Patent Publication Number: US-2022225697-A1

Title: Fishing wader with breathable stocking foot bootie

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a divisional of U.S. patent application Ser. No. 16/699,604 filed in Nov. 30, 2019, the contents of which are incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to the field of fishing waders, and more particularly, to a stockingfoot wader in which a portion of the foot section is fabricated with perforated neoprene fabric. 
     2. Description of the Related Art 
     There are numerous examples in the prior art that describe footwear which is designed to minimize the buildup of perspiration moisture within a shoe or sock. Some of these inventions are described below. None of these inventions is specifically designed to be incorporated with a fishing wader, and none possesses the unique multiple-layer structural features of the present invention, including, but not limited to, the bootie constructed of perforated neoprene, as described more fully below. 
     U.S. Pat. No. 4,222,183 (Haddox, 1980) discloses a reinforced, ventilated athletic shoe that comprises multiple pieces of air penetrable netting that are positioned between and attached to strips of conventional shoe cover material such as leather or cloth. 
     U.S. Pat. No. 4,898,007 (Dahlgren, 1990) discloses a moisture management sock in which the toe and heel portions are fabricated from knitted hydrophilic yarn, while the instep and other portions are fabricated from knitted hydrophobic yarn, so that water absorbed from the foot by the hydrophilic portions of the sock is wicked into the hydrophobic portions of the sock, where it is evaporated. 
     U.S. Pat. No. 5,095,548 (Chesebro, Jr., 1992) discloses a moisture control sock that comprises a combination of hydrophilic and hydrophobic yams, wherein the hydrophilic and hydrophobic yarns have cut free ends, and wherein the endmost stitch loops of the hydrophobic and hydrophilic yarns are formed in adjacent wales. 
     U.S. Pat. No. 5,319,807 (Brier, 1994) discloses a moisture-management sock and shoe combination. The sock portion of the invention includes a multi-layer moisture wicking panel that extends from the front ankle portion to the front toe portion. The moisture wicking panels of the sock portion are fabricated from hydrophilic and hydrophobic yams. The shoe portion of the invention includes a tongue, a toe box area, and a moisture wicking inner liner. The tongue of the shoe portion includes an outer layer of fabric such as nylon and a foam padding layer. The toe box area comprises and outer protective layer and an inner wicking fabric layer comprised of hydrophilic fibers. The moisture wicking inner liner is fabricated from one layer of hydrophilic and one layer of hydrophobic fabric. The claims of this patent cover the sock portion of the invention. 
     U.S. Pat. No. 5,353,524 (Brier, 1994) is similar to U.S. Pat. No. 5,319,548 above. The claims of the patent cover the shoe portion of the invention. 
     U.S. Pat. No. 5,265,677 (Dalhgren, 1994) discloses a sock and shoe combination that provides removal and dissipation of perspiration from the feet of a wearer. The sock portion of the invention comprises a combination of hydrophilic and hydrophobic fibers that wick moisture away from the foot. The shoe portion of the invention includes a tongue which is comprised of multiple layers of hydrophilic and hydrophobic material that wick moisture away from the outer surface of the sock portion of the invention and allow it to evaporate into the atmosphere. 
     U.S. Pat. No. 5,511,323 (Dahlgren, 1996) discloses a sock and shoe combination that facilitates the removal and dissipation of perspiration from the foot of a wearer. The knitted sock has a toe portion fabricated from hydrophilic material and an instep portion fabricated from hydrophobic foam. The shoe comprises a tongue portion which is fabricated from multiple stacked layers of hydrophilic and hydrophobic material. 
     U.S. Pat. No. 5,746,013 (Fay, Sr., 1998) discloses a shoe having a breathable liner, in which the liner is attached to the upper inside surface of the shoe, and in which the liner is comprised of an outer knit hydrophilic material, an inner knit hydrophobic material, and a middle layer comprised of monofilament hydrophobic yams that provides air chambers between the outer and inner layers. 
     U.S. Pat. No. 7,913,420 (Arizumi, 2011) discloses a skateboard shoe with a textured surface portion. The textured surface portion may be fabricated from a variety of polymer materials, and may optionally include apertures that allow air to pass into the shoe, and allow moisture to expire from the inside of the shoe into the air. 
     U.S. Pat. No. 8,146,266 (Vattes et al., 2012) discloses chimney structures for footwear and foot coverings. The chimney structures may be positioned on the inner sidewalls or the inner surface of the tongue of footwear, and provide pathways to vent heat and moisture away from the foot. The chimney structures may also be installed in socks, leggings, or other apparel. 
     U.S. Pat. No. 9,723,891 (Xanthos et al., 2017) discloses a rowing shoe that may optionally comprise sections made from air permeable materials that allow the shoe to breathe or ventilate. These sections may be formed in a mesh configuration and may be fabricated from any kinds of textile materials. 
     U.S. Patent Application Pub. No. US 2005/0241179 A1 (Chen, 2005) discloses a shoe with a breathable shell. The shell has a flexible corrugated portion that contains a plurality of vent holes. 
     U.S. Patent Application Pub. No. US 2012/0317841 (Taylor et al., 2012) discloses an athletic performance shoe which incorporates outer shell pieces and an optionally removable bootie. The outer shell pieces may be perforated to provide ventilation. The bootie may be made of “a porous material that can breathe to allow the ambient air circulation around the foot” [0034, lines 10-12]. 
     U.S. Patent Application Pub. No. US 2013/0000148 (Gellis, 2013) discloses a molded foot covering fabricated from an elastomeric material that preferably contains openings or perforations for breathability. 
     U.S. Patent Application Pub. No. US 2013/0219747 (Lederer, 2013) discloses an air-permeable tongue for shoes. The interior lining of the tongue is fabricated from breathable material and comprises a longitudinal slit to allow air circulation. 
     U.S. Patent Application Pub. No. US 2014/0352178 (Bruce, et al., 2014) discloses a type of ventilated footwear which consists of a shoe and a sock which is insertable into the shoe. The shoe contains at least one ventilation port. The sock contains plurality of moisture wicking panels, at least one of which is in fluid communication with the ventilation port of the shoe. The moisture wicking panels of the sock may be made from natural or man-made hydrophilic materials. 
     BRIEF SUMMARY OF THE INVENTION 
     The present invention is a fishing wader comprising: a body portion comprising a suspender assembly having two suspender straps, each suspender strap having a front end and a rear end, the front ends of the suspender straps being attached with stitching to two top extensions of a front pocket assembly, the front pocket assembly being attached with stitching to a chest piece, the rear ends of the suspender straps being attached with stitching to a top edge of a back piece; and a pair of booties, each bootie comprising a toe piece, an ankle piece, and a sole piece, the toe piece having: a top layer comprised of a laminated composite material, the laminated composite material comprising a waterproof breathable membrane; a middle layer comprised of a durable and resilient waterproof material, the material comprising a plurality of cutouts that penetrate completely through the middle layer; and a bottom layer; wherein the front pocket assembly is comprised of three stacked layers of material, the three stacked layers of material comprising an outer layer having a plurality of hexagonal-shaped holes, a water-permeable middle layer, and a water-permeable inner layer; wherein each of the three stacked layers of material has an outside edge, and the three stacked layers of material are attached to each other and to the chest piece by stitching around at least a portion of the outside edges of the three layers of material; and wherein the water-permeable middle layer and the water-permeable inner layer are configured to form a pocket accessible by two front pocket openings. 
     In a preferred embodiment, the suspender assembly comprises a slidable clasp that is configured to allow a distance between the tops of the suspender straps to be adjusted to fit a shoulder width of a wearer. Preferably, the outer layer of the front pocket assembly is comprised of high-strength nylon and configured to form an attachment face for fishing accessories on an outside of the front pocket assembly via the plurality of hexagonal-shaped holes; the middle layer of the front pocket assembly is comprised of stretchable polymer mesh fabric; and the inner layer of the front pocket assembly is comprised of a woven polymer fabric. The wader preferably comprises a vertically-oriented left side zipper that is adhered between a left edge of the chest piece and a left edge of the back piece and a vertically-oriented right side zipper that is adhered between a right edge of the chest piece and a right edge of the back piece; wherein the wader has a top circumference, and the left and right zippers are configured so that the top circumference of the wader is smaller when the zippers are fully zipped than when the zippers are unzipped. 
     In a preferred embodiment, the plurality of indentations in the middle layer of the toe piece are hexagonal. Preferably, each of the toe piece, ankle piece and sole piece has a durometer, the durometer of the toe piece and the durometer of the ankle piece is II using Gs-701N Type C durometer tester, and the durometer of the sole piece is 18 using Gs-701N Type C durometer tester. 
     In one embodiment, the bottom layer of the toe piece is comprised of a knitted fiber material. In another embodiment, the bottom layer of the toe piece is comprised of a woven fiber material. In yet another embodiment, the bottom layer of the toe piece is comprised of a breathable composite material. 
     The present invention is a fishing wader comprising: a body portion; and a pair of booties, each bootie comprising a toe piece, an ankle piece, and a sole piece, the toe piece having: a top layer comprised of a laminated composite material, the laminated composite material comprising a waterproof breathable membrane; a middle layer comprised of a durable and resilient waterproof material, the material comprising a plurality of cutouts that penetrate completely through the middle layer; and a bottom layer. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a front view of the present invention, which is a stockingfoot fishing wader. 
         FIG. 2  is a left side view of the present invention. 
         FIG. 3  is a right side view of the present invention. 
         FIG. 4  is a rear view of the present invention. 
         FIG. 5  is a perspective view of one bootie showing the top and front sides of the bootie. 
         FIG. 6  is a perspective view of one bootie showing the bottom and rear sides of the bootie. 
         FIG. 7  is an exploded isometric view of the toe piece material, showing the three layers that comprise the toe piece material, prior to bonding of the layers or shaping the toe piece. 
         FIG. 8  is an isometric view of the toe piece material after the three layers have been bonded together. 
         FIG. 9  is a front view of the front pocket assembly shown removed from the wader. 
         FIG. 10  is a rear view of the front pocket assembly shown with the wader partially removed for clarity. 
         FIG. 11  is a partial left side view of the wader body, showing the left side zipper in a zipped position. 
         FIG. 12  is a partial left side view of the wader body, showing the left side zipper in an unzipped position. 
     
    
    
     REFERENCE NUMBERS 
     
         
           1  Body portion 
           2  Bootie 
           3  Suspender assembly 
           4  Suspender straps 
           5  Front pocket assembly 
           6  Chest piece 
           7  Back piece 
           8  Slidable clasp 
           9  Outer layer of front pocket assembly 
           10  Hexagonal holes in outer layer of the front pocket assembly 
           11  Middle layer of front pocket assembly 
           12  Inner layer of front pocket assembly 
           13  Front pocket opening 
           14  Left side zipper 
           15  Right side zipper 
           16  Belt loop 
           17  Left upper leg piece 
           18  Right upper leg piece 
           19  Gusset piece 
           20  Left outside lower leg piece 
           21  Right outside lower leg piece 
           22  Left inside lower leg piece 
           23  Right inside lower leg piece 
           24  Gravel guard 
           25  Toe piece of bootie 
           26  Ankle piece of bootie 
           27  Sole piece of bootie 
           28  Waterproof tape 
           29  Hexagonal indentation in the top layer of the toe piece 
           30  Toe piece material 
           31  Top layer of toe piece material 
           32  Middle layer of toe piece material 
           33  Holes through middle layer of toe piece material 
           34  Bottom layer of toe piece material 
           35  Front pocket zipper 
           36  Pleat in wader top 
           37  Waterproof fabric backing piece for side zipper 
       
    
     DETAILED DESCRIPTION OF INVENTION 
     A. Overview 
     As used herein, the following terms shall have the following meanings: 
     “Left” and “right” refer to a wader wearer&#39;s left and right sides, respectively. 
     “Adhered” means attached with adhesive and/or stitching and covered with waterproof tape. 
     “Breathable” means permeable to air and water vapor. 
     “Waterproof” means impermeable to liquid water. 
     The present invention is a stockingfoot wader having a body portion and a pair of booties. The body portion of the wader is comprised of multiple pieces including a suspender assembly, a front pocket assembly, a chest piece, a back piece, a left upper leg piece, a right upper leg piece, a gusset (or crotch) piece, a left outer lower leg piece, a right outer lower leg piece, a left inner lower leg piece, a right inner lower leg piece and a pair of gravel guards. The chest piece, back piece, left upper leg piece and right upper leg piece are manufactured from three-layer laminated breathable waterproof fabric that is selected for maximum breathability. The left outer lower leg piece, a right outer lower leg piece, a left inner lower leg piece, and right inner lower leg piece are manufactured from four-layer laminated nylon breathable and waterproof fabric that is selected for maximum resistance to puncture and abrasion damage. The gusset is manufactured from three-layer laminated stretchable breathable and waterproof material that provides maximum range of movement for the legs when a wearer is walking. The gravel guards are manufactured from jersey-covered perforated neoprene, with the perforations reducing their weight. 
     Each bootie comprises a toe piece, an ankle piece and a sole piece. The toe piece is comprised of three layers of at least two different materials including an outer layer that comprises a waterproof breathable membrane, a middle layer that comprises an insulating and stretchable non-breathable material such as neoprene which has been modified with perforations or cut holes, and an inner layer comprised of either a second layer comprising a waterproof breathable membrane or a knit or woven jersey fabric material. The ankle piece and sole piece are comprised of an insulating and stretchable neoprene material that is covered on both sides with fabric backing. The inside surface of the bootie is treated with an antimicrobial agent to prevent odor. 
     B. Detailed Description of the Figures 
       FIG. 1  is a front view of the present invention, which is a stockingfoot fishing wader.  FIG. 2  is a left side view of the present invention.  FIG. 3  is a right side view of the present invention.  FIG. 4  is a rear view of the present invention. As shown in  FIGS. 1 through 4 , the present invention is comprised of a body portion  1  and a pair of booties  2 . The body portion  1  comprises a suspender assembly  3  having two suspender straps  4 . The front ends of the suspender straps  4  are attached with stitching to two top extensions of a front pocket assembly  5 , which is attached with stitching to the chest piece  6 . The rear ends of the two suspender straps  4  are attached with stitching to the top edge of the back piece  7 . The suspender assembly  3  is equipped with a slidable clasp  8  that allows the distance between the tops of the suspender straps  4  to be adjusted to fit the shoulder width of a wearer, thereby providing a comfortable fit for wearers with either wide or narrow shoulders. 
     The front pocket assembly  5  is comprised of three stacked layers of material, consisting of an outer layer  9  having a plurality of hexagonal-shaped holes  10 , a water-permeable middle layer  11 , and a water-permeable inner layer  12 . The three layers  9 ,  11 , and  12  are attached to each other and to the chest piece  6  by stitching around a portion of the outside edges of the three layers. Two front pocket openings  13  allow hand access into a pocket formed within the space between the middle layer  11  and the inner layer  12 . 
     The material of the outer layer  9  is a patented, commercially available fabric named HEXGRID®, comprised of high-strength nylon, manufactured by 5.11, Inc. of Modesto, Calif. The outer layer  9  forms an attachment face for fishing accessories such as fly boxes, bear spray, etc., which may be removably attached to the outside of the front pocket assembly via the hexagonal holes  10 . The hexagonal holes  10  are in the shape of regular hexagons, each having a side length of approximately 1.5 centimeters, and with a spacing between adjacent parallel sides of adjacent holes  10  of approximately 0.5 centimeter. The middle layer  11  of the front pocket assembly  5  is comprised of stretchable, highly permeable polymer mesh fabric. The inner layer  12  of the front pocket assembly  5  is comprised of a permeable woven polymer fabric. 
     As shown in  FIG. 2 , a generally vertically-oriented left side zipper  14  (shown in the zipped position) is adhered between the left edge of the chest piece  6  and the left edge of the back piece  7 . As shown in  FIG. 3 , a generally vertically-oriented right side zipper  15  (also shown in the zipped position) is adhered between the right edge of the chest piece  6  and the right edge of the back piece  7 . As described in detail in reference to  FIGS. 11 and 12 , when the two zippers are unzipped, the circumference of the top of the wader has a maximum circumference, enabling a wearer to easily don the wader; when the zippers are zipped up, the circumference of the top of the wader is reduced, providing a trimmer and snugger fit. A belt loop  16  is adhered to the lower center of the back piece  7  for use with an optional wader belt (not shown). 
     The bottom left edge of the chest piece  6  is adhered to the top edge of the left upper leg piece  17 , and the bottom right edge of the chest piece  6  is adhered to the top edge of the right upper leg piece  18 . The inside edges of the left upper leg piece  17  and the right upper leg piece  18  are adhered to the left and right edges, respectively, of the gusset piece  19 . A portion of the bottom edge of the left upper leg piece  17  is adhered to the top edge of the left outside lower leg piece  20 . A portion of the bottom edge of the right upper leg piece  18  is adhered to the top edge of the right outside lower leg piece  21 . A portion of the bottom edge of the left upper leg piece  17  and the bottom left edge of the gusset piece  19  are adhered to the top edge of the left inside lower leg piece  22 . A portion of the bottom edge of the right upper leg piece  18  and the bottom right edge of the gusset  19  piece are adhered to the top edge of the right inside lower leg piece  23 . The front edge of the left outside lower leg piece  20  is adhered to the front edge of the left inside lower leg piece  22 , and the front edge of the right outside lower leg piece  21  is adhered to the front edge of the right inside lower leg piece  23 . The fabric pieces  17 - 23  are shaped so that the knee of the wearer is covered by four-layer, maximum durability material, while the back of the knee is covered with three-layer, flexible material. The top edge of a gravel guard  24  and a bootie  2  are adhered to the bottom edges of the left outside lower leg piece  20  and the left inside lower leg piece  22 , and to the lower edges of the right outside lower leg piece  21  and the right inside lower leg piece  23 . The bottom edges of the gravel guards  24  are not adhered to other pieces of material, and are therefore free to be pulled up or down over the tops of the booties  2  and wading shoes (not shown). 
       FIG. 5  is a perspective view of one bootie  2  showing the top and front sides of the bootie  2 . The bootie  2  is comprised of a toe piece  25 , an ankle piece  26 , and a sole piece  27 . Waterproof tape  28  covers the seam between the toe piece  25  and the ankle piece  26 , and also covers the seam between the toe piece  25  and the sole piece  27 . Hexagonal indentations  29  in the top layer of the toe piece  25  occur where the material of the top layer of the toe piece  25  has been pulled downward into the hexagonal cutouts of the middle layer (explained in detail in reference to  FIGS. 7 and 8 ) of the toe piece  25 . 
       FIG. 6  is a perspective view of one bootie  2  showing the bottom and rear sides of the bootie  2 . Waterproof tape  28  covers the seam between ankle piece  26  and the sole piece  27 . As shown in  FIGS. 5 and 6 , the toe piece  25  extends over an area from the wearer&#39;s toes to the instep; the ankle piece  26  extends over an area that covers the wearer&#39;s ankle and lower shin; and the sole piece  27  extends over an area covering the wearer&#39;s foot bottom and the back of the lower calf. 
       FIG. 7  is an exploded isometric view of the toe piece material  30 , showing the three layers that comprise the toe piece material  30 , prior to bonding of the three layers or shaping the toe piece  25  (shown in  FIGS. 5 and 6 ). In a first embodiment, the top layer  31  of the toe piece material  30  is a laminated composite material that comprises a waterproof breathable membrane. The top layer  31  may optionally comprise one or more layers of permeable protective fabric on one or both sides of the waterproof breathable membrane. The top layer  31  is preferably a preassembled, commercially available or a preassembled, custom manufactured material. One example of a suitable preassembled material is GORE-TEX®, manufactured by W. L. Gore &amp; Associates, Inc. of Newark, Del. GORE-TEX® is a laminate material that comprises an abrasion resistant outer shell, an internal stretched polytetrafluorethylene breathable membrane, and a protective wicking underlayer. 
     The middle layer  32  of the toe piece material  30  is comprised of a durable and resilient waterproof material such as rubber, latex, or synthetic rubber such as silicone, neoprene, nitrile, or latex, which has been modified by the addition of strategically cut or punched holes  33  that penetrate completely through the material of the middle layer  32 . Although the hole shape or size is not critical, in the example shown in  FIG. 7 , the perforations or cut holes  33  in the middle layer  32  are regular hexagonal in shape, with the sides each hexagon having a length of approximately one centimeter, with a spacing between parallel sides of adjacent hexagonal holes of approximately one centimeter, and a percentage of cutout area of approximately 50% of the surface area of the material of the middle layer  32 . The nominal thickness of the neoprene in the toe piece, the ankle piece and the sole piece is 4 millimeters. The durometer of the toe and ankle pieces  25 ,  26  is approximately 11 (using Gs-701N Type C durometer tester), and the durometer of the sole piece  27  is approximately 18 (using Gs-701N Type C durometer tester). The three layers of material comprising the toe piece are bonded together with a film or liquid adhesive, which is applied to both sides of the middle layer. The bonding process requires controlled conditions of compression, temperature, and curing time to provide optimal adhesion of the three layers. 
     In a first embodiment, the bottom layer  34  of the toe piece material  30  is comprised of a knitted or woven fiber material such as jersey fabric. The material of the bottom layer  34  is selected so as to provide moisture wicking, in order to transfer foot perspiration away from the foot, through the holes  33  of the middle layer  32 , and out to the atmosphere through the breathable membrane of the top layer  31 . In a second embodiment, the bottom layer  34  is comprised of a second layer of breathable composite material similar to the top layer material  31 , rather than knitted or woven fiber material. 
       FIG. 8  is an isometric view of the toe piece material  30  after the three layers  31 ,  32 , and  34  have been bonded together. As shown, the bonding process results in a visible pattern of hexagonal indentations  29  in the top layer  31 . These indentations are not required for functionality of the material, but they provide aesthetic appeal. 
       FIG. 9  is a front view of the front pocket assembly  5  shown removed from the wader, showing the outer layer  9  comprising hexagonal-shaped holes  10 , the middle layer  11 , outside edges of the inner layer  12 , and two front pocket openings  13  that allow hand access to the space between the middle layer  11  and the inner layer  12 . 
       FIG. 10  is a rear view of the front pocket assembly  5  shown with the wader partially removed for clarity, showing the inner layer  12  of the front pocket assembly  5 , a portion of the inside surface of the top edge of the chest piece  6 , and a horizontal front pocket zipper  35 . The top edge of the front pocket zipper  35  is stitched to the inner layer  12  of the front pocket assembly  5 , while the bottom edge of the front pocket zipper  35  is stitched to the chest piece  6 , thereby forming a zippered pocket within the space between the inside surface of the inner layer  12  and the outside surface of the chest piece  6 . 
       FIG. 11  is a partial left side view of the wader body, showing the left side zipper  14  in a zipped position.  FIG. 12  is a partial left side view of the wader body, showing the left side zipper  14  in an unzipped position. The left side zipper  14  is installed into the wader body such that when the left side zipper  14  is zipped up as shown in  FIG. 11 , a pleat  36  is formed in the material at the top of the wader behind the zipper, thereby effectively reducing the circumference of the wader top. When the left side zipper  14  is unzipped, as shown in  FIG. 12 , the pleat  37  is removed, thereby restoring the full circumference of the wader top. The structure and operation of the right side zipper  15  (shown in  FIG. 3 ) is identical to the left vertical side zipper  14 . In a preferred embodiment, each side zipper  14 ,  15  provides about 5 centimeters of increase in the top circumference of the wader when the zipper is moved from the zipped to the unzipped position. As shown, the wader comprises a waterproof fabric backing piece  37  that is installed behind the left side zipper  14  and which is attached to the left edge of the chest piece  6  and the left edge of the back piece  7 , thereby preventing water from entering the wader when the left side zipper  14  is in either a zipped or unzipped position. A similar waterproof fabric backing piece (not shown) is installed behind the right side zipper  15 .