Patent Publication Number: US-8984694-B2

Title: Debris inhibitor for shoes and methods for making same

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional Patent Application No. 61/325,086, filed Apr. 16, 2010, the entire disclosure of which is hereby incorporated in its entirety. 
    
    
     FIELD OF INVENTION 
     The present invention relates to methods of manufacturing debris inhibitors for shoe, including athletic and outdoor shoes. 
     BACKGROUND OF THE INVENTION 
     Athletes, such as football, lacrosse, softball, baseball and field hockey players, play on large surface fields that are most often found in outdoor settings. Traditionally, these fields were comprised of natural grass surfaces. In the past several decades, artificial surfaces have been implemented to replace the traditional grass playing surfaces. The artificial turf surfaces have raised many concerns regarding injuries to the lower extremities, e.g., the legs, knees, ankles and toes. These artificial surfaces do not accommodate for contact between the player&#39;s body and the ground as would be found in natural surfaces. 
     Advances in artificial turf playing surfaces have been made to address some of these issues. For example, some artificial fields now employ “crumb rubber” and other types of filler that is spread over the field to simulate natural surfaces both aesthetically and functionally. These fillers tend to get into players&#39; shoes and can create abrasions with the concomitant risk of infections. 
     During games and practices, players can get these fillers in their shoes. Once in the shoes, these fillers can cause injuries to the foot and the toes, such as blisters, torn skin, and damage to the toe nails. These types of breaches in the skin and nails can expose the players to potential infections from the life threatening microorganisms. Moreover, these fillers can cause structural injuries to the players, such as aggravating turf toe injuries, causing bone bruising and instability during play. 
     Products are needed that can effectively inhibit entry of these field fillers and other objects from getting into the players&#39; shoes. Ideally, these products would cover the shoe in a protective manner as to cover the entry points of the shoe that could permit passage of debris from the playing surface into the shoe. The inventors have developed such a product that inhibits playing field debris from entering the shoes and exposing the players to health risks such as physical injury and unneeded exposure to potentially infectious microorganisms. 
     SUMMARY OF THE INVENTION 
     The present invention provides methods for manufacturing an over-the-shoe debris inhibitor from a tubular woven material. The tubular woven material is initially cut at a length sufficient enough to provide a debris inhibitor of desired length. 
     In one embodiment, initial raw cuts provide enough material to form hem lines at each end of the debris inhibitor. The hem lines are formed by folding and stitching the material to form bands at each end that serve as openings for the debris inhibitor. 
     Along a side length of the debris inhibitor, straight cuts are made perpendicular to the length of the material that are at a desired depth that is less than the circumference of the tubular woven material. These straight cuts provide unexpected characteristics regarding manufacturing and functionality of the debris inhibitor. The straight cuts are at a desired depth and provide openings or passages for cleats from an athletic shoe. 
     The straight cuts provide for conformity of the debris inhibitor to an athletic shoe, e.g., cleated athletic shoe. The straight cuts also provide for passage and conformity to a heel of the shoe and cleats to aid in inhibiting debris from entering the athletic shoe. 
     In another embodiment of the present invention, a method is provided for manufacturing an over-the-shoe debris inhibitor from a tubular woven material that results in a debris inhibitor with a stirrup design. 
     This method comprises, in part, making two raw cuts of the tubular woven material to a desired length. A band of desired width or thickness is formed at the location of the first raw cut by folding the first raw cut material and stitching a hem line. Also, a stirrup is formed in the direction of the second raw cut by making two shaped cuts. The two shaped cuts are made so that two sides of a stirrup are formed, wherein the two sides to the stirrup are stitched together at the ends to complete the stirrup. The angles of the two shaped cuts provide unexpected characteristics that provide conformity to the athletic shoe and aid in the stability and inhibitory aspects of the debris inhibitor. 
     In another embodiment of the present invention, an inhibitor system is provided comprising a sock/inhibitor combination, wherein a sock of desired material is attached to the internal side of the inhibitor. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  shows a debris inhibitor of the present invention. 
         FIG. 2  shows an angled, bottom-to-top view of an expanded debris inhibitor of the present invention. 
         FIG. 3  shows a top-to-bottom view of an expanded debris inhibitor of the present invention. 
         FIG. 4  shows a side view of a debris inhibitor of the present invention while in use with a cleated athletic shoe. 
         FIG. 5  shows an angled, bottom-to-top view of a debris inhibitor of the present invention in use with a cleated athletic shoe. 
         FIG. 6  shows a debris inhibitor of the present invention. 
         FIG. 7  is a side view of a debris inhibitor of the present invention. 
         FIG. 8  is frontal view an expanded debris inhibitor of the present invention. 
         FIG. 9  is bottom view of an expanded debris inhibitor of the present invention. 
         FIG. 10  is an angled frontal view of a debris inhibitor of the present invention while in use with an athletic shoe. 
         FIG. 11  is an angled bottom-to-top view of a debris inhibitor of the present invention while in use with an athletic shoe. 
         FIG. 12  is an angled back-to-front view of a debris inhibitor of the present invention while in use with an athletic shoe. 
         FIG. 13  is a side view of a debris inhibitor of the present invention while in use with an athletic shoe. 
         FIG. 14  illustrates a cutting pattern for one embodiment of the present invention. 
         FIG. 15  is side view of an inhibitor system of the present invention with a sock component. 
         FIG. 16  is an angled bottom view of an inhibitor system of the present invention with a sock component. 
     
    
    
     DETAIL DESCRIPTION OF THE INVENTION 
     The material used in the present invention can be any material capable of multi-directional stretch. The material should be capable of being formed into a seamless tube via machine weaving. The machine woven material tube is formed prior to the cutting. 
     In a preferred embodiment, the material is formed from a ply nylon and elastic combination. As an example, the ply nylon can be a two-ply or a three-ply nylon. Furthermore, the ply nylon and elastic material should be in a ratio that permits the desired multi-directional stretch necessary for the invention. The ratio of ply nylon to elastic is in the range of about 50% to about 50%; about 60% to about 40%; about 70% to about 30%; about 80% to about 20%; about 90% to about 10%; about 95% to about 5%; and about 97% to about 3%, respectively. 
     It will be appreciated by those of skill in the art that other materials are encompassed that allow for the multi-directional stretch of the present invention. Without limitation, these materials encompass such other materials as polyesters and elastane, for example. It will also be appreciated by those of skill in the art that materials within the scope of the present invention may also include antimicrobial and moisture wicking characteristics, for example. 
     Inhibitor for Use with Cleated Shoes 
     The inhibitor  100 , as seen in  FIG. 1 , is a woven tube of material as described herein. Inhibitor  100  is constructed to accommodate a cleated athletic shoe, and inhibitor  100  is an over-the-shoe product for inhibiting debris from entering the shoe while in use. The circumference of inhibitor  100  can vary depending on the size and type of athletic shoe. 
     The cleated athletic shoe is inserted through ankle-opening  160 . Toe-opening  110  permits the toe portion of an athletic shoe to pass through the inhibitor. Bottom portion  118  and bottom portion  130  are proportioned to accommodate the spacing of cleats on the athletic shoe, wherein bottom portions  118  and  130  fit between the cleats without impeding the purpose of the cleats while in use. Cut  120  and cut  140  are proportioned to permit the cleats to project through the inhibitor. Portion  170  covers the top of the cleated athletic shoe. Portion  150  covers from the lower area of the back heel of the cleated athletic shoe upward to ankle-opening  160 . Ankle-opening  160  is meant to mate in a secured or tight fitting fashion with the area around the wearer&#39;s leg just above the top of the cleated athletic shoe. 
     Toe-band  116  and ankle-band  166  represent the opposite ends of the completed product. Hem-line  114  and hem-line  164  are the result of the cutting, folding and stitching of the further most toe cut and the further most ankle cut of the tube material. When the tube material is cut at the toe portion, the cut end is folded back into the inner side of inhibitor  100 . Once folded into the inner side of inhibitor  100 , hem-line  114  is created by stitching the folded in portion to the inner side of inhibitor  100 . Once hem-line  114  is stitched, toe-band  116  is formed. Toe-band  116  may comprise additional material within the fold; e.g., elastic, which forms additional stability to toe-band  116 . Width of toe-band  116  and placement of hem-line  114  may vary based on the type and size of athletic shoe, and may also vary based on the cleat placements on the athletic shoe. 
     When the tube material is cut at ankle-opening  160 , the cut end is folded back into the inner side of inhibitor  100 . Once folded into the inner side of inhibitor  100 , hem-line  164  is created by stitching the folded in portion to the inner side of inhibitor  100 . Once hem-line  164  is stitched, ankle-band  166  is formed. Ankle-band  166  may comprise additional material within the fold; e.g., elastic, which forms additional stability to ankle-band  166 . 
     Toe-end  112  and ankle-end  162  serve as the end portions of the completed product after toe-band  114  and ankle-band  164  are formed by stitching hem-line  114  and hem-line  164 . 
     The process of cutting the tube material to form the desired length of inhibitor  100  requires multiple cuts at strategic locations along the tube material. First, the tube material is cut to form a raw cut across the full circumference of the tube material at the toe end and the ankle end. The raw cuts at each end are subsequently folded into the inner portion of inhibitor  100  to and hemmed to form hem-lines  114  and  164 . Once the raw cuts are hemmed, toe-band  116  and ankle-band  166  are formed, and comprise a doubled layer of tube material due to the folding inward and hemming to the inner portions of inhibitor  100 . The size of toe-band  116  and ankle-band  166  will depend in part on the size of inhibitor  100  that is desired. 
     The raw cut that is folded into the inner surface of inhibitor  100  to form ankle-band  166  can will vary in regards to the distance between ankle-opening  160  and hem-line  164 . Again, this distance between these to reference points will depend on the size of the overall inhibitor  100  size. Alternatively, this distance may depend on the type of athletic cleat, e.g., low-, mid-, and high-top cleated shoes. 
     The raw cut at the toe is folded back into the inner area of inhibitor  100  to form toe-band  116 . Toe-band  116  can be any desired length as measured from toe-end  112  to hem-line  114 . The length, however, should be hemmed between toe-end  112  and cut  120 . The length of toe-band  116  should be in a range of about ¼″ to about 1″. In one embodiment, toe-band  116  is formed by folding the raw cut into the inner area of inhibitor  100  and hemmed to form a toe-band  116  length of about ⅜″ once hem-line  114  is created. Therefore, toe-band  116  will comprise two layers of tube material by the folding and hemming process as described herein. The distance between hem-line  114  and cut  120  can be in the range of about ⅛″ to about ¾″. In one embodiment, the distance between hem-line  114  and cut  120  is about ½″. 
     Cut  120  is a straight cut that is perpendicular to bottom portion  118 , bottom portion  130  and portion  150  in the tube material that forms inhibitor  100 . The depth of cut  120  will vary depending on the type of cleated shoe. The depth of cut  120  can be in the range of about ¾″ to about 1¼″. In one embodiment, cut  120  is made to a depth of about 1″. 
     Cut  140  is a straight cut that is perpendicular to bottom portion  118 , bottom portion  130  and portion  150  in the tube material that forms inhibitor  100 . The depth of cut  140  will vary depending on the type of cleated shoe. The depth of cut  140  can be in the range of about ¼″ to about 1¼″. In one embodiment, cut  140  is made to a depth of about 1″. 
     Cut  120  and cut  140  are straight cuts as described herein. The straight cut is necessary; when a cut other than a straight cut is made, the tube material presents in a waived and uneven manner. Without the straight cut, inhibitor  100  presents certain manufacturing difficulties when the material is shored up with stitching along the cut to prevent tearing or fraying of the tube material. Several approaches were attempted to make cut  120  and cut  140 ; however, the non-straight cuts resulted in a wavy and uneven appearance that did not permit the opening created by each cut to conform to the cleat pattern of the athletic shoe. Cut  120  and cut  140  are also necessary because the straight cuts in inhibitor  100  prevent the stretch or pulling up of inhibitor  100  to an area above the top of the shoe where it would be ineffective in inhibiting debris from entering the cleated shoe, especially regarding cut  140 . Additionally, cut  120  and cut  140  reduces manufacturing cost with the straight cut rather than alternative more complicated and costly cut patterns. 
     Once the material is weaved into tube form, the tube can be cut to any desired length. For example, the tubed material can be cut for lengths of sizes for small, medium, large and extra-large. The cut lengths, related to sizes, can be based on any equations used in the industry for sizing apparel for different age groups and sexes in athletics, for example. Only as an example and not intended as a limitation, inhibitor  100  lengths for the sizes of small, medium, large and extra-large for average sizes can be 8″, 10″, 12″, and 14″. 
     The cuts necessary to form inhibitor  100  as defined in the invention will vary based in part on the type of shoe, age and sex of the athlete, and the materials to be employed in the manufacture. By example only and not intended as a limitation on the present invention, the following patterns are provided as guidance in the manufacture of inhibitor  100 . All measurements are based on either the raw cut at the toe portion of inhibitor  100  or toe-end  112 . 
     The raw cut at the toe of inhibitor  100  is made as described herein. Toe-band  116  is formed and characterized as described herein. Cut  120  is formed and characterized as described herein. Examples of inhibitor  100  are provided in Table 1, wherein toe-band  116 , ankle-band  166  and cut  120  are as described above. In Table 1, cut  140  is formed and characterized as described herein, and may also have the following patterns (Table 1) as relates to some of the sizes available through the present invention. 
     
       
         
           
               
             
               
                 TABLE 1 
               
             
            
               
                   
               
               
                 Pattern for Inhibitor 100 with Cut 140 
               
            
           
           
               
               
               
            
               
                   
                 Distance of Cut 140 
                 Distance of Cut 140 
               
               
                   
                 from raw cut at Toe 
                 from Toe-end 112 
               
               
                   
                 (prior to folding and 
                 (after folding and 
               
               
                 Size 
                 hemming) 
                 hemming) 
               
               
                   
               
               
                 Small 
                 3¼″ 
                 2½″ 
               
               
                 Medium 
                 3¼″ 
                 2½″ 
               
               
                 Large 
                 3¾″ 
                 3″  
               
               
                 Extra-Large 
                 4¼″ 
                 3½″ 
               
               
                   
               
            
           
         
       
     
     Cut  120  and cut  140  are made by a straight cut that is perpendicular to bottom portion  118 , bottom portion  130  and portion  150 . Once the straight cut is made to the desired depth as described above, the tube material is stitched along the edges of the cut to stabilize the tube material along the edges of the straight cut. As discussed above, it is the straight cut pattern of cut  120  and cut  140  that provides the unexpected ability to prevent the tube material from presenting in a waived and uneven manner. 
       FIGS. 2-3  show inhibitor  100  in expanded form to illustrate one embodiment of the present invention. While not athletic shoe is shown,  FIGS. 2-3  show one aspect of how inhibitor  100  would conform to an athletic shoe.  FIGS. 4-5  illustrate inhibitor  100  in use on a cleated athletic shoe. 
       FIG. 4  provides an in use side view showing cleats passing through cuts  120  and  140 .  FIG. 2  illustrates how cuts  120  and  140  in inhibitor  100  expand to accommodate bottom portions of the athletic shoe. This accommodating expansion is further illustrated in  FIG. 5 , wherein cuts  120  and  140  expand to conform to the positioning of cleats on an athletic shoe. 
     Inhibitor with a Stirrup 
     Another embodiment of the present invention is found in  FIG. 6 . Inhibitor  200  of  FIG. 6  is an over-the-shoe product for inhibiting debris from entering the shoe while in use. Inhibitor  200  is a weaved tube of material as described above. The shoe is inserted through ankle-opening  210 . Toe-opening  244  permits the toe portion of the shoe to pass through inhibitor  200 . Heel-opening  246  permits the heel portion of the shoe to pass through inhibitor  200 . Stirrup  240  secures inhibitor  200  around the sides and bottom of the outside of the shoe. 
     Ankle-band  212  is formed by making a raw cut on the tube material at one end. The raw cut is folded back into the inner surface of inhibitor  200  and hemmed to the inside surface, thereby forming hem-line  214 . The distance from ankle-opening  210  to hem-line  214  can be any distance desired to accommodate a particular shoe type and size. In certain embodiments, ankle-band  212  can have a thickness from about ½″ to about ¼″; however, this aspect can be adjusted as desired. Ankle-band  212  can comprise additional materials (e.g., elastic) that provide additional stability to ankle-band  212 . Such material would be inside the space created by the folding and stitching to form ankle-band  212 . Ankle-band  212  is designed to provide secure attachment to the wearer&#39;s leg just above the top portion of the shoe while in use. 
     Back portion  220  inhibits debris from entering the back of the shoe while in use, and covers the back of the shoe and back of the lower leg above the top of the shoe while in use. Front portion  230  inhibits debris from entering the front of the shoe while in use, and covers the front of the shoe and front of the lower leg above the top of the shoe while in use. 
     Cut  222  is made at the desired depth and angle toward stirrup  240  to permit passage of the heel of the shoe through inhibitor  200 . Cut  222  can be made at a depth of about 2″ to about 2½″ from back portion  220  toward stirrup  240 . In one embodiment, the depth of cut  222  is about 2¼″ in back of the tube material. The angle of cut  222  is in a range from about 15° to about 40° off the perpendicular to back portion  220 . It will be understood by the skilled artisan that cut  222 , and the depth and angle thereof, should be such to accommodate the passage of the heel of a shoe through inhibitor  200  and out heel-opening  246 . 
     As seen in  FIG. 14 , a cut pattern is illustrated for one embodiment of the present invention. Cut  222  is formed by two cuts. Cut  224  is made based on the degree of angles described herein. Also, cut  224  is made in a range from about 1¼″ to about 1¾″. Cut  226  is made in a range from about 1″ to about 1½″. In one embodiment, cut  224  is made at about 1½″ and cut  226  is made at about 1¼″ to form heel-opening  246  of stirrup  240 . In one embodiment, heel-opening  246  has a cut height  227 . Cut height  227  is in a range from about 1½″ to 2″; more specifically a cut height of 2″. The depth of heel-opening  246  is represented by cut depth  228 . In one embodiment, cut depth  228  is made from about 1½″ to about 1⅝″; more specifically a cut depth of 1⅝″. 
     Cut  232  is made at the desired depth and angle toward stirrup  240  to permit passage of the toe of the shoe through inhibitor  200 . Cut  232  can be made at a depth of about 1¼″ to about 2¼″ from front portion  230  toward stirrup  240 . In one embodiment, the depth of cut  232  is about 2″ in front of the tube material. The angle of cut  232  is in a range from about 25° to about 60° off the perpendicular to front portion  230 . It will be understood by the skilled artisan that cut  232 , and the depth and angle thereof, should be such to accommodate the passage of the toe of a shoe through inhibitor  200  and out toe-opening  244 . 
     As seen in  FIG. 14 , a cut pattern is illustrated for one embodiment of the present invention. Cut  232  is formed by two cuts. Cut  234  is made based on the degree of angles described herein. Also, cut  234  is made in a range from about ¾″ to about 1″. Cut  236  is made in a range from about 1″ to about 1¼″. In one embodiment, cut  234  is made at about 1″ and cut  236  is made at about 1¼″ to form toe-opening  244  of stirrup  240 . In one embodiment, heel-opening  244  has a cut height  237 . Cut height  237  is in a range from about 2″ to about 2¼″; more specifically a cut height of 2¼″. The depth of toe-opening  244  is represented by cut depth  238 . In one embodiment, cut depth  238  is made from about 1″ to about 1 1/16″; more specifically a cut depth of 1 1/16″. 
     The cut pattern illustrated in  FIG. 14  shows a raw cut prior to formation of ankle-band  212  and forming stirrup  240  by forming seam  242 . Therefore, the raw cut length has to be sufficient to form the desired lengths, heights and widths described herein. The measurements of the desired final product will depend, for example, on the thickness of ankle-band  212 . These adjustments will be readily appreciated by the skilled artisan. For example, the length of tube material after raw cuts at each end can be from about 10″ to about 10½″; more specifically about 10¼″. 
     It will be understood by the skilled artisan that the depths and angles of cut  222  and cut  232  will affect the positioning of stirrup  240 . In one embodiment, the depth and angle of cut  222  and cut  232  will be such that stirrup  240  will be positioned toward front portion  230 . 
     Once the desired depths and angles of cut  222  and cut  232  are determined and made, the tube material forming the sides of stirrup  240  are stitched together to form seam  242 , which in turn completes the formation of stirrup  240 . In one embodiment, seam  242  is made from along a line from back portion  220  to front portion  230  or vice versa. 
     After cut  222  and cut  232  are made, the edges of each cut are stitched in a manner that provides stability and prevents fraying of inhibitor  200 . 
     As seen in  FIG. 6 , length  254  represents the overall desired length of inhibitor  200  as defined from ankle-opening  210  to seam  242 . Length  254  can be in a range from about 7″ to about 10″. In one embodiment, length  254  is about 9″; however, length  254  will depend on the desired shoe type and size. 
     Width  252  represents the overall desired width of inhibitor  200  as defined from front portion  230  to back portion  220 . Width  252  can be in a range from about 3¾″ to about 5″. In one embodiment, width  252  is about 4½″; however, width  252  will depend on the desired shoe type and size. 
     Width  250  represents the overall desired width of stirrup  240  as defined from front portion  230  to back portion  220 . Width  250  can be in a range from about 1½″ to about 2½″; however, width  250  will depend on the desired shoe type and size. 
     In one embodiment, stirrup  240  comprises a slightly forward angular design in toe-opening  244  as compared to heel-opening  246 . With the slightly forward angular design in toe-opening  244 , stirrup  240  forms an unexpectedly tighter mating with the shoe while in use. The tighter mating aids in preventing inhibitor  200  from moving up the shoe to expose the top of the shoe, thereby permitting debris to enter the shoe while in use. This tighter mating is illustrated in  FIGS. 12-13 . 
     As seen in  FIGS. 11-13 , stirrup  240  covers the shoe around the arch of the shoe. This is achieved by the overall angles of cuts  222  and  232 , which allow for the forward positioning of stirrup  240 . When inhibitor  200  is pulled up over the shoe and ankle, this forward positioning of stirrup  240  focuses the stretch in the stirrup and front of inhibitor  200 , and limits the stretching effect on heel-opening  246 . This also helps prevent heel-opening  246  from rising up over the back of the shoe, while maintaining the necessary fit against the shoe to inhibit debris from entering the shoe. 
     In certain embodiments, inhibitor  200  is shown in expanded form in  FIGS. 7-9 ; a side view, a front view, and a top-down view, respectively. In certain other embodiments, inhibitor  200  is shown in use in  FIGS. 11-13 . 
     Inhibitor System 
     In another embodiment, inhibitor system  300  is shown in  FIG. 15 . Inhibitor system  300  is a combination of sock  302  and inhibitor  100 , wherein sock  302  is attached to the internal side of inhibitor  100 . Sock  302  is preferably attached about ankle-band  166 . For example, sock  302  is attached about hem-line  164 . Sock  302  can be of any material commercially used for athletics or outdoor purposes. Such materials are determined by the desired purpose of inhibitor system  300 . 
     Sock  302  can extend beyond ankle-band  166  to any desired length. The top of sock  302  may also be flush or even with the top of ankle-band  166 ; however, sock  302  will remain attached about ankle-band  166  as described herein. Inhibitor system  300  is designed for the wearer to insert the foot through sock opening  306 . Since sock  302  is attached about ankle-band  166 , the wearer can roll inhibitor  100  up sock  302 , allowing for the passage of the foot through sock  302 , with the wearer&#39;s toes passing through sock  302  to end at toe portion  304 . Sock  302  can then be inserted into an athletic shoe or outdoor shoe. Once the shoe is positioned and tied, the wearer can roll inhibitor  100  down over the shoe for a secure fit. 
       FIG. 16  shows an angled bottom view of inhibitor system  300  as expanded. Cut  120  and cut  140  are shown in the expanded view, with the sock in view without the shoe on the foot. Toe portion  304  of the sock is shown extending beyond toe-band  116 . 
     While the present invention is described above in detail and in reference to the drawings, it should be appreciated that the invention is not limited to the disclosed embodiments, and is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the claims and specification. Modifications and variations in the present invention may be made without departing from the novel aspects of the invention as defined in the claims, and this application is limited only by the scope of the claims.