per square yard and a tear strength in the range of about 35 pounds to about 100 pounds in the machine direction and in the range of about 25 pounds to about 60 pounds in the cross direction, said second layer being effective to substantially prevent movement of said wall sections of said first layer relative to one another under the application of a shear force to said first layer having a magnitude on the order of that resulting from front-to-back, side-to-side or rotational movement of the foot of an individual within an article of footwear.

2. The sheet material of claim 1 in which said first layer is formed of an ethylene-vinyl acetate copolymer.

3. The sheet material of claim 2 in which said ethylene-vinyl acetate copolymer has a vinyl acetate content in the range of about 3% to 40% by weight.

4. The sheet material of claim 1 in which said first layer has in the range of about 7 to 107 apertures per square centimeter.

5. The sheet material of claim 1 in which said apertures are square in shape, said apertures forming spaced columns of first wall sections and spaced rows of second wall sections which intersect said first wall sections, said first layer having in the range of about 8 to 9 columns of first wall sections per lineal centimeter and in the range of about 8 to 9 rows of second wall sections per lineal centimeter.

6. A sheet material, comprising:

a first layer formed of a slip-resistant, non-absorbent and thermally non-conductive thermoplastic material, said first layer being formed with a plurality of apertures having wall sections therebetween, said first layer having an outer, exposed surface and an inner surface;

a second layer affixed to said wall sections of said first layer, said second layer being formed of a non-woven material consisting of a mixture of moisture-wicking fibers and moisture-absorbent fibers which are intertwined with one another in all directions throughout the thickness of said second layer, said non-woven material having a basis weight in the range of about 2 ounces per square yard to about 5 ounces per square yard and a tear strength in the range of about 35 pounds to about 100 pounds in the machine direction and in the range of about 25 pounds to about 60 pounds in the cross direction, said second layer being effective to substantially prevent movement of said wall sections of said first layer relative to one another under the application of a shear force to said first layer having a magnitude on the order of that resulting from front-to-back, side-to-side or rotational movement of the foot of an individual within an article of footwear.

7. The sheet material of claim 6 in which said moisture-wicking fibers are acrylic fibers.

8. The sheet material of claim 6 in which said moisture-absorbent fibers are cellulosic fibers.

9. The sheet material of claim 6 in which said first layer is formed of an ethylene-vinyl acetate copolymer.

10. The sheet material of claim 9 in which said ethylene-vinyl acetate copolymer has a vinyl acetate content in the range of about 3% to 40% by weight.

11. The sheet material of claim 6 in which said first layer has in the range of about 7 to 107 apertures per square centimeter.

12. The sheet material of claim 6 in which said apertures are square in shape, said apertures forming spaced columns of first wall sections and spaced rows of second wall sections which intersect said first wall sections, said first layer having in the range of about 8 to 9 columns of first wall sections per lineal centimeter and in the range of about 8 to 9 rows of second wall sections per lineal centimeter.

13. The sheet material of claim 6 in which said wall sections of said first layer have a height dimension and a width dimension each in the range of about 0.38 to 3.8 millimeters.

14. The sheet material of claim 6 in which said moisture-wicking fibers and said moisture-absorbent fibers each have a length in the range of about 1.9 to 7.6 centimeters.

15. The sheet material of claim 6 in which said moisture-wicking fibers and said moisture-absorbent fibers each have a substantially round cross section.

16. The sheet material of claim 6 in which said moisture-wicking fibers and said moisture-absorbent fibers are crimped.

17. The sheet material of claim 6 in which said second layer has a mixture in the range of about 25% to less than 50% moisture-wicking fibers, and 75% to greater than 50% moisture-absorbent fibers, by weight.

18. The sheet material of claim 6 in which said second layer has a mixture in the range of about 30% to 40% moisture-wicking fibers, and 60% to 70% moisture-absorbent fibers, by weight.

19. The sheet material of claim 6 in which said moisture-wicking fibers contain an antimicrobial agent.

20. The sheet material of claim 6 in which said moisture-wicking fibers and said moisture-absorbent fibers each have a denier per filament in the range of about 0.75 to 3.0.

21. A sheet material, comprising:

a first layer formed of a slip-resistant, non-absorbent and thermally non-conductive thermoplastic material having a plurality of apertures defining wall sections therebetween, said first layer having an outer, exposed surface and an inner surface;

a second layer formed of a non-woven material consisting of a mixture of moisture-wicking fibers and moisture-absorbent fibers which are intertwined with one another in all directions throughout the thickness of said second layer;

one of said slip-resistant, non-absorbent and thermally non-conductive thermoplastic material forming said first layer, and said fibers forming said second layer, being at least partially meltable to permit heat bonding of said inner surface of said first layer and said second layer;

said non-woven material having a basis weight in the range of about 2 ounces per square yard to about 5 ounces per square yard and a tear strength in the range of about 35 pounds to about 100 pounds in the machine direction and in the range of about 25 pounds to about 60 pounds in the cross direction, said second layer being effective to substantially prevent movement of said wall sections of said first layer relative to one another under the application of a shear force to said first layer having a magnitude on the order of that resulting from front-to-back, side-to-side or rotational movement of the foot of an individual within an article of footwear.

22. The sheet material of claim 21 in which said thermoplastic material is partially meltable.

23. The sheet material of claim 21 in which said moisture-wicking fibers are acrylic fibers.

24. The sheet material of claim 21 in which said moisture-absorbent fibers are cellulosic fibers.

25. The sheet material of claim 21 in which said moisture-wicking fibers and said moisture absorbent fibers each have a length in the range of about 1.9 to 7.6 centimeters.

26. The sheet material of claim 21 in which said moisture-wicking fibers and said moisture-absorbent fibers each have a substantially round cross section.

27. The sheet material of claim 21 in which said moisture-wicking fibers and said moisture-absorbent fibers are crimped.

28. The sheet material of claim 21 in which said second layer has a mixture in the range of about 25% to less than 50% moisture-wicking fibers, and 75% to greater than 50% moisture-absorbent fibers, by weight.

29. The sheet material of claim 21 in which said second layer has a mixture in the range of about 30% to 40% moisture-wicking fibers, and 60% to 70% moisture-absorbent fibers, by weight.

30. The sheet material of claim 21 in which said moisture-absorbent fibers contain an antimicrobial agent.

31. The sheet material of claim 21 in which said moisture-wicking fibers and said moisture-absorbent fibers each have a denier per filament in the range of about 0.75 to 3.0.

32. A sheet material comprising:

a first layer formed of a slip-resistant, non-absorbent and thermally non-conductive thermoplastic material, said first layer being formed with a plurality of apertures having wall sections therebetween, said first layer having an outer, exposed surface and an inner surface;

a second layer having a first surface connected to said inner surface of said first layer and a second surface, said second layer being formed of a non-woven material consisting of a mixture of moisture-wicking fibers and moisture-absorbent fibers which are intertwined with one another in all directions throughout the thickness of said second layer, said non-woven material having a basis weight in the range of about 2 ounces per square yard to about and a tear strength in the range of about 35 pounds to about 100 pounds in the machine direction and in the range of about 25 pounds to about 60 pounds in the cross direction, said second layer being effective to substantially prevent movement of said wall sections of said first layer relative to one another under the application of a shear force to said first layer having a magnitude on the order of that resulting from front-to-back, side-to-side or rotational movement of the foot of an individual within an article of footwear;

a third layer affixed to said second surface of said second layer, said third layer being formed of a cushioning material.

33. The sheet material of claim 32 in which said moisture-wicking fibers are acrylic fibers.

34. The sheet material of claim 32 in which said moisture-absorbent fibers are cellulosic fibers.

35. The sheet material of claim 32 in which said first layer is formed of an ethylene-vinyl acetate copolymer.

36. The sheet material of claim 35 in which said ethylene-vinyl acetate copolymer has a vinyl acetate content in the range of about 3% to 40% by weight.

37. The sheet material of claim 32 in which said first layer has in the range of about 7 to 107 apertures per square centimeter.

38. The sheet material of claim 32 in which said apertures are square in shape, said apertures forming spaced columns of first wall sections and spaced rows of second wall sections which intersect said first wall sections, said first layer having in the range of about 8 to 9 columns of first wall sections per lineal centimeter and in the range of about 8 to 9 rows of second wall sections per lineal centimeter.

39. The sheet material of claim 33 in which said wall sections of said first layer have a height dimension and a width dimension each in the range of about 0.38 to 3.8 millimeters.

40. The sheet material of claim 32 in which said second layer has a mixture in the range of about 25% to less than 50% moisture-wicking fibers, and 75% to greater than 50% moisture-absorbent fibers, by weight.

41. The sheet material of claim 32 in which said second layer has a mixture in the range of about 30% to 40% moisture-wicking fibers, and 60% to 70% moisture-absorbent fibers, by weight.

42. The sheet material of claim 32 in which said moisture-wicking fibers contain an antimicrobial agent.

43. The sheet material of claim 32 in which said moisture-wicking fibers and said moisture-absorbent fibers each have a denier per filament in the range of about 0.75 to 3.0.

44. The sheet material of claim 32 in which said cushioning material forming said third layer is formed of a material selected from the group consisting of latex foam, urethane foam, crosslinked polyethylene foam, ethylene-vinyl acetate foam, ethylene-vinyl acetate enhanced crosslinked polyethylene foam, sponge rubber foam and vinyl sponge foam.