Waterproof, breathable articles of apparel

A method of making an article of apparel used to cover a wearer's extremities comprising the steps of:

• (a) depositing a heat activated adhesive on the surface of a stretchable, waterproof, breathable membrane to form a coated membrane, said heat activated adhesive comprising a powdered adhesive having particles ranging in size from about 200 toll about 300 microns;
• (b) forming said coated membrane into a bladder having a perimeter of a first size and having an extremity receiving portion in the general shape of the wearer's extremity to be covered, said bladder having a smooth outer surface and a smooth inner surface generally conformable to the contours of the extremity to be covered;
• (c) placing said bladder over a first stretch and return fabric member constructed from a knitting yarn having a multiplicity of stretchable yarn components, said first stretch and return fabric member being of a second size smaller than said first size and being in the general shape of the wearer's extremity to form a first assemblage having a third size;
• (d) placing a stretch and return second fabric member constructed from a knitting yarn having a multiplicity of stretchable yarn components over said first assemblage to form a second assemblage, said second fabric member being of a fourth size larger than said third size of said first assemblage;
• and
• (e) heating said second assemblage to a temperature of between about 345 and about 400 degrees Fahrenheit to form a heated second assemblage;
• (f) compressing said heated second assembly at a pressure of between about 5 p.s.i. and about 20 p.s.i. to form a composite in which said first and second fabric members are securely bonded to said bladder.

A method of making a sock used to cover a wearer's foot comprising the steps of:

• (a) depositing a heat activated adhesive on the surface of a stretchable, waterproof, breathable membrane having a thickness of between about 0.001 inch to about 0.0118 inch to form a coated membrane, said heat activated adhesive comprising a powdered adhesive having particles ranging in size from about 200 to about 300 microns;
• (b) forming said coated membrane into a bladder having a perimeter of a first size and having an extremity receiving portion in the general shape of the wearer's foot, said bladder having a smooth outer surface and a smooth inner surface generally conformable to the contours of the wearer's foot;
• (c) placing said bladder over a first stretch and return fabric member constructed from a knitting yarn having a multiplicity of stretchable yarn components, said first stretch and return fabric member being of a second size smaller than said first size and being in the general shape of the wearer's extremity to form a first assemblage having a third size;
• (d) placing a stretch and return second fabric member constructed from a knitting yarn having a multiplicity of stretchable yarn components over said first assemblage to form a second assemblage, said second fabric member being of a fourth size larger than said third size of said first assemblage;
• and
• (e) heating said second assemblage to a temperature of between about 345 and about 400 degrees Fahrenheit to form a heated second assemblage;
• (f) compressing said heated second assembly at a pressure of between about 5 p.s.i. and about 20 p.s.i. to form a composite in which said first and second fabric members are securely bonded to said bladder.