Systems and methods for flexible footwear
A footwear article, the footwear article including a sock having a proximal end and a distal end, the proximal end having an opening configured to receive a human foot and the distal end terminating in a curved closed cavity configured to receive a toe portion of the human foot, the distal end and the proximal ended defining an tubular body therebetween, the tubular body having a curved heel portion proximate the opening of the distal end, the heel portion extending to the toe portion forming a sole portion on an underside of the sock and a rubber layer disposed on at least a portion of the underside of the sock.
1 . A method for forming a footwear article, the method comprising:
selectively immersing only a sole portion of a sock into a coagulant;
stretching the sock over a form after removing the sock from the coagulant, the form having a shape of at least a portion of a human foot;
immersing the sole portion of the sock into a rubber solution;
immersing the sole portion of the sock into a leaching solution, wherein the leaching solution removes water-based chemicals from the sole portion of the sock; and
drying the sole portion of the sock, wherein drying the sole portion of the sock activates a hardening process of the rubber solution thereby forming a rubber layer on the sole portion, and wherein the sole portion of the sock is an underside of the sock extending from a heel portion of the sock to a toe portion of the sock.
2 . The method of claim 1 , wherein the method further comprises washing and drying the sock and the rubber layer.
3 . The method of claim 1 , wherein the coagulant comprises at least a salt, at least a surfactant, at least a thickening agent, and at least a release agent in a water-based solvent.
4 . The method of claim 3 , wherein the salt is calcium nitrate.
5 . The method of claim 1 , wherein immersing the sole portion of the sock in the rubber solution comprises immersing the sole portion of the sock for 2-5 minutes.
6 . The method of claim 1 , wherein drying the sole portion of the sock comprises drying the sole portion of the sock at 60-105 degrees Celsius.
7 . The method of claim 1 , wherein drying the sole portion of the sock comprises drying the sole portion of the sock for 20-25 minutes.
8 . The method of claim 1 , wherein an immersion time of the sock in the rubber solution corresponds to a thickness of the rubber layer disposed on the sock.
9 . The method of claim 1 , wherein immersing the sole portion of the sock in the rubber solution produces bubbles on the rubber layer disposed on the toe portion and the heel portion of the sock.
10 . The method of claim 9 , wherein the bubbles disposed on the toe portion and the heel portion are configured to provide grip to the sole portion of the sock when worn.