Protective shoe coverings

A protective shoe covering of a single piece of flexible material having an upper section and heel, toe and sole covering portions with an opening in its upper section. The single piece of flexible material has a pair of opposed panels so joined together along sole, toe, and heel covering portions that the remaining upper section of the shoe covering is without seam, thereby providing improved bacteria and dust barrier properties.

BACKGROUND OF THE INVENTION 
The present invention relates to sanitary protective foot and shoe 
coverings and more particularly to disposable sanitary protective 
coverings adapted to be used as shoe coverings. 
Protective shoe coverings are employed for various purposes in hospitals 
and similar institutions where it is required that foreign matter from 
shoes be prevented from contaminating surrounding areas. One typical area 
where such products are extensively used is in operating rooms where the 
operating room personnel must prevent contamination of the room, equipment 
and other materials in the room from foreign matter carried by the shoes 
or boots of the personnel entering the room. In addition, such coverings 
also protect the foot wear, and in some instances, the lower portions of 
trousers and socks of the personnel from becoming soiled due to contact 
with, for example, soiled or contaminated operating room materials such as 
wet sponges, toweling, irrigating liquids, drippings and the like. Another 
application of protective shoe coverings is found in areas of patient 
isolation to prevent contamination of shoes and cross-contamination of 
patients. Furthermore, depending upon their particular use, the shoe 
coverings are also employed to dissipate or reduce the possibilty of 
generating static electricity between shoes worn by personnel and the 
floor surfaces; the latter requirement is essential when the foot wear 
coverings are employed in operating rooms where gaseous anesthetic 
mixtures are employed. 
The art contains many proposed types and variations of foot or shoe 
coverings for the above purposes; typically, they are made of suitable 
flexible material providing the characteristics required for a particular 
use. In general, such disposable foot wear coverings well known in the art 
are comprised of several component parts which are assembled together by 
suitable means, and provided with suitable tying means added to the 
resulting product. Thus, such foot coverings are fabricated from an 
assemblage of several components, requiring several manufacturing steps to 
provide a completed product. 
Foot coverings of a single or few components are taught in U.S. Pat. Nos. 
3,824,714; 3,798,503 and 3,648,109, which illustrate disposable foot 
coverings of a single length of flexible material manufactured by a simple 
and economical process which eliminates extra manufacturing steps 
associated with foot coverings assembled from several component parts. 
However, although foot wear coverings made from a single piece of material 
have been taught, the fabrication of those shoe coverings include seams or 
stitches on the upper, front portion of the shoe coverings. 
Notwithstanding their advantages, these foot wear coverings have not proven 
entirely satisfactorily under all conditions of service for the reason 
that bacteria and dust particles are able to penetrate at the seam or 
juncture of the component parts or at the seam or juncture of the panels 
in the case of a single piece of material, especially when the seam is 
located on the upper front portion of the covering. 
Besides protective coverings for the shoes of the wearer, protective 
coverings in the form of low cut boots are also used by hospital and 
institution personnel. One typical protective boot is disclosed in U.S. 
Pat. No. 3,824,714. This boot covers the shoes of the wearer and encloses 
the trouser leg of the wearer so as to afford protection in those areas. 
Included on this boot and other typical boots is an electrically 
conductive tape to minimize static electricity build-up; tie string means 
are included on the upper portion of the boot to secure the upper portion 
snugly around the ankle of the wearer. 
While tie string means are well known to secure both shoes and boots to the 
foot of the wearer, some problems have surfaced in their use. For 
instance, tie strings on protective boots may keep the boot flaps held 
around the leg of the wearer; however, due to loosening of the tie strings 
oftentimes the boot flaps do not remain up on the leg of the wearer, but 
tend to slide down. When this happens, the trousers and/or socks of the 
wearer become exposed to contaminated operating room materials. 
SUMMARY OF THE INVENTION 
In accordance with the present invention there is provided an improved shoe 
covering which is fabricated from a single length or piece of flexible 
material. The new shoe covering is simple and economical to manufacture; 
easy to put on and remove; and may be provided with elastic means to 
tightly seal the shoe of the wearer from the outside environment. 
The footwear of the present invention, whether a shoe covering or a boot 
for covering the shoes and trousers of the wearer, provides a number of 
advantages which have been lacking in the prior art. The seamfree front of 
the footwear of this invention reduces the chance of contamination of the 
room and protects the footwear from coming into contact with soiled or 
contaminated operating materials, for example, wet towels, irrigating 
liquids, etc. In accordance with one aspect of the invention, a protective 
shoe cover is made from a single piece of flexible material. The flexible 
material has a pair of opposed panels joined together along a substantial 
portion of the edges of the panels to define a shoe-shaped enclosure with 
an opening in the upper section of the enclosure for receiving a shoe of 
the wearer. To form the shoe-shaped enclosure the edges of the panels are 
joined at the heel, sole and toe covering portions, thereby providing a 
seam in those portions. Included in the enclosure is an upper portion with 
an opening being formed by the free, unjoined edges of the panels. The 
remaining upper portion of the shoe covering between the opening and the 
toe covering portion is a section of the flexible material which is 
completely free of a seam. 
Another advantage of this invention is that these shoe coverings may employ 
a conductive strip which is attached flat to the sole covering portion of 
the shoe covering to ensure comfort and reduce the hazard of static 
electricity building up in the body of the wearer in attendance during 
hospital surgery. 
A further advantage in the footwear of this invention is provided by the 
use of an elastic means around the foot-receiving opening in preferred 
embodiments of the shoe covering. The elastic holds the covering securely 
on the shoe of the wearer while preventing the covering from slipping off 
during use. 
In accordance with another aspect of the present invention, a new 
protective covering for the trousers and lower leg of the wearer in the 
form of a flexible boot has been discovered. When embodiments of the 
shoe-shaped bottom portion of the boot are constructed of a single piece 
of material with no seam on the front portion, the boot will have all the 
aforementioned advantages of the shoe covering. The boot of the present 
invention has means which prevents the boot from sliding down the trousers 
after the upper section of the boot has been secured around and fastened 
to the leg of the wearer. This advantage insures the comfort and safety of 
the wearer and reduces contamination and cross-contamination of patients 
and the users in areas of the operating room clean air rooms, etc. 
These advantages are accomplished in the present instance by providing a 
boot for covering a shoe and the lower leg of a wearer including a lower 
section of a flexible material in the form of a shoe-shaped enclosure with 
an opening for receiving the shoe or foot of the wearer. An upper section 
of flexible material is joined to the lower section substantially around 
the opening and extending in an upward direction from the opening to form 
a covering for encircling the lower leg of the wearer. The material of the 
upper section includes an inside surface and an outside surface. Adhesive 
means are located on the inside surface of the upper section for 
adhesively fastening the upper section to the leg or trousers of the 
wearer whereby in use, the booot is prevented from sliding down from the 
trousers. 
In the preferred embodiment of the boot of the present invention, a 
conductive strip is attached to the lower section and is placed inside the 
boot to ensure that the wearer is protected against electrical charges. 
The preferred embodiment also includes a collar joining the upper and 
lower sections of the boot including elastic means for securing the lower 
section on the shoe of the wearer, the elastic producing a good fit and 
improving the appearance of the product, while reducing the chances of the 
trousers slipping out. 
The footwear covering of the present invention conform to the shoe of the 
wearer due to the configuration of flat sole, round toe and collar means 
around the opening through which the foot of the wearer is inserted. This 
snug fit provides for comfortable movements of the wearer without the 
danger of tripping.

DETAILED DESCRIPTION OF THE INVENTION 
Referring to the drawings, there is shown in FIGS. 1 to 4 the preferred 
embodiment of the protective foot wear covering of the present invention, 
generally designated 10. As shown in FIGS. 1 and 2, the protective 
footwear covering fits over the shoe of the wearer. In this instance, the 
product illustrated is adapted to be used as an operating room foot wear 
covering, to prevent contamination from a shoe or a foot, to prevent 
soiling of the users foot apparel, and to provide grouning means to 
prevent the build-up of static electricity. 
As illustrated more clearly in the embodiment of FIG. 5, shoe cover 10 is 
made from a single piece of flexible material or blank 9, such as a 
polyethylene film backed nonwoven fabric, with a thickness of 
approximately 0.003 inch (0.0076 cm.) Blank 9 comprises a pair of opposed 
panels indicated by reference numerals 11a and 11b, which, in a layflat 
condition, are of a substantially identical configuration. Panels 11a and 
11b, are joined to each other along center line 12 of blank 9. Desirably, 
the panels 11a and 11b are integrally joined at the center 12 of a single 
piece of material or blank 9. The free margins of panels 11a and 11b form 
sole covering portions 14a and 14b, heel covering portions 16a and 16b, 
toe covering portions 18a and 18b, and free edge or margin portions 19a 
and 19b which, in the finished product cooperate to form a foot or 
shoe-receiving opening 20 into which the wearer inserts his foot. A length 
of elastic material 22 is attached to the free edge or margin portion 19a 
and 19b around the opening 20. This elastic material secures and holds the 
shoe covering against the foot of the wearer to retain the covering on the 
shoe. 
Any suitable means for securing the sole covering portions 14a and 14b, the 
heel covering portions 16a and 16b, and the toe covering portions 18a and 
18b respectively, toegther may be employed; for example, the edges of the 
respective cover portion may be stitched, heat sealed when thermosplastic 
materials are use, glued and the like. The preferred embodiment 
illustrated in the drawings utilizes stitching, the seams of the joined 
portions being evident. In the finished product depicted in the drawings 
the portions of the panels which are joined define a shoe-shaped enclosure 
23. Panels 11a and 11b form an upper portion 24 of the enclosure 23 which 
is without any seams in the area between the opening 20 and the toe 
covering portion 18a and 18b. The absence of the seam provides a better 
barrier against contamination between the surrounding and the shoe of the 
wearer. This upper portion of the footwear covering 10 generally assumes 
the contour of the wearer's foot or shoe. The sole covering portion 26 of 
the footwear covering 10 is generally flat as best illustrated in FIG. 4. 
It is to be noted that the seams where the panels of the enclosure 23 are 
joined together are positioned under the sole and behind the heel of the 
shoe, thereby greatly reducing the possibility of cross-contamination 
between the shoe of the wearer and the environment. The front of the upper 
portion 24 of the footwear covering 10 is joined along toe covering 
portion 18a and 18b, the contour of which is substantially round as best 
shown in FIG. 1. Thus, toe covering portion 18a and 18b will, when the 
footwear covering is in use, provide a contour conforming generally to the 
shoe. While the round toe accommodates most shoe styles, other 
configurations, such as, for example, a square configuration, may also be 
utilized for the toe covering portion. 
In keeping with the invention the opening 20 is located in the upper 
portion 24 of the enclosure 23, generally adjacent the heel covering 
portion 17, as best seen in FIG. 3. The remaining upper portion between 
the opening 20 and the toe covering portion 18a and 18b is a section of 
the flexible material of the enclosure 23 which is free of any seams. 
Further, in accordance with the invention the foot covering, when intended 
for operating room use, preferably is fabricated from a suitable 
anti-static material, or in the alternative, includes an anti-static strip 
28. The inclusion of the anti-static strip 28 is to provide a means to 
ground the wearer and prevent static electricity build-up, and is included 
in accordance with conventional techniques and practices. As indicated, 
the strip 28 may be of any suitable material inherently or rendered 
electrically antistatic and secured to the shoe covering in a conventional 
location to perform its function. Generally, the strip 28 is secured to 
the sole covering area 26 of the shoe covering, leaving a free end portion 
as shown in FIG. 3 which may then be tucked inside the footwear covering 
or inside the sock 29 of the wearer when in use as seen in the drawings. 
The preferred footwear covering of the present invention which also 
protects the lower leg or trousers of the wearer is depicted in FIGS. 6 
and 7. This preferred footwear is a boot 60 with a lower section 61 made 
of flexible material in the form of a shoe-shaped enclosure. The 
shoe-shaped enclosure has a toe covering portion 62, a sole covering 
portion 64 and a heel covering portion 65 and also foot-receiving opening 
66 into which the shoe or foot of the wearer is inserted. In the preferred 
form the lower, shoe-shaped section is the same or similar covering as 
defined in FIGS. 1 to 4 of the invention, namely, being constructed of a 
single length of flexible material while having no seams on the upper 
front portion thereof. While this shoe-shaped section is preferred, any 
flexible shoe-shaped material will suffice as the lower section of the 
boot, including those shoe-shaped sections or enclosures with multiple 
components such as separate upper portions and sole portions stitched 
around the periphery of the sole portion. 
The boot 60 also includes an upper section 68 of flexible material joined 
to the lower section 61 substantially around the opening 66. In one form 
the upper section 68 and the lower section 61 may be formed from one piece 
of material so that the respective sections are integral in nature. 
However, where economical and practical the upper and lower sections are 
separate pieces joined together by stitching, gluing, etc. It is often 
desirable to include a collar at the point where the upper and lower 
sections are joined, so that the boot can be secured to the shoe of the 
wearer without slipping off. The collar 69 may be a gathering of the 
material by stitching or the like in order to provide some means of 
preventing the shoe portion from slipping off during use. Preferably, 
however, the collar 69 includes an elastic which provides the means to 
secure the lower, shoe-shaped section 61 of the shoe on the wearer's foot. 
While joined to the lower section around its opening, the upper section 68 
has flexible material extending in an upward direction to form a covering 
for encircling the lower leg of the wearer. In the particular boot 
illustrated the upper section 68 extends upwardly from the opening 66 so 
that two opposing wrappable flap segments 72 and 74 of the flexible 
material of the upper section 68 are formed. A gap 70 or break in the 
material separates the flaps 72 and 74 so that subsequent overlapping of 
the flaps can take place during use by the wearer. 
Located on flaps 72 and 74 of this embodiment are adhesive areas 75. The 
adhesive area 75 is positioned on the inside surface of the flaps so that 
the adhesive surface can be pressed against either the leg of the wearer 
or, preferably, the trousers of the wearer during use. Use of the adhesive 
attachment means will provide not only a technique for holding the upper 
section 68 around the leg of the wearer, but also a sufficient means for 
holding the upper section in place without subsequent sliding down. Any 
well known pressure-sensitive adhesive may be used to satisfy the 
requirements of this invention. While both flaps are shown with adhesive 
areas in the attached illustration, it is only essential that one flap 
have adhesive on the inside surface since other fastening means may be 
associated with the outside surface of the first flap or the inside 
surface of the second flap to secure the second flap in place as will 
hereinafter be described. 
To protect the pressure-sensitive adhesive during storage, shipping and 
before use it is desirable to cover the adhesive 75 with a protective 
release sheet 76. Release sheets to protect adhesive areas are well known, 
and may be selected accordingly to perform the function indicated. When 
the boot is ready for use, the wearer simply peels the protective release 
sheet from the adhesive area thereby exposing the adhesive which is to 
perform the fastening. 
Since these boots are generally worn in operating areas with explosive 
gaseous atmospheres, it is further desirable to include an anti-static 
strip 71 on the boot. The strip 71 is attached to the sole covering 
portion 64 of the lower section 61 and, in the embodiment shown, is sewn 
so that it extends inside the heel covering portion 65 of the lower 
section. By being sewn inside, the anti-static strip is in ready position 
to be tucked in the shoe or the sock of the wearer to prevent undesirable 
static electricity build-up. Of course, the anti-static strip 71 may be 
sewn so that it extends outside the lower section of the boot, as long as 
it is made long enough to be tucked inside the shoe or the sock of the 
wearer. 
FIGS. 8, 9 and 10 show the boot on the shoe of the wearer and the technique 
of securing the upper section of the boot to the trousers of the wearer to 
prevent the boot from sliding down. In the worn position the lower section 
61 encloses the shoe of the wearer and is held securely on that shoe by 
means of the collar 69. At this time, before securing the upper flaps, the 
wearer conveniently tucks the anti-static strip 71 into his shoe or sock 
81 in order to effect the proper static grounding. As best seen in FIG. 8, 
the adhesive area on one upper extending flap 74 is exposed, the flap is 
wrapped around the lower leg, and the adhesive is pressed against the 
wearer's trousers to make an adhesive fastening. This fastening secures 
the flap 74 against the trousers 82 so that the upper section will not 
slide down the trousers 82 of the wearer. 
After wrapping the first flap 74 and adhesively securing that flap to the 
trousers, the wearer exposes the adhesive area on the other flap 72 by 
removing the protective release sheet 76 from the adhesive area, and wraps 
flap 72 around the lower leg and over the first flap 74. FIG. 9 shows the 
two flaps wrapped around the leg or trousers of the wearer in the 
completely fastened position. It can be seen that one of the two flaps 
(e.g., flap 74 in the illustrations) is adhesively fastened to the 
trousers 82 of the wearer; the second of the two flaps (e.g., flap 72 in 
the illustrations) partially overlaps, and is adhesively fastened to the 
outside surface of the first flap 74. This overlapping of the flaps not 
only secures the boot to the leg of the wearer, and prohibits the boot 
from sliding down, but also effectively covers the entire lower portion of 
the leg so as to reduce contamination while protecting the lower leg of 
the wearer from contact with contaminated materials. 
Instead of an embodiment in which both flaps have an adhesive area on the 
inside surface of the flap, other means of securing the second flap to the 
first flap may be utilized. For instance, in FIG. 10 there is shown an 
embodiment of a boot 90 in which a first flap 91 of the upper section 92 
includes an adhesive area on the inside surface thereof; in FIG. 10 the 
adhesive on the first flap is not seen since the flap 91 has been pressed 
and adhesively fastened to the trousers 94 of the wearer. 
On the outside surface of first flap 91 is a fastening means 95, such as a 
pressure-sensitive adhesive. With the pressure-sensitive adhesive 95 on 
the outside surface of first flap 91 no adhesive means is required on the 
second flap 97; secured flap 97 merely needs to be wrapped over and around 
the outside surface of first flap 91 in order to be receptive to the 
pressure-sensitive adhesive means 95 located thereon, thereby providing a 
fastening of the second flap. 
Of course, fastening means 95 on the outside surface of first flap 91 is 
not restricted to pressure-sensitive adhesives. Other fastening 
techniques, such as the "VELCRO" type system may suitably be employed. 
When using the "VELCRO" type system, the fastening means 95 on the first 
flap may be, e.g., the male portion of the system, and on the inside 
surface of second flap 97, there is located, e.g., the female portion of 
the "VELCRO" fastener 98. This system is used in conjunction with adhesive 
fastening means on the inside surface of first flap 91. Other fastening 
means to perform the above-described function may also be used. 
The footwear coverings of the present invention may by made from any 
suitable material having sufficient flexibility to permit conformity of 
the material to the footwear being worn. Such materials, include, by way 
of example, woven and nonwoven fabrics of thermoplastic fibers, 
cellulosics, and the like, resin coated woven and nonwoven fabrics as well 
as resin coated papers, and the like. By way of specific example, the 
preferable materials for forming the footwear coverings include nonwoven 
fabrics of natural or synthetic fibers or blends thereof, particularly 
mixtures of rayon and similar fibers with pulp fibers, resinous fiber 
materials such as those made of polyolefins (polyethylene) and copolymers 
of ethylene with other comonomers; polypropylene and copolymers thereof; 
polyvinylchlorice, etc. and resin coated paper and the like. Laminates of 
resinous films and wovens or nonwoven fibers and laminates of resinous 
films and paper products are also suitable materials for the present 
invention. The size, type, thickness, stiffness and other characteristics 
of the material must be selected, however, to fulfill the requirement that 
the material possess sufficient flexibility to conform to the outline of 
the shoe or similar article of footwear in use. 
Any particular material chosen may have additional characterisitics 
included therein or imparted thereto by various additive treatments. For 
instance, moisture resistance may be provided to the material of the shoe 
covering by treating the material with a water-repellent agent. In the 
case of footwear covering for hospital use, such as in operating rooms, 
the preferred materials are resin coated nonwoven fabrics, such as 
polyethylene-coated fabrics, which provide dust impermeability and 
moisture resistance. 
In still other forms of the footwear coverings of the present invention, 
other materials such as metallized plastic or fabric materials may be 
employed, or in still other cases, various types of metallic foils, such 
as aluminum and tin may be suitably formed into the foot coverings of the 
present invention. Such materials find application in various fields of 
use where the properties imparted to the covering by the metallic 
components are required. 
The foot covering products of the present invention may be made in any 
desirable size and proportion to accomodate varying shoe or foot sizes for 
the intended users. However, for most purposes, a single size has been 
found to be sufficient for most types of shoe coverings, due to the nature 
of the products of the present invention. 
The shoe coverings of the invention may be made by any suitable method 
known in the art. In general, a single length of flexible material is 
folded and cut to the desired shape by using a suitable die or other 
means. The specific manner of cutting will depend upon the type of 
material required. In the case of thermoplastic or other similar resins, 
these may be die-cut by suitable apparatus. For a continuous operation, 
the cutting may be carried out in a continuous-in-line formation technique 
by folding the material, feeding the folded material through a rotating 
cutter and subsequently discharging the cut shoe covering lengths or 
portions to a subsequent sealing operation. 
Thus, it is apparent that there has been provided, in accordance with the 
invention, protective coverings that fully satisfy the aims, advantages 
and aspects set forth above. While the invention has been described in 
conjunction with specific embodiments thereof, it is evident that many 
alternatives, modifications and variations will be apparent to those 
skilled in the art in view of the foregoing description. Accordingly the 
complete invention is intended to embrace all such alternatives, 
modifications and variations as fall within the spirit and broad scope of 
the described invention.