Abstract:
A cycling shoe cover is designed to provide maximum protection from the elements such as rain, snow, and cold. It also provides aerodynamic benefit with minimum weight. The cover is flexible unitary made from an elastomer, such as silicone or latex rubber, and is highly elastic and waterproof. The upper part of the cover fits snugly over the cyclist&#39;s ankle to prevent water egress into the shoes from above. The lower part of the cover snugly cover and seals to the bottom edge of the shoe without interfering with the cycling shoe&#39;s cleat or attachment to the cycle pedal.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    The present application claims the benefit of priority to the U.S. Provisional patent application of the same title that was filed on Jan. 19, 2013, having application Ser. No. 61/754,534. 
     
    
     BACKGROUND OF INVENTION 
       [0002]    The field of inventions is protective covers for shoes or footwear, and more particularly bicycle shoes such as those used in competitive bicycle racing and the practice thereof. 
         [0003]    Currently most avid cyclists wear cycling shoes with cleats attached to the bottom of the shoes, which allow firm and secure contact with cycling pedals. Prior art shoe covers are intended to keep both the feet of the cyclist dry in inclement weather, or when splashes from puddles and mud may hit the cyclist. Such shoe covers protect portion of the shoe to some extent, but do not really keep the cyclist&#39;s feet dry. Further, such prior art or current cycling shoe covers are typically made from sheets of foamed and elastic fabric covered or filled “Neoprene”™ brand rubber or “Lycra”™ or “Spandex” brand fabric materials, which are heavy or can lose water resistance after prolonged exposure to rain and snow. Most of these shoe covers are designed to slip over the shoe from below, a “bottom-up” installation process, and are secured with a zipper or Velcro™ brand hook and loop fasteners along a seam at the back or side of the foot and ankle These covers are made by the attachment of multiple precut fabric pieces, which creates multiples seams, allowing water to egress through the seams. 
         [0004]    The third and most important weakness of the bottom-up design is that the seal around the ankle cannot be made sufficiently snug to prevent substantial water egress from above. The fourth weakness is that the bottom-up design is costly to produce, because of the materials, the attachment of multiple precut pieces of these materials to each other, and the formation of these seams and, as well as the attachment of stays or fasteners. 
         [0005]    Accordingly, it is an object of the invention to provide a new and improved cycling shoe cover that overcomes the above deficiencies of the prior art. 
         [0006]    It is a further object to provide such a shoe cover a show cover that can be made at significantly reduced costs. 
         [0007]    The above and other objects, effects, features, and advantages of the present invention will become more apparent from the following description of the embodiments thereof taken in conjunction with the accompanying drawings 
       SUMMARY OF INVENTION 
       [0008]    In the present invention, the first object is achieved by providing a tubular member formed of an elastic waterproof material, the tubular member comprising: a first tubular portion having an upper opening at the proximal end disposed orthogonal to a primary axis of thereof, and a distal end opposite the proximal end, and a second tubular portion closed at the distal end and connected in sealed unitary engagement at the proximal end in an orthogonal orientation to the distal end of the first tubular portion, and having a first generally elliptical opening on a lower portion thereof that is opposite the opening in the first tubular member. 
         [0009]    A second aspect of the invention is characterized in by a die for forming a sock like protective cover, the die comprising a first generally planar portion having a foot like shape with rounded edges and a second portion extending downward from the rounded edge of the sole portion of the first generally planar portion. 
         [0010]    Another aspect of the invention is characterized in by a method of forming a unitary elastic waterproof sock like protective cover, the method comprising the steps of providing the above die, coating the die with an elastomer forming liquid, solidifying the elastomer forming liquid on the die to replicate the shape of the die, removing the solidified form from the die, slitting the solidified form at an intermediate position on the second downward extending portion to leave a residual sleeve below a sole shaped lower portion of the sock like protective cover, rolling the residual sleeve upward on itself to form a thick continuous annular bead about the perimeter of the opening in the sole shaped lower portion of the sock like protective cover, wherein the rolled bead adheres to itself 
         [0011]    Another aspect of the invention is achieved by providing a unitary sock like tubular waterproof elastic member comprising an upper foot receiving portion on an upper surface thereof having a shape adopted to receive an ankle and heel of a person, and a lower sole portion at the bottom of the upper foot receiving portion having at least one generally elliptical hole formed therein. 
         [0012]    Another aspect of the invention is characterized by providing a second generally elliptical opening on the lower sole portion or second tubular portion thereof. 
         [0013]    Another aspect of the invention is characterized by the elastic waterproof material that forms the tubular member material has a greater thickness along the perimeter of the first and/or second generally elliptical opening that on the portions distal therefrom. 
         [0014]    Another aspect of the invention is characterized by the perimeter of the first and/or second generally elliptical opening that on the portions distal therefrom being an annular bead with a circular cross-section having a thickness of about 2-4 mm. 
         [0015]    Another aspect of the invention is characterized by the elastic waterproof material being capable of stretching at least about 25%. 
         [0016]    The above and other objects, effects, features, and advantages of the present invention will become more apparent from the following description of the embodiments thereof taken in conjunction with the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0017]      FIG. 1A  is a top plan view of a first embodiment of the inventive shoe cover disposed on a flat surface, whereas  FIG. 1B  is a cross-sectional elevation of the portion indicated by section line B-B in  FIG. 1A . 
           [0018]      FIG. 2  is a perspective view showing the show cover of  FIG. 1  installed over a cycling shoe, with the extent of the show cover illustrated by a mesh pattern. 
           [0019]      FIG. 3A  is a side elevation view of a mold used to form the show cover of  FIGS. 1 and 2 , whereas  FIG. 3B  is a front elevation view thereof and  FIG. 3C  is a cross-sectional elevation at section line C-C in  FIG. 3A . 
           [0020]      FIG. 4  is a top plan view of another embodiment of the inventive shoe cover disposed on a flat surface. 
           [0021]      FIG. 5  is a perspective view showing the shoe cover of  FIG. 4  installed over a cycling shoe, with the extent of the show cover illustrated by a mesh pattern. 
           [0022]      FIG. 6A  is a side elevation view of a mold used to form the show cover of  FIGS. 4 and 5 , whereas  FIG. 6B  is a front elevation view thereof and  FIG. 6C  is a cross-sectional elevation at section line C-C in  FIG. 6A . 
           [0023]      FIG. 7  is a top plan view of another embodiment of the inventive shoe cover disposed on a flat surface. 
           [0024]      FIG. 8  is a perspective view showing the show cover of  FIG. 7  installed over a cycling shoe, with the extent of the show cover illustrated by a mesh pattern. 
           [0025]      FIG. 9A  is a top plan view of another embodiment of the inventive shoe cover disposed on a flat surface, whereas  FIG. 9B  is an enlarged cross-sectional elevation of the highlighted region in  FIG. 9A . 
           [0026]      FIG. 10A  is a side elevation view of a mold used to form the show cover of  FIGS. 8 and 9 , whereas  FIG. 10B  is a front elevation view thereof and  FIG. 10C  is a cross-sectional elevation at section line C-C in  FIG. 10A . 
           [0027]      FIG. 11A  is a side elevation view of a mold used to form the show cover of  FIG. 12-17 , whereas  FIG. 11B  is a front elevation view thereof and  FIG. 11C  is a cross-sectional elevation at section line C-C in  FIG. 11A . 
           [0028]      FIGS. 12 ,  13 ,  14  and  15  illustrate consecutive steps of a user installing the shoe cover constructed using the mold illustrated in  FIG. 11A-C , with the extent of the show cover illustrated by a mesh pattern. 
           [0029]      FIG. 16  is a first perspective view of the installed shoe cover constructed using the mold illustrated in  FIG. 11A-C , with the extent of the show cover illustrated by a mesh pattern. 
           [0030]      FIG. 17  is a first perspective view of the installed shoe cover constructed using the mold illustrated in  FIG. 11A-C , with the extent of the show cover illustrated by a mesh pattern. 
       
    
    
     DETAILED DESCRIPTION 
       [0031]    Referring to  FIGS. 1 through 17 , wherein like reference numerals refer to like components in the various views, there is illustrated therein a new and improved All Weather Cycling Shoe Cover, generally denominated  100  herein. 
         [0032]    In accordance with the present invention, the All Weather Cycling Shoe Cover is a generally sock shaped elastic member  100  for protecting the shoe and foot of a cyclist from exposure to cold temperature, water, snow, mud and road debris. It is formed as a unitary thin elastic member from a waterproof material, such as natural rubber, natural rubber blends, latex rubber, synthetic rubber, polyisoprene, polychloroprene rubber (“Neoprene”™), nitrile rubber, butyl rubber, silicone rubber, polyvinyl chloride, polyurethane, and the like. 
         [0033]    In one embodiment of the invention, the sock like member  100  has a generally tubular shape when opened and elastically expanded by a shoe or foot and ankle that are wider than the sock like member  100 . The sock like shape of show cover  100  is generally formed by a first generally cylindrically shaped tube member  110  having an opening  115  at the proximal end that is disposed orthogonal to a primary axis of the first cylindrical tube member  110 , and a second tubular member  120  is closed at the distal end  121  (for receiving the toe end of a shoe) connected in sealed engagement at the proximal end to the distal end of the first cylindrical member  110 . first generally cylindrically shaped tube member  110  designed to snugly fit around the cyclist&#39;s upper ankle The second tubular portion is sloped downward from the intersection with the first cylindrical member to snugly accommodate a shoe. The second tubular member  120  has at least one generally elliptical opening  125  around a lower or outer side portion thereof, which is on the opposing side of the shoe cover  101  from the first opening  115 . The generally elliptical opening  115  is disposed on the outer side  101  of the second cylindrical member closer to the closed distal end  121  than the end connected to tubular member  110 . When a first embodiment of the shoe cover  100  is installed as shown in FIG.  2 , 5 , the aperture or opening  125  in  FIG. 2  accommodates the cleat  16  that extends downward from near the toe of shoe, while the heal piece  17  is optionally covered by the lower surface of shoe cover  100 . 
         [0034]    As the shoe cover  100  is intended to stretch over the user&#39;s  10  shoe  15  to provide a tight seal, the sock like member  100  need not have a full 3-dimensional pseudo or anatomical foot or shoe shape. Hence, the reference to the parts of the cover having a generally cylindrical or tubular shape should not be considered limiting, but merely to exemplary, as alternative shapes in the generally form of a foot, but smaller than the intended users foot and shoe dimensions, will provide similar benefits 
         [0035]    In a second embodiment of the invention shown in  FIG. 4 , the sock like member  100  includes a second generally elliptical opening  126  disposed on the bottom between the proximal end  122  of the second tubular member and a first generally elliptical opening  115 . The aperture or opening  125  in  FIG. 5  accommodate the cleat  16  that extends downward from the heel of the shoe, while the heal piece  17  extends through the second opening  126 , shown in  FIG. 5 . 
         [0036]      FIG. 3A-3B  illustrates the process of forming the shoe cover sock like member using a generally planar sock shaped die  300 . The dimensions shown in  FIG. 3A  are in mm and are intended to be merely exemplary, and non-limiting. The face  310  of the die  300  is preferably flat, will all edges  311  rounded, preferably at a radius that is half the thickness of the die forming plate, which is preferably about ¼ inch (about 6-7 mm). The bottom of the die  300  that would correspond to the placement of the first elliptical opening has a protuberance or extension  330  in along an axis that is parallel to the cylindrical axis of what will become the first cylindrical tube member  110 , but extending in the opposite direction. The die  300  is held by this protuberance  330 , as for example via the holes shown therein when dipped in an elastomer forming liquid, such as for example a concentrated solution or either latex or other elastic polymers, or a monomer, pre-polymer or other oligomeric liquid or mixture. A thin liquid coating will remain on die  300  upon removal and draining of excess liquid. Then, upon solidification of this liquid coating, such as upon drying to remove solvent, or alternatively the curing and cross-linking of the monomer, pre-polymer or other oligomer in the elastomer forming liquid, a thin elastic coating is formed on the die  300  having the general shape of a sock  100 . It should be appreciated that the same die shape can be deployed when the liquid elastomer forming fluid is applied to the surface thereof by spray coating, curtain coating and the like. 
         [0037]    After application and curing or otherwise sufficient solidification of the liquid elastomer forming compound on the outer surface of the die  300 , the sock  100  is slit at positions  340  and optionally  350  to create a thicker perimeter around the generally elliptical openings  125  and  126 . The portion  355  between slit position  350  and the intended bottom  101  of the sock  100  is rolled over itself to form the thicker edge or band  118  at the perimeter of the first elliptical opening  125  defined by protuberance  330 . Slitting can occur after removal from die  330 . However, in a more preferred embodiment of the invention, the perimeter  118  of each generally elliptical opening  125  and  126  is considerably thicker than the elastic material that forms the body of the sock like member  100 . When the sock like shoe cover  100  is formed of latex rubber, the thickness over the surface thereof distal form the opening is preferably about 0.2 mm to about 0.4 mm, with the thicker edge or band  118  at the elliptical and/or upper opening preferably having a circular cross-section with a diameter of about 3 mm to about 5 mm, and more preferably about 4 mm. Preferably, heat is used to further cure the latex, and the slitting is carried our while the latex is hot to enable self adhesion and/or residual curing to complete the reactions necessary to form a strong and coherent thicker edge  118  upon roller the portion between slit position  355  and the bottom  101 . 
         [0038]    In the embodiment shown in  FIG. 6 , the die  300  has a first and second protuberance  330  and  332  to form the generally elliptical hole or slit  125  and  126  respectively of the shoe cover shown in  FIGS. 4 and 5 . Edge  118  is similarly formed by rolling portion  365  formed on the second die protuberance  332 . It should be understood that either or both of holes  125  and  126  can optionally be circular and need not be have a perfect elliptical shape, as the term elliptical is used to generally embrace rectangular holes rounded corners or a slit with rounded sides. However, to the extent that the intended hole or slit  126  is not intended to stretch significantly on opening, the opening  126  may be formed without the use of protuberance  332 , deploying for example die  300  of  FIG. 3 , and slitting the lower bottom surface  101  after molding. 
         [0039]    In  FIG. 7 , the shoe cover  100  is formed by slitting the freshly cast preform after removal from the die  300  at reference line  340 ′ ( FIG. 6 ), generally removing a significant portion of the first cylindrical tube member  110  and placing the upper opening  116  at an acute angle across the primary axis of the second tube member  120 .  FIG. 8  illustrates the expanded cover  100  of  FIG. 7  installed to cover the shoe  15  of the user  10 , in which sock  13  is now exposed both above the shoe  15  and the shoe cover  100 . The embodiment of  FIG. 7  can be installed over the shoe after the user is wearing the shoe. 
         [0040]    In a more preferred embodiment of the invention, illustrated with the aid of 
         [0041]      FIG. 9A ,  9 B and  FIG. 10 , the die  300  in  FIG. 10  has a series of 2 or more spaced apart and indented annular channels  360  and  361  around what will become the first cylindrical portion  110  of the sock  100 . As the channels  360  and  361  will tend to retain more elastomer forming liquid compound on coating the die  300 , due to surface tension, upon extraction from die  300  filled annular channels will replicate into a pair of spaced apart annular bands or flange  160  and  161  on the corresponding portion of the sock like shoe cover member  100  as shown in the embodiment in  FIGS. 9A and 9B . Then, upon installation on the ankle  11  of the user  10 , these bands  160  and  161 , will form a tighter sealing surface by concentrating a compressive stress in a narrow region on the user&#39;s leg/ankle  11  or sock  13  to further preclude water egress in harsher conditions. As shown in  FIGS. 9A and 9B , these bands  161  and  162  preferably have a height (H) of about 2-4 mm and a depth (D) of about 1.0 to about 1.5 mm. They are also preferably separated from each other by about 5 to 20 mm, and more preferably by about 10 mm, and are also preferably disposed about 5 to 20 mm, but more preferably about 10 mm, from the top of the sock like shoe cover  100 . 
         [0042]    In  FIG. 11A-C , the die  300  has a single large protrusion  330  that is intended to form a lower generally elliptical opening  125  in the bottom of the sock shown in  FIG. 12-17 . 
         [0043]    It should now be appreciated that the sock like shoe cover of the various embodiments, is preferably placed on the ankle to form a water tight seal before or after socks are worn. Thus, as shown in  FIG. 12  the cyclist  10  first places the shoe cover  100  over the ankle  11 , then puts on the socks  13  ( FIG. 13 ) and cycling shoe  15  on in  FIG. 14 , and finally in  FIG. 15  pulls the shoe cover over the shoe  15  from above. The shoe cover  100  is flipped over the shoe and cradles the edge of the sole by about 1 cm all around to provide a secure fit. Because the shoe cover  100  will not be in contact with the cleat  16 , it will not interfere with the engagement of the cleat  16  and pedal of a bicycle. The aperture or opening  125  in  FIG. 17  accommodate both the cleat  16 , and the heal piece  17 . 
         [0044]    It should now be appreciated that the inventive shoe cover  100  uniquely and inventively departs from prior art design by enabling a “top-down” installation, which covers the entire shoe from above with a single piece of material. This ensures a tight seal around the ankle and the entire upper surface of the shoe, providing maximum water, snow, and wind resistance. 
         [0045]    It should be understood that the shoe cover  100  is intended to stretch at least about 20 to 30% of the original length to form a snug fit at the user&#39;s  10  ankle or calf  11 . However, the elastomer forming the shoe cover  100  should also be about to stretch without tearing, undergoing permanent deformation or strain hardening when stretched by at least about 40% to about 80%, and preferably at least 60% to fit over the shoe and retain a tight seal at the ankle  11  by remaining stretched to about 15 to 30%, and more preferably at least about 20%, on the user&#39;s calf and ankle above the shoe  15 . However, the shoe cover  100  is also preferably sized so that once installed on the shoe it has preferably stretched at least about 20 to 30% at each hole or aperture in the sole portion and to both reduce water egress into the shoe from above and slippage of the cover during cycling. 
         [0046]    For example, a well fitted shoe cover  100  will stretch about 60% at the portion that extends over the toe, and 80% to extend over the heal. Then upon fitting over the shoe  15 , the elastic material while relaxing is still stretched preferably about 20 to 30% at the apertures  125  or  126  on the bottom or sole portion  101 . 
         [0047]    If the shoe cover  100  needs to be removed from the shoe while the cleat is engaged with the pedal, the cyclist can simply tear the cover off and discard it. Whereas discarding a “bottom-up” shoe cover would be prohibitively expensive, discarding the “top-down” shoe cover (the present invention) would be economically feasible because the cover is made of a single-mold piece of inexpensive elastomer, such as latex rubber. In contrast, with the “bottom-up” shoe cover, the cyclist has to disengage the pedal from the cleat in order to remove the cover, which can be dangerous. 
         [0048]    While the invention has been described in connection with a preferred embodiment, it is not intended to limit the scope of the invention to the particular form set forth, but on the contrary, it is intended to cover such alternatives, modifications, and equivalents as may be within the spirit and scope of the invention as defined by the appended claims.