Low-cost disposable protective foot covering

Low-cost, single-use, disposable foot coverings and a method of using them to facilitate the protection of the feet of individuals who remove their shoes and would otherwise have to walk barefoot are disclosed. Assemblages of a number of such foot coverings (e.g., in the form of a continuous serrated roll of them) and methods of making the assemblages are also disclosed. The foot coverings may be particularly useful at security stations (e.g., in airports) where individuals must remove their shoes for inspection and then walk barefoot until their shoes are returned to them.

BACKGROUND OF THE INVENTION AND OTHER INFORMATION

This invention concerns low-cost, disposable, protective footwear that can be easily and quickly put on and removed from the foot.

People in public places are sometimes required to remove their shoes, leaving them barefoot. (As used herein, the term “barefoot” refers to feet without shoes whether or not the feet are covered by socks or stockings, and the term “shoes” refers to all types of outer footwear, e.g., leather dress shoes, moccasins, sneakers, slippers, sandals, boots, and clogs.) For example, passengers at airports are often required to remove their shoes for inspection at security checkpoints and to pass through metal detectors while still barefoot. Aside from the possible discomfort caused by being barefoot on cold floors, walking on those floors, which are often heavily trafficked, is unsanitary.

Providing temporary footwear that has been pre-checked by security personnel to the millions of passengers around the world who travel by air each day so that they could pass through security checkpoints without being barefoot would be an almost impossible task. In the United States alone, there are on average about 1.7 million airline passengers each day. Even if only a third of them were required to remove their shoes for security screening, well over a million separate pieces of temporary footwear would be required for them. Unfortunately, it is possible that eventually all passengers will be required to remove their shoes and walk barefoot through security screening.

Removable overshoes are known (see, e.g., U.S. Pat. Nos. 2,449,936, 2,924,029, 2,986,823, 3,422,550, and 6,023,856), and in at least one airport, reusable bedroom-type slippers are furnished to passengers who remove their shoes to go through security check-points; however, to date, as far as is known by the inventor, there has been no solution to the present problem and, hence, the need remains for a solution, preferably one that is simple, economical, and easily implemented.

BRIEF SUMMARY OF THE INVENTION

An invention that satisfies those needs and provides still other benefits that will be apparent to those skilled in the art has now been developed. Broadly speaking, in one aspect this invention concerns a low-cost, single-use, disposable, elongate foot covering having a length and a width and comprising (a) a thin, substantially planar, elongate bottom portion having a length, a width, and a joining section and (b) a thin, substantially planar, elongate top portion having a length, a width, and a joining section, the top portion being superposed on the bottom portion and the two portions being joined to each other at their joining sections so that a concavity is formed between the top and bottom portions for receiving the foot of a person, the top section when lying completely flat having an opening too small to permit the foot to pass through but when not lying flat permitting the foot to pass through for placing in the concavity.

In another aspect, the invention concerns a continuous roll of a plurality of the foot coverings of this invention that are connected serially to one another on the roll by temporary connection means that also facilitate their separation from one another.

In another aspect, the invention concerns a method of manufacturing the continuous roll comprising the steps: (a) providing an elongate sheet of material having a length, a width, two elongate edges, one at each side of the sheet defining the width, an elongate central section running the length of the sheet, and two elongate edge sections running the length of the sheet, each one of the two elongate edge sections including a different one of the two edges; (b) folding the two elongate edges sections onto the elongate central section of the sheet to bring the two edges near each other; and (c) joining the two elongate edge sections to the elongate central section to form the roll of the plurality of the foot coverings.

In another aspect, this invention concerns a method of manufacturing a continuous roll of a plurality of the foot coverings comprising the steps: (a) providing an elongate tube of material having a width when the tube is lying flat and also having a length and (b) flattening the tube and forming parallel joinder lines that go across the width of the tube to form the roll of the plurality of the foot coverings.

In another aspect, the invention concerns a stack of a plurality of the foot coverings of this invention that are arranged for easy removal of one or more of the foot coverings at the top of the stack from the rest of the stack.

In another aspect, the invention concerns a method for facilitating the protection of the feet of individuals who remove their shoes and would otherwise have to walk barefoot, the method comprising providing to those individuals the foot coverings of this invention and allowing those individuals to temporarily wear those foot coverings.

In another aspect, the invention concerns a method for facilitating the protection of the feet of individuals who remove their shoes in connection with security screening at airports and would otherwise have to walk barefoot, the method comprising providing to those individuals the foot coverings of this invention and allowing those individuals to temporarily wear those foot coverings during security screening.

In another aspect, the invention concerns a method for facilitating security screening at airports by providing to the airports the foot coverings of this invention for use by individuals who are going to go through security screening.

The foot covering of this invention is preferably transparent (e.g., when used at airports to facilitate security screening) and of thin plastic film (e.g., for cost and manufacturing reasons). The foot covering is preferably made of a single (continuous) generally rectangular piece of thin plastic film having two oppositely disposed long sides and two oppositely disposed shorter sides. The piece of plastic film may be thought of as being divided into three sections, a main section and two wing sections of different lengths. The two wings sections are folded over onto the main section, and the main section becomes the bottom of the foot covering and the two wing sections become the top of the foot covering. The outer edges of the wing sections (which are the edges of the two shorter sides of the piece of plastic film) are brought close enough to form an opening through which the foot of a user may be inserted into the concavity that is formed inside when the two wing sections are joined to the main section along their longer edges (e.g., using tape, adhesive, tacking, or hot melt sealing). The front (toe) portion of the foot (i.e., the portion in front of the ankle) is inserted into the portion of the concavity formed by the main section and longer wing section. The rear (heel) portion of the foot is inserted into the portion of the concavity formed by the main section and shorter wing section. At least a part of the top of the foot covering is sufficiently deformable so that the opening, which is too small to permit a foot to pass through it and be placed inside the concavity when the top is lying flat, can be deformed enough to enlarge the opening sufficiently to allow the foot to pass through and be placed inside the concavity.

Making the foot covering from a continuous piece of material (e.g., as just described) or from an elongate tube (as described below) facilitates manufacturing a continuous roll of such foot coverings. Preferably the foot coverings on such a roll are joined by means (e.g., serrations) that facilitate easy separation of the foot coverings on the roll from one another, analogous to the way individual sheets on a roll of paper toweling for the kitchen are serially joined and can be torn from the roll.

The foot coverings are inexpensive to manufacture, can be easily distributed to potential users (e.g., by placing rolls of the foot coverings at security stations in airports, where the foot coverings needed can be easily torn from the rolls by passengers and/or security personnel), can be made of thin plastic film (preferably made from recycled material) and preferably can be recycled after use, can be transparent (which facilitates security screening of the feet themselves), protect the feet against dirt and pathogens, and can be easily and rapidly put on and removed from the feet. Other features and advantages will be apparent to those skilled in the art.

These drawings are for illustrative purposes only and should not be used to unduly limit the scope of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The foot covering of this invention can be made of any material that allows some or all of the advantages of this invention to be achieved. Thin plastic film (e.g., not more than just a few mils in thickness and perhaps only a mil in thickness) is preferred (a “mil” is a thousandth of an inch). When used in a security setting, clear (transparent) plastic is preferred although translucent or opaque materials may be used in some cases.

The material should be flexible enough so that at least a part of the top portion of the foot covering near the opening can be deformed to the extent necessary to easily and rapidly place the foot inside the foot covering as well as to easily and rapidly remove the foot covering from the foot. The material should also be resilient enough so that the foot covering can return at least partially to its original shape after the foot has been placed inside of it so that it captures (traps) the foot to the extent necessary to keep the foot covering on the foot while in use (e.g., while standing or walking). The material should also be strong enough so that it can be deformed, return to its original shape, and provide sufficient protection to the foot while in use. Puncture resistance and impermeability (to liquids, dirt, etc.) are also desirable. The material preferably is also recyclable.

Typical materials of construction are polyolefin films (e.g., polyethylene film). Woven and non-woven materials may also be used. Different materials may be used for different parts of the foot covering although a single material for the entire foot covering will usually be preferred. The material should provide sufficient traction on the floors where the foot covering will be used, for example, on the smooth floors often found near security checkpoints at airports. Materials that are too smooth and slippery (e.g., some plastic films) may be treated at least on the major face that will become the outside of the bottom of the foot covering to impart sufficient traction. Any suitable treatment may be used (e.g., roughening the surface, placing microscopic amounts of slightly tacky polymer on the surface, for example, by spraying).

InFIG. 1, foot covering20is being placed on left foot22. Right hand32and left hand34are spreading the sides of opening40apart so that front (toe) portion24of foot22can be placed in front (toe) portion36of the foot covering and rear (heel) portion26of foot22can be placed in rear (heel) portion38of the foot covering.

As show inFIGS. 2 and 3, the resilience of the material causes it to try to return to its original shape (i.e., the shape without the foot inside) so that the two sides or edges defining opening40press against the front and rear of leg30at about the height of ankle28, thereby keeping the foot covering on the foot while in use. Bottom portion44of the foot covering is proximate the sole of the foot and top portion42(which is in two parts, the front (toe) and rear (heel) sections) is proximate the top of the foot. Bottom portion44is joined to top portion42around their respective peripheries by joinders46,48, and50.

With reference toFIG. 4, rectangular piece52, from which foot covering20may be formed, has two oppositely disposed long sides54and56and two oppositely disposed short sides58and60and may be thought of as comprising three panels (or sections) of different sizes. Leftmost panel (wing section)36lies between or is defined or bounded by short side (edge)58and fold line48, central panel44lies between or is defined or bounded by fold lines48and50, and rightmost panel (wing section)38lies between or is defined or bounded by fold line50and short side (edge)60. Stated differently, leftmost panel36is between short side (edge)58and central panel44, and rightmost panel38is between central panel44and short side (edge)60. Fold lines48and50may be imaginary or may be actual scores, depressions, etc. in piece52, depending on the material and method used to manufacture the foot covering from single piece52. Joining sections90,92,94,96,98, and100, which in this embodiment are at the edge portions of the three panels, are used to attach wing sections36and38to central panel44to form concavity88of the foot covering (FIG. 3).

For foot coverings made from two or more separate pieces (and not from one piece, as inFIG. 4), joinders48and50may be the same as one or more of the other types of joinders used to connect the pieces together. In other words, adhesive may be used along the long sides of the pieces to connect them together, tape may be used along the front edges of front panel36and central panel44to connect them together, and a hot melt seam may be used along the rear edges of rear panel38and central panel44to connect them together. Preferably, however, foot covering20is made from one continuous piece of material and the front and rear joinders are continuous portions of the material (e.g., as at imaginary fold lines48and50).

The size, shape, and location of all of the joining sections may be any size, shape, and location that allow the benefits of this invention to be achieved. Thus, the joining sections need not be straight and need not extend to the edge of each panel. In other words, one or more of the joining sections may be displaced from the one or more proximate edges of the piece or pieces used to make the foot covering and the resulting one or more joinders will be displaced from the edges of the foot covering.

The joinders may be hot melt, adhesive, solvent, tape, tacking, rivets, or any other type of connector that allow the benefits of this invention to be achieved. The joinders may be continuous or discontinuous. For example, a continuous joinder line of adhesive need not be used and just a few spots of adhesive may be used. Preferably, however, a continuous joinder line will be used.

InFIG. 5, arrows62and64indicate panels36and38being folded up and over at fold lines48and50, so that edges58and60come towards one another, to form partially folded piece66. When this folding has been completed (so that panels36and38are superposed on panel44), joining sections90and94will lie on top of joining section92and joining sections96and100will lie on top of joining section98.

InFIG. 6, the folding of panels36and38onto panel44has been completed and two joinders46have been formed along the two long sides (indicated by reference numerals54and56inFIG. 4), thereby forming completed foot covering20. With reference also toFIGS. 4 and 5, joining sections90and94have been connected to joining section92to form one joinder46(preferably a hot melt seam), joining sections96and100have been connected to joining section98to form the other joinder46(preferably a hot melt seam), and the material at imaginary fold lines48and50constitutes joinders48and50. Joinders46,48, and50keep front (toe) portion36and rear (heel) portion38of the foot covering attached to bottom portion44, thereby forming concavity88into which the foot is placed (FIG. 3). Panels36and38have become and together comprise two-part top portion42of the foot covering (seeFIGS. 2 and 3), and panel44has become bottom portion44of the foot covering (seeFIGS. 2 and 3). Edges58and60have become the two long sides defining opening40and the material of construction is sufficiently deformable so that edges58and60can be moved apart sufficiently to allow a foot to be placed inside the foot covering (seeFIGS. 1 to 3).

FIGS. 7 and 8depict two different assemblages of the foot coverings of this invention. InFIG. 7, hand34is tearing one foot covering20from continuous roll68of identical foot coverings, which roll is mounted and free to rotate on shaft102, the tearing occurring along and being facilitated by serrations70between the foot coverings. InFIG. 8, hand32is removing topmost foot covering20from stack72of identical foot coverings through opening76in container74.

FIG. 9schematically illustrates a preferred method for making continuous roll68of foot coverings20. Continuous sheet of film82travels in the direction indicated by arrow110and is fed between curved flight bars78and80, which are separated by a space narrower than the width of film82when it is lying flat. The geometry of the apparatus (e.g., the shape, size, location, and separation of the flight bars) helps cause wing panels36and38(seeFIG. 4) to be folded over and brought together above main panel44(seeFIG. 5), thereby bringing edges58and60together to form opening40.

The folded film passes between bars84and86of apparatus104, which inserts a line of serrations70and also heats the folded film (top and bottom) along two narrow lines parallel to, close to, and on each side of the line of serrations sufficient to cause formation of two heat seal lines. Thus, one of the elongate heat seals is at the trailing long side of the foot covering on the downstream or exit side of apparatus104(i.e., the left side of apparatus104inFIG. 9) and the other elongate heat seal is at the leading long side of the foot covering on the upstream or feed side of apparatus104(i.e., the right side of apparatus104inFIG. 9). The completed foot coverings, connected by serrations70, are taken up on roll68as the roll rotates in the direction indicated by arrow112. Instead of producing a connected series of foot coverings, the foot coverings may be cut apart from one another by or after leaving apparatus104(even after they have been temporarily stored as a roll) to produce individual unconnected foot coverings, e.g. for stacking in a container (see, e.g.,FIG. 8).

Any temporary connection means that connects the foot coverings to one another serially (e.g., so that the connected series can be wound up on a roll) and that facilitates their separation from one another can be used. For example, continuous or discontinuous score lines, depressions, through-holes, any other suitable means or a mixture of such means can be used, but serrations (a series of discontinuous elongate cuts or holes through the connected foot coverings, which cuts or holes lie along a line, desirably a straight line) are preferred.

In another method of forming a connected series of the foot coverings of this invention, a tube of blown film is formed and then run through apparatus104or the like. Use of the tube eliminates the need to fold the wing sections (panels36and38inFIGS. 4 to 6) onto the central section (panel44), which is required when using a sheet (piece52ofFIG. 4), because the two edges58and60are already continuously joined to one another. Dies, anvils, lasers, or any other suitable means can be used to form any desired opening40in the tube prior to (or in some cases after) forming joinders46across the width of the tube and adding the temporary connection means (e.g., serrations70) using apparatus104or the like. After forming the series of foot coverings (by forming joinders46), the foot coverings may be separated from one another, e.g., for stacking.

The tube fed to apparatus104may be elongate (from which many foot coverings may be made) or may be the size of just a single foot covering, just as a flat sheet of film fed to apparatus104may be continuous (as inFIG. 9) or may be of a size for just a single foot covering; however, when using a tube or a flat sheet of film, an elongate tube or elongate sheet will generally be preferred so that a series of connected foot coverings are produced by apparatus104.

Regardless of whether made from a single piece (e.g., a sheet or a tube) or from a plurality of pieces, the foot covering itself will have superposed top and bottom portions joined to each other.

FIG. 10is a simplified plan view of preferred foot covering20, whose manufacture is illustrated inFIG. 9, and does not show the two elongate heat seals along the two long sides or the serrations. Edges58and60(also seeFIG. 4) define elongate opening40.

Opening40of foot covering20ofFIG. 11is wider than opening40inFIG. 10because edges58and60were not brought as close together before top portion42(which comprises wing panels36and38) was heat sealed (joined) to bottom portion44(seeFIGS. 1 to 6).

InFIG. 12, opening40is diagonally disposed, which may facilitate use of this foot covering on the right foot (for the left foot, opening40would be diagonally disposed in the opposite direction). InFIG. 13, the foot covering has rounded corners106. InFIG. 14, opening40is similar to that ofFIG. 10except that a short cut perpendicular to the longer part of the opening has been added, so that opening40now has four flaps108. The opening ofFIG. 15is X-shaped, the opening ofFIG. 16is oval, and the opening ofFIG. 17lies in the same direction as the length of the foot covering rather than perpendicular to the length (as inFIG. 10). These openings40can be formed whether starting with a tube or with a sheet of film.

Opening40can have any shape, size, and location that allow the benefits of this invention to be achieved; however, an elongate opening whose length is perpendicular to the length of the foot covering (as inFIGS. 10,11, and13) is preferred.

It is also preferred that the opening not be too close to the rear edge of the foot covering (because the rear portion of the opening is desirably at or near the ankle). Thus, the opening should be not at the rear edge and usually will be at least 1 millimeter, desirably at least 2 millimeters, more desirably at least 3 millimeters, most desirably at least 4 millimeters, preferably at least 5 millimeters, more preferably at least 6 millimeters, and most preferably at least 7 millimeters from the rear edge. In a foot covering suitable for an adult, the opening will usually be at least 25 millimeters from the rear edge. For example, with reference toFIG. 6, opening40is at least 7 millimeters from the rear edge of the foot covering, which rear edge inFIG. 6is joinder50. With reference toFIGS. 10 to 17, no portion of opening40in any of the foot coverings will be closer than 1 millimeter to the respective rear edge (the rear edge being the edge of each foot covering at the right side of each figure), and those openings will typically be at least 7 millimeters or more from the rear edge.

When the top portion of the foot covering is lying flat, the opening will typically be too small for a foot to pass through. Thus, the opening must be deformable enough so that a foot can be placed through the opening while it is being deformed and into the concavity. The opening must also be resilient enough so that it tries to return to its original size and shape after the foot has been placed inside the foot covering to thereby trap the bottom of the leg to prevent the foot covering from falling off the foot while in use. The opening preferably fits snugly around the bottom portion of the leg to keep foreign objects (e.g., liquids, dirt) from entering the foot covering.

The foot covering can have any size and shape that allow the benefits of this invention to be achieved. In most cases, a roughly rectangular shape will be preferred (with or without rounded corners or other curvatures, indentations, or protuberances). For an adult, the foot covering will typically be 12 to 14 inches (approximately 30 to 36 centimeters) long and 5 to 6 inches (approximately 13 to 15 centimeters) wide. Different sizes may be provided at the point of use. For example, at a security station at an airport, several rolls may be provided, each with a different size foot covering (e.g., large, medium, and small). Regardless of its length and width, the thickness of the foot covering will usually be no greater than 30 mils, often no greater than 20 mils, desirably no greater than 10 mils, more desirably no greater than 5 mils, most desirably no greater than 4 mils, preferably no greater than 3 mils, and more preferably no greater than 2 mils.

In summary, the present invention provides a foot covering that is inexpensive and easy to manufacture, can be made of low-cost materials, can be easily distributed to potential users (e.g., at airports), can easily and quickly be dispensed one at a time, can be made transparent (e.g., to facilitate security checks), protects the feet against dirt and pathogens, can be easily and rapidly put on and removed from the feet, can be made of recyclable materials, and is inexpensive enough to be used just once.

The invention has been described in an illustrative manner and the terminology that has been used is intended to be in the nature of description rather than of limitation. Modifications and variations that can be made should be apparent in light of the teachings herein. It is, therefore, to be understood that within the scope of the appended claims, the invention can be practiced otherwise than as specifically described and that the claims are intended to cover all modifications and variations falling within the true spirit and scope of the invention.