Patagonia IS Merrell. Patagonia doesn't make their shoes. They have a licensing agreement with Merrell who actually builds and distributes their shoes. Patagonia FOOTWEAR as an organization simply takes design cues from teh Patagonia team to try to design a footwear line that compliments the aesthetic and green principles held by Patagonia clothing. I like Patagonia Footwear's designs, but their use of green materials has lead to some durability issues.
We sell close to a couple thousand pairs of shoes a year. In terms of product failures nothing, and I mean NOTHING rivals the blow out failures of KEEN. Our KEEN failure rate is the worst I've seen in 15 years of retail. Second to KEEN is Merrell. The fewest number of blowouts comes from Asolo, Scarpa, Lowa and La Sportiva. Salomon probably should be on that list, too as they're pretty solid.