Patent Application
20160007676
This application is related to and claims priority benefits from German Patent Application No. DE 10 2014 213 303.3, filed on Jul. 9, 2014, entitled Multifunctional outdoor shoe, in particular mountain shoe, mountain running shoe, trail running shoe or climbing shoe, as well as method for its manufacture (“the '303.3 application”). The '303.3 application is hereby incorporated herein in its entirety by this reference.
The present invention relates to a shoe, in particular a multifunctional outdoor shoe like a mountain shoe, mountain running shoe, a trail running shoe, a climbing shoe or an approach shoe, as well as a method for the manufacture of such a shoe.
By the use of soles, shoes are provided with a plethora of different properties, which may be developed to different degrees, depending on the specific type of shoe.
In order to prevent, for example, injuries or overstraining of the musculoskeletal system of the user, a sole can provide stability to the foot of the user and also lead to a cushioning of forces, which act on the user of the shoe and, in particular, his foot during ground contact of the foot.
The sole and, in particular, the outsole of a shoe can also allow an improved traction of the shoe on the ground, in order to prevent, for example, slipping of the user. This is of extraordinary importance, in particular, for mountain running or -hiking, when doing via ferratas or when climbing, because slipping could potentially lead to a fall of the user or severe injuries otherwise inflicted.
Furthermore, a shoe sole can protect the shoe from excessive wear by its increased abrasion resistance. This is important for mountain running or -hiking, doing via ferratas or climbing, too, as during these activities, high abrasion forces act on the sole that are caused by the high pressure with which the sole is pressed onto the ground and the often very rough and stony ground conditions.
In addition, shoe soles usually serve protective purposes, for example, in order to protect the foot of the user from injuries, which may be caused by sharp or pointed objects on which the user may tread, for example pointed stones or sharp rock ridges.
In order to provide the desired functionality, the use of vulcanized rubber as material for outsoles is known from the prior art. Vulcanized rubber distinguishes itself by good elasticity- and traction properties and is at the same time very abrasion resistant.
For example, U.S. Pat. No. 1,947,173 discloses a shoe, in particular a bathing shoe, wherein a heel filler and an arch stiffener connected therewith are enclosed by a rubber composition in a mold under the influence of pressure and heat.
U.S. Pat. No. 3,098,308 discloses a shoe with an outsole of moldable non-porous rubber, which constitutes the wear surface of the shoe and is directly secured to an upper. In a vulcanizing process, the rubber enters into a direct connection with a welt of the upper.
Finally, U.S. Pat. No. 4,294,022 discloses boots for divers comprising a sock made of elastomeric material, preferably covered by nylon fabric on one or two sides. The boot further comprises an outsole together with a back stay, a toe-cap and a foxing, made of non-cellular rubber and directly vulcanized as a unit on the sock. To this end, the sock is covered with a neoprene base cement and subsequently with a natural rubber base cement, prior to vulcanization.
The shoes known from the prior art may be less comfortable when worn for a longer period of time, in particular if the shoe upper is itself formed from rubber, which can hence lead, for example, to an excessive sweating of the foot. Furthermore, the connection of the shoe upper to the sole only exists in individual regions along the rim such that the stability of the shoe- and sole construction needed for climbing, for example, may not be provided. In addition, the shoes known from the prior art require an increased manufacturing effort that may necessitate the use of additional binders.
It is therefore, among other things, desirable to provide shoes, in particular multifunctional outdoor shoes like mountain shoes, mountain running shoes, trail running shoes, climbing shoes, shoes for via ferratas or approach shoes, which are comfortable to wear over longer periods of time and which comprise the stability and durability of the connection of the sole to the shoe upper that is necessary for mountain running or mountain hiking, climbing or doing via ferratas. It may also be desirable to provide shoes that can be easily manufactured without the use of additional binders.
The soles of the shoes may comprise the fraction and abrasion resistance that is necessary for mountain running, mountain hiking or climbing and the shoes should at the same time protect the foot of the user from injuries. It may also be desirable to provide a method for the manufacture of such shoes, which should be as simple as possible and which allows refraining from the use of additional bonding agents or binders and environmentally hazardous substances as far as possible.
The terms “invention,” “the invention,” “this invention” and “the present invention” used in this patent are intended to refer broadly to all of the subject matter of this patent and the patent claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below. Embodiments of the invention covered by this patent are defined by the claims below, not this summary. This summary is a high-level overview of various embodiments of the invention and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this patent, any or all drawings and each claim.
According to certain embodiments of the present invention, a shoe comprises: (a) a shoe upper; (b) a textile two-dimensional region connected to the shoe upper, which extends beneath a foot of a user of the shoe when worn; and (c) an outsole unit comprising a rubber material, wherein the textile two-dimensional region is connected to the rubber material of the outsole unit without a bonding agent.
In some embodiments, the textile two-dimensional region is connected to the outsole unit by vulcanizing the rubber material.
In certain embodiments, the textile two-dimensional region occupies more than 30% of a total area beneath the foot of the user.
The textile two-dimensional region, in some embodiments, comprises a Strobel sole.
In some embodiments, the entire textile two-dimensional region is connected to the rubber material of the outsole unit.
The shoe upper, in certain embodiments, is connected to the rubber material of the outsole unit without a bonding agent. In some embodiments, the shoe upper is connected to the outsole unit by vulcanizing the rubber material.
In certain embodiments, the textile two-dimensional region is mechanically connected to the rubber material of the outsole unit by the rubber material at least partially permeating the textile two-dimensional region.
The textile two-dimensional region, in some embodiments, is chemically connected to the rubber material of the outsole unit.
In some embodiments, the outsole unit is integrally formed as a single piece that comprises a tread surface and at least one of the following: a toe cap; a lateral side wing; a medial side wing; and a heel cap. The heel cap, in certain embodiments, is integrally formed as a single piece with the outsole unit such that a heel of a user stretches a material of the heel cap so that the heel cap contours the heel of the user when worn.
The outsole unit, in some embodiments, is integrally formed as a single piece that comprises at least one of: at least one first profile element in a forefoot region, which comprises an indentation disposed on a surface of the at least one first profile element and arranged in a direction of a heel of a wearer when worn; and at least one second profile element in a heel region, which comprises an indentation disposed on a surface of the at least one second profile element and arranged in a direction of toes of wearer when worn.
In certain embodiments, the outsole unit is integrally formed as a single piece that comprises at least one third profile element, wherein the at least one third profile element is arranged at a rim of the outsole unit, wherein the at least one third profile element comprises a defined edge at the rim.
The shoe, in some embodiments, further comprises a releasable insole. In certain embodiments, the releasable insole comprises a shell element and a cushioning region, wherein the shell element comprises a larger deformation stiffness than the cushioning region. In some embodiments, the shell element comprises reinforcement wings in a medial region and a lateral region of toe joints.
In certain embodiments, the releasable insole comprises at least one of the following: a heel support; a midfoot support; a recess for an electronic component; and a reinforcement foil in at least one of a forefoot region, a midfoot region, and a heel region, wherein the reinforcement foil comprises thermoplastic polyurethane. The reinforcement foil, in some embodiments, increases a stiffness of the releasable insole.
In some embodiments, the rubber material comprises at least one of the following materials: butyl-rubber, butadiene-rubber, natural rubber, styrene-butadiene-rubber, and nitrile-rubber.
The rubber material, in certain embodiments, comprises nitrile-rubber comprising at least one of the following materials in parts: ethylene-vinyl-acetate, lignosulfonate, and silanes.
According to certain embodiments of the present invention, a method of manufacturing a shoe comprises: (a) positioning a mounting in a molding arrangement, wherein a shoe upper and a textile two-dimensional region connected to the shoe upper, which extends beneath a foot of a user of the shoe when worn, are arranged on the mounting; (b) positioning at least one sole material comprising a rubber material in at least one recess located in at least one of the molding arrangement, the shoe upper, and the textile two-dimensional region; (c) closing the molding arrangement; and (d) connecting the rubber material to the textile two-dimensional region without a bonding agent.
In some embodiments, step (d) comprises vulcanizing the rubber material under at least one of pressure and heat. The vulcanizing in step (d), in certain embodiments, is performed under the following conditions: a temperature in the closed molding arrangement of 150° C.-200° C.; a closing force of the molding arrangement of 100 kg-200 kg; and a duration of the vulcanization process of 5 min-15 min.
The molding arrangement, in certain embodiments, comprises at least one fixed part and a plurality of movable mold parts that form an essentially closed molding space after closing the molding arrangement in step (c). In some embodiments, prior to closing the molding arrangement in step (c), a two-dimensional piece of the at least one sole material is positioned within a corresponding recess of at least one of the plurality of movable mold parts.
In the following detailed description, embodiments of the invention are described referring to the following figures:
a,
1
b,
1
c, and 1d are perspective views of a shoe, according to certain embodiments of the present invention.
e is a detail view of a sole of the shoe of
f is a rear view of the shoe of
g is a front view of the shoe of
h is a cross-sectional view of the shoe of
i is a detail view of a heel region of the shoe of
j is a top view of a shoe, according to certain embodiments of the present invention.
a, 2b, 2c, and 2d are perspective views of an insole, according to certain embodiments of the present invention.
a and 3b are perspective views of a molding arrangement, according to certain embodiments of the present invention.
a, 4b, 4c, and 4d are graphs showing experimental data related to friction, according to certain embodiments of the present invention.
According to an aspect of the invention, this problem is at least partially solved by a shoe, in particular by a multifunctional outdoor shoe, for example a mountain shoe, a mountain running shoe, a climbing shoe, a shoe for doing via ferratas or an approach shoe, which comprises a shoe upper and a textile two-dimensional region connected to the shoe upper, which extends beneath the foot of the user of the shoe. The shoe further comprises an outsole unit with a rubber material. Herein, the two-dimensional region is connected to the rubber material of the outsole unit without a bonding agent.
The shoe upper may be provided in such a manner that the desired wearing comfort is achieved. The shoe upper can, in particular, be breathable but at the same time impermeable to water and dirt and it can conform to the shape of the foot of a user or user without creating uncomfortable pressure points. To this end, the shoe upper may, for example, comprise a textile fabric from natural and/or synthetic materials, for example polyester, PET-polyester or polyamide. In some embodiments, the material of the shoe upper is heat- and color stable so that it does not get discolored or loses its structure during a manufacturing process (like the one more closely described further below, for example).
Further, because the outsole unit is connected to the textile two-dimensional region that extends beneath the foot, a particularly resistant and durable connection of the outsole unit and the shoe upper connected to the textile two-dimensional region is created, compared to a connection only existing at the rim of the sole, which can also withstand the high loads occurring during hiking or climbing.
The textile design of the two-dimensional region further allows that the rubber material of the outsole unit forms a matrix material with the two-dimensional region during the manufacture, wherein a mechanical connection can exist—for example by the rubber material flowing into or around openings, loops, honeycombs or other structures of the textile two-dimensional region—and on the other hand a chemical connection can exist, wherein the chemical connection may be achieved through the choice of the rubber material and/or the material of the textile two-dimensional region without additional bonding agents or binders. In some embodiments, a mechanical as well as a chemical connection is created, such that the connection is particularly durable and resistant.
The rubber material may be a vulcanized or partially vulcanized rubber material, for example on the basis of natural rubber (caoutchouc). It is, however, pointed out that, within this document, all materials are implied by the term rubber material that, after conclusion of the manufacturing process, comprise properties that are similar or equal to those of vulcanized rubber, in particular similar properties with respect to abrasion resistance, elasticity and traction on different grounds. The rubber material may hence also be a thermo-formable plastic or something similar.
The use of such a rubber material in the outsole unit further allows providing the outsole unit with the abrasion resistance, fraction and elasticity that are desirable, in particular, for multifunctional outdoor shoes like mountain shoes, mountain running shoes, climbing shoes, shoes for doing via ferratas or an approach shoe. Herein, the outsole unit may exclusively be comprised of the rubber material or it may comprise additional materials of functional elements. The outsole unit can, for example, comprise additional reinforcing elements or a recess for an electronic chip (GPS), for example for determining the position of the user in cases of emergency, and so forth. Possible is also an RFID or NFC chip, which comprises information about the shoe (for example manufacturer, size, model, color, intended field of use, promotional videos, and so forth).
It is explicitly mentioned in this context that the outsole unit may also comprise different rubber materials in different partial regions. For example, a particularly abrasion resistant rubber material at the rim of the sole may be combined with a rubber material providing particular high traction in regions in which the sole will primarily contact the ground, in order to avoid fast wear at the rim of the sole and in order to increase the traction of the sole at the rim, while at the same time prevent slipping or sliding of the user. Or a particularly abrasion resistance rubber material in the forefoot region may be combined with a rubber material in the heel region providing a particularly high traction, in order to minimize the wear during push-off over the forefoot during climbing and to prevent slipping when treading on the heel. These are merely two possible examples for the combination of different rubber materials, and further possibilities are possible for the skilled person.
In the following, further embodiments of inventive shoes are described. Explicit reference is, however, made to the fact that these possibilities are to be understood as optional and need not be present in all embodiments of inventive shoes.
The two-dimensional region may, in particular, be connected to the outsole unit by vulcanizing of the rubber material.
As base material, in particular, unvulcanized rubber may be considered, wherein, as already mentioned, in different partial regions of the outsole unit, different materials or mixtures of materials may be used, in order to influence the properties of the outsole unit locally. In addition, partially or entirely vulcanized rubber in a mix with unvulcanized rubber may be used in partial regions of the outsole unit.
In some embodiments, the two-dimensional region occupies more than 30% of the total area beneath the foot of the user. The two-dimensional region occupies more than 50% of the total area beneath the foot of the user in certain embodiments. Furthermore, in some embodiments, the two-dimensional region occupies more than 80% of the total area beneath the foot of the user.
The higher the percentage of the total area beneath the user that is occupied by the two-dimensional region, the higher the resistance and durability of the connection between the outsole unit and the two-dimensional region may be and therefore also the connection to the shoe upper. In particular, compared to a connection existing only at the rim of the sole, this can increase the lifetime and stability of the shoe and hence its suitability for, for example, doing via ferratas or climbing.
The two-dimensional region may, in particular, be provided as a Strobel sole.
Strobel soles are often used for the manufacture of sports shoes and they are hence easily obtained and processed. Furthermore, they allow further influencing of the flexibility- and stability properties of the shoe and, in particular, the shoe upper in a beneficial manner.
In some embodiments, the two-dimensional region is board lasted, that together with the shoe upper it comprises a moccasin-construction, that it is glued to the shoe upper, or that it comprises a combination of these possible ways of construction.
It is possible that the entire two-dimensional region is connected to the rubber material of the outsole unit.
By such a connection over the entire two-dimensional region, the resistance and durability of the connection between the rubber material of the outsole unit and the textile two-dimensional region and hence the shoe upper may be further increased. In principle, it is, however, also possible that the rubber material of the outsole unit is only connected to the textile two-dimensional region in partial regions thereof. This may, for example, be desirable if certain regions of the foot or the sole of the foot shall be provided with a larger degree of freedom of movement. Moreover, such a partial connection may also be used for providing, for example, ventilation openings in the unconnected regions.
Furthermore, the shoe upper may be connected to the rubber material of the outsole unit without a bonding agent.
This allows further influencing of the stability, durability, traction, elasticity properties, suitability for climbing, impermeability to water, and so forth of the shoe as desired. Also here, a matrix material may form during the manufacture, wherein on the one hand a mechanical connection may exist—for example by the rubber material flowing into or around openings, loops, honeycombs or different structures of the shoe upper, in particular if the shoe upper also comprises a textile fabric—and on the other hand a chemical connection may exist, wherein the chemical connection may be achieved without additional bonding agents or binders due to the choice of the rubber material and/or of the material of the shoe upper. In certain embodiments, a mechanical as well as a chemical connection exists.
The shoe upper may be connected to the outsole unit by vulcanizing of the rubber material.
In this context, and as already explained just now, a matrix material may form of the vulcanized rubber material of the outsole unit and the material of the shoe upper, in particular a textile material of the shoe upper. In this way, layers of the rubber material with different layer thicknesses may be connected to the shoe upper in a durable and abrasion resistant manner. It is, for example, possible that thin layers with layer thicknesses of <2 mm or <1.5 mm, but also very thin layers with layer thicknesses of <1 mm are connected to the shoe upper in a durable and abrasion resistant manner. Just as well, however, thicker layers with layer thicknesses >2 mm or even >3 mm or >5 mm may be connected with the shoe upper in a durable and abrasion resistant manner, too. In particular, with respect to the possibility of such thin layers, it is mentioned that in conventional gluing methods for the manufacture of outsoles, rubber in such thin layers could easily tear when it is pulled into shape and glued.
It is further pointed out that the layer thickness of the rubber material may also vary across the outsole unit. For example, in the region of the toes and/or the heel, a rubber layer with a larger layer thickness may be vulcanized onto the two-dimensional region and the shoe upper, in order to create a stable toe-/heel cap in this manner (see below). Simultaneously, the shoe upper may be protected by a thin rubber layer without a significant weight increase from the ingress of dirt and water by the rubber material of the outsole unit, for example in the region above the forefoot/instep or at the rims of the foot.
It is possible that the two-dimensional region and/or the shoe upper are mechanically connected to the outsole unit. This possibility has already been pointed out several times. A mechanical connection can, for example, be created by the rubber material of the outsole unit flowing into or around openings, loops, honeycombs or different structures of the two-dimensional region and/or the shoe upper, such that a matrix material forms. Herein, thin (<2 mm or <1.5 mm), very thin (<1 mm), as well as thicker layers (for example >2 mm, >3 mm or >5 mm) of the rubber material may be connected to the two-dimensional region and/or the shoe upper.
The rubber material may, in particular, have at least partially permeated the two-dimensional region and/or the shoe upper and in this manner lead to a mechanical connection. Such a mechanical connection may be particularly close and hence resistant and durable.
It is further also possible that the two-dimensional region and/or the shoe upper are chemically connected to the outsole unit.
The two-dimensional region and/or the shoe upper can, in particular, be connected to the outsole unit both mechanically as well as chemically.
A chemical connection of the outsole unit to the two-dimensional region and/or the shoe upper can, for example during the vulcanizing, be achieved without bonding agents or binders, if the rubber material and the material of the two-dimensional region and/or the shoe upper are chosen suitable to this end. As possible material for the shoe upper, polyester, PET-polyester or polyamide have already been mentioned. Further possible materials and components of the rubber material, which may, in particular, allow such a chemical connection without additional bonding agents or binders, will be described further below.
The outsole unit may be integrally provided as a single piece and in addition to a tread surface comprise at least one of the following elements: a toe cap, a lateral side wing, a medial side wing, a heel cap.
Since the rubber material of the outsole unit comprises high elasticity and abrasion resistance in certain embodiments, these elements can particularly well adapt to the foot of the user and protect it from water, dirt and injuries. In addition, they can increase the durability of the shoe in these regions. These desirable effects are further promoted by the integral design of the outsole unit. These elements can also serve the purpose to selectively adjust and increase the stability of the shoe and its sole in individual regions. For example, by the use of such side wings, a sliding of the foot in a sideward direction may be prevented or hampered.
The heel cap may, in particular, be integrally provided as a single piece together with the outsole unit in such a manner that the heel of the user leads to a stretching of the material of the heel cap such that the heel cap nestles against the heel of the user.
The heel cap can, for example, be designed and dimensioned in such a manner that it is somewhat narrower than the heel of the user and/or comprises a certain degree of “pre-tension”. When donning the shoe, the material of the heel cap is then initially stretched, such that a restoring force is created in the material. This restoring force leads to the heel cap nestling against the heel of the user and abutting it as precisely fitting as possible, which can result in a good fit of the shoe and a good stabilization of the foot. In addition, this can help avoid formation of blisters at the heel. In particular, the use of a rubber material in the outsole unit and the heel cap is beneficial in this context, as rubber may be very elastic and can therefore promote this nestling effect.
In addition, the heel cap can itself be provided with sufficient stability such that no additional reinforcement material is required in the region of the heel cap. If desired, it is, however, possible to further increase the stability in the region of the heel cap by inserting an insole (see below).
The outsole unit may further be integrally provided as a single piece and may comprise at least one first profile element in the forefoot region that each comprises an indentation in the direction of the heel and/or comprises at least one second profile element in the heel region that each comprises an indentation in the direction of the toes.
The first and second profile elements may, for example, serve the purpose of improving the traction of the shoe, for example when hiking on grit, scree, or gravel. Herein, the individual first and/or second profile elements may, for example, be arranged a distance apart from one another chosen large enough that no individual objects like stones or sticks or clay (in order to prevent a “clay clumping”) get stuck between the profile elements and thus lead to slipping of the foot when treading or pushing off. In addition, the surface of the first and/or second profile elements may be chosen small enough that they penetrate into the ground far enough or engage with the ground also on harder soil, damp clay, grass and so forth that the desired traction is achieved.
The indentations in the direction of the heel of the first profile elements, which are arranged in the forefoot region, can engage with the ground during push-off of the foot in the forward direction and hence prevent or hamper slipping of the foot in the backward direction. The indentations in the direction of the toes of the second profile elements, which are arranged in the heel region, can engage with the ground when treading with the heel and hence prevent or hamper slipping of the foot in the forward direction. To this end, the indentations can, for example, comprise a V-shape, with the tips of the V serving the purpose of engaging with the ground.
The outsole unit can furthermore be integrally provided as a single piece and comprise at least one third profile element, for example in the medial toe region, wherein the third profile elements are arranged at a rim of the outsole unit and each comprise a clearly defined edge at the rim.
The respective edge can, in particular, facilitate treading on small landings, ledges or steps in the rocks.
During climbing, when doing via ferratas or during the approach, it is often necessary to tread on small landings, ledges or protrusions in the rocks, for example with the region beneath the big toe, wherein a large percentage of body weight is supported on this small region of the outsole when lifting the body up from the leg muscles. In this situation, slipping can lead to a fall or other very serious injuries. In order to avoid this, third profile elements may be arranged, for example, in the medial toe region and, in particular, at the rim of the sole beneath the region of the big toe, which comprise a clearly defined edge at the rim of the outsole unit and which facilitate treading on such small structures and prevent or hamper slipping. The angle at this clearly defined edge can, for example, be 70° or 80° or 90° or a different angle in the range of, for example, 70°-90°. The angle may also change along the profile element in order to be adapted to the characteristic movement patterns for climbing, for example twisting in the foot or the hips, in order to facilitate such movements. In addition, a rubber material may used for the third profile elements, which comprises a high stability and stiffness and which doesn't yield under the above-mentioned high loads during ascent.
It is possible that the shoe further comprises a releasable insole.
The insole may contribute to providing the shoe with the desired stability and stiffness as well as the desired cushioning properties. Hence, during the manufacture and construction of the shoe upper and the outsole unit, the primary focus may be on different properties, for example the traction and abrasion resistance. Also, by use of a changeable insole, for example, the stability and cushioning properties of the shoe may be changed during use, for example, during a hike, during mountain running or when doing a via ferrata, without the user having to carry a complete second pair of shoes. This may lead to a significant reduction in weight.
For example, when doing a via ferrata, climbing passages are often interspersed with longer walking passages or approach passages. In the climbing passages, for example, a harder, lightweight and less cushioned insole may be inserted, which provides a high degree of stability to the shoe, allows a strong push-off over the forefoot region and in general allows for a direct feedback from the rock to the foot. On walking passages or the descent, on the other side, a softer and more comfortable insole may be inserted, which protects the musculoskeletal system of the user and guards against fatigue or injuries. By use of a shallower insole it is furthermore possible to have the foot sit deeper within the shoe. This can provide a significantly higher degree of stability. This is, for example, possible for a mountain- or trail running competition. After the competition, the properties of the shoe may be changed. For example, a thicker insole may be inserted for a recovery period.
The insole can comprise a shell element and a cushioning region, wherein the shell element comprises a larger deformation stiffness than the cushioning region.
Herein, the shell element can provide the shoe with the desired stability. The cushioning region, on the other hand, can serve to dampen and cushion the forces, which act on the musculoskeletal system of the user during impact on the ground. To this end, the shell element can, for example, surround the cushioning region along the rim of the insole and on the side of the insole facing away from the foot, in order to provide the desired stability, whereas directly beneath the foot the cushioning region is arranged in order to absorb the impact forces.
As a material for the shell element, for example, materials with a hardness of 55 shore C may be considered, for example ethylene-vinyl-acetate (EVA) with a hardness of 55 shore C. However, different hardnesses (softer or harder) are also possible, for example hardnesses in the range of 45 shore C (very soft)-70 shore C (very hard) or values from individual subranges within this range, for example values in the range 45-55 shore C, 55-60 shore C or 60-70 shore C, and so forth. Furthermore, polyurethane, thermoplastic rubber or cork, for example with a hardness in one of the ranges just mentioned, may be considered as material for the shell element.
It is possible that the cushioning region comprises at least one of the following materials: (expanded) ethylene-vinyl-acetate, foamed ethylene-vinyl-acetate, (expanded) thermoplastic polyurethane, foamed polyurethane, (expanded) polypropylene, (expanded) polyamide, (expanded) polyetherblockamide, (expanded) polyoxymethylene, (expanded) polystyrene, (expanded) polyethylene, (expanded) polyoxyethylene, (expanded) ethylene-propylene-diene-monomer. The cushioning region can, in particular, comprise randomly arranged particles that comprise at least one of the previously mentioned expanded materials and that are potentially connected with one another, for example, by fusing of the particle surfaces. Cushioning regions or cushioning elements from such randomly arranged particles of an expanded material as well as methods for their manufacture are, for example, described in documents DE 10 2012 206 094 A1 and EP 2 649 896 A2.
These materials, in particular the expanded materials, are particularly well suited to cushion and absorb the impact forces acting during impact. In particular, randomly arranged particles from expanded thermoplastic polyurethane or expanded polyetherblockamide, which are fused at their surfaces, have the property that the energy absorbed during absorption of the impact forces is to a large degree returned to the foot of the user, which facilitates the endurance of the user.
Furthermore, materials with a hardness of, for example, 40 shore C are well suited for the cushioning region. However, different hardnesses (softer or harder) are also possible, for example hardnesses in the range from 30 shore C (very soft)-55 shore C (very hard) or values from individual subranges within this range, for example values in the range of 30-40 shore C, 40-45 shore C or 45-55 shore C, and so forth. For example, EVA with a hardness of 40 shore C is well suited as a material for the cushioning region.
The shell element may comprise reinforcement wings in the medial and lateral region of the toe joints.
In certain embodiments, the reinforcement wings, which may correspond to respective side wings of the outsole unit, serve the purpose of stabilizing the foot of the user sufficiently with regard to sideward movements. In case such a stabilization is missing, this can potentially lead to an uncomfortable and unsecured wearing sensation and promote injuries. The reinforcement wings can furthermore prevent or minimize a movement of the insole relative to the inside of the shoe. This may be desirable for the benefit of the stability of the shoe.
The reinforcement wings may be (jointly) provided with different heights, for example in order to achieve a strong or not so strong reinforcement and/or stabilization. It is also possible that the reinforcement wing on the medial side has a different height/thickness/design than the reinforcement wing on the lateral side, in order to limit or to influence/control a sideward movement of the foot selectively, for example in a direction to the lateral side or to the medial side. It is, in particular, possible that the medial reinforcement wing is designed with a greater height than the lateral reinforcement wing, leading to a stronger stabilization of the inside of the foot and having a supporting effect during running. The reinforcement wings can further also be partially elastic, in order to provide the foot of the user with a defined freedom of movement.
The insole may further comprise at least one of the following elements: a heel support, a midfoot support, a recess for an electronic component, a reinforcement foil in the forefoot region and/or the midfoot region and/or the heel region. In particular, a reinforcement foil with thermoplastic polyurethane may be considered.
Such additional elements may further serve the purpose of fine-adjustment of the stability- and elasticity properties of the insole and the entire shoe. These properties may be individually adjusted to the respective requirements, for example high stability and direct feedback for climbing, and higher cushioning and a behavior, which is good for the joints during walking/hiking.
The reinforcement foil may, in particular, increase the stiffness of the insole in the forefoot region and/or in the midfoot region and/or in the heel region.
Herein, it is possible that different materials or different material thicknesses are used for the reinforcement foil in different regions of the insole, in order to achieve a certain stiffness of the insole in the respective regions. Such a reinforcement foil can further limit or control a widening or sideward expansion of the material of the cushioning region and/or the shell element under a pressure load on the insole. Also, the degree of influence may be adjusted to the respective wishes by a corresponding choice of different materials, material thicknesses, designs and arrangements of the reinforcement foil on the insole.
The insole can comprise dimensions that lead to a stretching of the shoe upper upon insertion of the insole into an inside of the shoe upper.
The stretching of the shoe upper can lead to restoring forces in the shoe upper, which lead to a securing of the insole in the shoe without additional securing devices and prevent or hamper a sliding of the insole. This can, in particular, lead to a force-fit connection between the two elements.
In some embodiments, the rubber material comprises at least one of the following materials: butyl-rubber, butadiene-rubber, natural rubber (caoutchouc), styrene-butadiene-rubber, nitrile-rubber, in particular nitrile rubber comprising at least one of the following materials in parts: ethylene-vinyl-acetate, lignosulfonate, silanes.
Styrene-butadiene-rubber, in particular vulcanized styrene-butadiene-rubber, comprises particular good traction properties and abrasion resistance and is hence well suited for use in the outdoor field, in particular for climbing. Nitrile rubber, in particular nitrile rubber comprising ethylene-vinyl-acetate, lignosulfonate and/or silanes in parts, allows, in particular, the rubber material to enter into a chemical connection with the textile two-dimensional region and potentially the textile fabric of the shoe upper during the vulcanizing without additional bonding agents or binders being necessary for this. It is pointed out that all these materials are not harmful for the human.
A further aspect of the invention is provided by a method for the manufacture of a shoe, in particular a multifunctional outdoor shoe, for example a mountain shoe, a mountain running shoe (a trail running shoe), a climbing shoe or an approach shoe, comprising a positioning of a mounting in a molding arrangement, wherein a shoe upper and a textile two-dimensional region connected to the shoe upper, which extends beneath a foot of a user of the shoe are arranged on the mounting. The method further comprises positioning at least one sole material comprising a rubber material in at least one recess in the molding arrangement and/or on the shoe upper and/or on the two-dimensional region, closing the molding arrangement, and connecting the rubber material to the two-dimensional region without the use of a bonding agent.
The method hence allows a simple manufacture of an inventive shoe without the use of additional bonding agents or binders, wherein a durable and resistant connection between the rubber material and the two-dimensional region can still be obtained. It is again pointed out that the sole material and, in particular, the rubber material can comprise different material compositions in different regions, which translates to corresponding different properties of the manufactured shoe at the respective positions after conclusion of the method.
It is further mentioned that the mounting can, for example, be a last, in particular a last made of metal like, for example, aluminum, steel or a mixture thereof, which withstands the temperatures (see below) occurring during the method.
The step of connecting the rubber material to the two-dimensional region can comprise a vulcanizing of the rubber material under the influence of pressure and/or under the provision of heat for the creation of an outsole unit.
It is a particular benefit of the method described here that the method allows the manufacture of an integral unit with, for example, an outsole, a toe cap, medial side parts, lateral side parts and a heel cap. By vulcanizing the rubber material onto the two-dimensional region and potentially the shoe upper, it can furthermore be ensured that individual parts do not get detached from the two-dimensional region/shoe upper. This is in particular so as the rubber material can form a matrix material with the two-dimensional region, and potentially with the shoe upper, too, as previously mentioned, which can on the one hand comprise a mechanical connection and on the other hand can comprise a chemical connection. In certain embodiments, both a mechanical as well as a chemical connection exists. This also allows achieving thin (<2 mm or <1.5 mm) or very thin (<1 mm) layer thicknesses of the vulcanized rubber material, which are nonetheless connected to the two-dimensional region or the shoe upper in an abrasion resistant and durable manner, which is very hard or impossible to achieve with a gluing method.
In the method, the vulcanizing may be performed under the following conditions: a temperature in the closed molding arrangement of 150° C.-200° C., further in a range of 160° C.-190° C., and still further in a range of 165° C.-175° C.; a closing force of the molding arrangement of 100 kg-200 kg, further in the range of 140 kg-160 kg, and still further in the range of 145 kg-155 kg; and a duration of the vulcanization process of 5 min-15 min, further in the range of 6 min-10 min, and still further of 8 min.
As closing force of the molding arrangement, for example the force with which the individual parts of the molding arrangement are pressed onto each other during the vulcanizing may be implied.
These process parameters have turned out desirable in order to achieve a vulcanization in a manner that the vulcanized rubber material comprises the desired properties, wherein at the same time the shoe upper and the two-dimensional region are not damaged or impaired. Care has, in particular, to be taken that the pressure in the molding arrangement is chosen large enough in order that the rubber material completely fills the molding arrangement during vulcanizing and does not leave the molding arrangement, but at the same time not so high that the molding arrangement damages the shoe upper or the textile two-dimensional region arranged on the mounting. To this end, the boundaries of the molding arrangement should also not comprise any sharp-edged regions.
In some embodiments, manufacturing parameters in different ranges or intervals are also possible, for example temperatures in the closed molding arrangement in the range 150° C.-160° C., 160° C.-170° C., 170° C.-180° C., 180° C.-190° C., 190° C.-200° C. or even higher or lower temperatures, closing forces in the range 100 kg-110 kg, 110 kg-120 kg, 120 kg-130 kg, . . . , 190 kg-200 kg or even higher or lower closing forces, as well as a duration of the vulcanization process in the range of, for example, 5 min-8 min, 8 min-12 min, 12 min-15 min or even longer or shorter process durations.
In some embodiments, the molding arrangement comprises a plurality of movable mold parts, which, together with potentially existing unmovable parts of the molding arrangement, form an essentially closed molding space after closing of the molding arrangement, in which the mounting along with the shoe upper and the textile two-dimensional region connected therewith are arranged.
This allows a particularly simple positioning of the mounting in the mold and can facilitate an automatization of the method.
It is also possible that, prior to the closing of the molding arrangement, in or on at least some of the movable parts a two-dimensional piece of the sole material is positioned within a corresponding recess of the movable mold part.
As far as unmoving mold parts do exist, it is also possible that in or on at least some of the unmovable mold parts a respective two-dimensional piece of the sole material is positioned within a corresponding recess of the unmovable mold part.
Finally, it is also possible that such a two-dimensional piece of the sole material is positioned directly on the textile two-dimensional region and/or the shoe upper. This allows, in a simple manner, to position sole materials with different compositions in different regions of the shoe or the sole and hence to selectively influence the properties of the manufactured shoe and, in particular, the outsole unit selectively in individual partial regions.
The subject matter of embodiments of the present invention is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described.
Certain embodiments of the invention are described in the following detailed description with reference to multifunctional outdoor shoes like mountain shoes, mountain running shoes, climbing shoes or approach shoes. It is emphasized, however, that the present invention is not limited to these embodiments. Rather, the present invention can also be beneficially applied to street shoes, running shoes, shoes for fishing, working shoes, and so forth.
It is further pointed out that in the following only individual embodiments of the invention will be more closely described. The skilled person we realize, however, that the elements and design options described in the context of these specific embodiments may also be modified or combined with one another in a different manner within the scope of the invention and that individual elements may also be omitted if they seem dispensable for a specific shoe. In order to avoid redundancies, reference is, in particular, made to the explanations in the “Summary of the invention”, which also remain applicable for the following description.
a-j show embodiments of an inventive shoe 100.
The shoe 100 may, for example, be used as a multifunctional outdoor shoe, in particular a mountain shoe, a mountain running shoe, a trail running shoe, a climbing shoe or an approach shoe. The shoe 100 comprises an shoe upper 110.
As already explained, the shoe upper 110 may be provided such that the desired wearing comfort is achieved. The shoe upper 110 may, in particular, be breathable but at the same time impermeable to water and dirt and it may nestle against the foot of the user without the creation of uncomfortable pressure points. To this end, the shoe upper 110 may, for example, comprise a textile fabric from natural and/or synthetic materials, for example polyester, PET-polyester or polyamide. In certain embodiments, the material of the shoe upper 110 is heat- and color stable in a manner such that, during a manufacturing process (as, for example, more closely described below), it does not get discolored or loses its structure.
Connected to the shoe upper 110 is a textile two-dimensional region 120, which extends beneath the foot of the user of the shoe 100. The shoe 100 further comprises an outsole unit 130 with a rubber material, wherein the two-dimensional region 120 is connected to the rubber material of the outsole unit 130 without a bonding agent.
As the outsole unit 130 is connected to the textile two-dimensional region 120, which extends beneath the foot, instead of only at the rim of the sole, a resistant and durable connection between the outsole unit 130 and the shoe upper 110 connected to the textile two-dimensional region 120 results. Based on the configuration of the textile design of the two-dimensional region 120, the rubber material of the outsole unit 130 forms a matrix material with the two-dimensional region 120 during the manufacture, wherein a mechanical connection and/or a chemical connection can exist. In certain embodiments, both a mechanical as well as a chemical connection exists, such that a particularly durable and resistant connection may be achieved.
In the shoe 100 shown here, the two-dimensional region 120 is connected to the outsole unit 130 by vulcanizing of the rubber material.
In certain embodiments, the outsole unit 130 comprises different rubber materials in different partial regions. For example, a particularly abrasion resistant rubber material at the rim of the sole may be combined with a rubber material providing particular good fraction in regions in which the sole primarily contacts the ground, in order to avoid fast wear on the rims of the sole, while at the same time avoiding slipping or sliding of the user. In further embodiments, a particularly abrasion resistant rubber material in the forefoot region may be combined with a rubber material providing particular good traction in the heel region, in order to minimize the wear during push-off over the forefoot and during climbing and prevent slipping when treading with the heel, and so forth. Rubber materials, which are suited for this, will be discussed in more detail further below.
As can, for example, be gathered from
It is, however, pointed out that within the scope of the invention the two-dimensional region 120 could also be a board lasted region, or the two-dimensional region 120 could comprises a moccasin construction together with the shoe upper 110, or it may be glued to the shoe upper, and so forth.
In the present case, the entire two-dimensional region 120 is connected to the rubber material of the outsole unit 130. This leads to a particularly close and durable connection of the outsole unit 130 with the two-dimensional region 120, and hence to the desired stability and durability of the shoe 100.
In case of the shoe 100, also the shoe upper 110 is connected to the rubber material of the outsole unit 130 without a bonding agent, wherein in the present case the shoe upper 110 is connected to the outsole unit 130 by vulcanizing of the rubber material. Also here, a matrix material has formed from the vulcanized rubber material of the outsole unit 130 and the material of the shoe upper 110, which in the present case also comprises a textile material, wherein on the one hand a mechanical connection can exist and on the other hand a chemical connection. In certain embodiments, both a mechanical as well as a chemical connection exists. Reference is further made to the possibility that, for example, the outsole unit 130 and the two-dimensional region 120 are connected both mechanically and chemically, whereas the outsole unit 130 and the shoe upper 110 are only connected mechanically, and so forth.
This allows thin and very thin layers (for example <2 mm, <1.5 mm or <1 mm) as well as thicker layers (>2 mm, >3 mm or >5 mm) of the rubber material of the outsole unit 130 to be connected with the shoe upper 110 in a durable and abrasion resistant manner. Hence, the shoe upper 110 may, for example, be protected from the ingress of dirt and water by the rubber material of the outsole unit 130 without a significant weight increase, for example in the region of the toes or at the rim of the foot. It is, however, also possible to connect thicker layers of the rubber material of the outsole unit 130 to the shoe upper 110, like for example in the region of the toe cap 140 or the heel cap 148, see below.
As shown in
In order to achieve the chemical connection of the rubber material with the shoe upper 110 or the two-dimensional region 120, the rubber material can comprise at least one of the following materials: butyl-rubber, butadiene-rubber, natural rubber (caoutchouc), styrene-butadiene-rubber (SBR), nitrile-rubber (NBR), in particular nitrile rubber comprising at least one of the following materials in parts: ethylene-vinyl-acetate (EVA), lignosulfonate, silanes. In particular, NBR-based rubber materials, which comprise EVA, lignosulfonate and/or silanes in parts are well suited to enter into the desired chemical connection with the textile material of the two-dimensional region 120 and the shoe upper 110 during the vulcanizing. SBR-parts in rubber materials on the other hand mainly serve to increase the fraction and the abrasion resistance of the vulcanized rubber material.
In the present case, the entire outsole unit 130 is integrally provided as a single piece. First, the outsole unit 130 comprises a base surface or tread surface 135.
In addition, the outsole unit 130 comprises the following further elements: a toe cap 140, a lateral side wing 142, a medial side wing 145, and a heel cap 148. It is pointed out that in this context it is, in particular, possible to use different kinds of rubber for the different elements of the outsole unit 130 mentioned above, which may be specifically adjusted to the functionality of the respective elements. Furthermore, by the use of a rubber material for the outsole unit 130, the toe cap 140 and the heel cap 148 can adapt to the specific anatomical conditions of the foot of each user, such that no blisters or pressure points are created.
In case of the shoe 100, the heel cap 148 is, in particular, integrally provided as a single piece together with the outsole unit 130 in such a manner that the heel of the user of the shoe 100 leads to a stretching of the material of the heel cap 148 when the shoe 100 is donned, and by way of the restoring forces in the flexible rubber material of the heel cap 148 created in this manner the heel cap 148 nestles against the heel of the user and encloses it, such that the heel is well secured and stabilized.
For example, by use of a tailored last, for example a last 310 (see below), the heel cap 148 may be pre-shaped during the manufacture of the shoe 100 such that the stretching of the material of the heel cap 148 described above and hence the nestling effect of the heel cap 148 is achieved. To this end, the last may be narrower in the heel region than a conventional “standard last” for a shoe of the respective size. The use of such a narrower last during the manufacturing process also has the effect that the heel cap 148 already comprises a base stability even without inserted insole 200 (see below) or an additional heel part. The inserted insole 200 then further increases the stiffness of the heel region. As already mentioned, it is a significant benefit of the slightly inward curved, pre-shaped heel cap 148 that it “nestles against” the heel when inserting the foot into the shoe 100 since the rubber material may be very elastic.
Corresponding explanations may also apply to the toe cap 140.
It is also a benefit of the shoe 100 that by the use of an insole 200 (see below) the stability and stiffness of the shoe 100 may be further increased or influenced. This fact, and the above described base stability of the heel cap 148 and/or the toe cap 140, make it possible to do without additional reinforcement elements in the heel cap 148 and/or the toe cap 140, such that this adaption- or nestling effect is not impaired.
Furthermore, the outsole unit 130 comprises multiple first profile elements 150 in the forefoot region, which each comprise an indentation 155 disposed on a surface facing the heel of the shoe, and multiple second profile elements 160 in the heel region, which each comprise an indentation 165 disposed on a surface facing the toe of the shoe. In particular, at the rim of the sole, the profile elements 150 and 160 form a kind of saw-tooth structure with teeth pointing in the backward direction and tilted surfaces pointing in the forward direction, as shown in
If, for example, the user of the shoe 100 moves along rocks, the above mentioned saw-tooth structure does not impair movements of the user for movements in the forward direction, because in this direction the tilted surfaces of the saw-tooth structure are arranged. Should the user of the shoe 100, however, move backwards or slip or fall, then the teeth of the saw-tooth structure pointing in the backward direction assume a “breaking function”.
Furthermore, the outsole unit 130 comprises multiple third profile elements 170 in the medial toe region. The third profile elements 170 are arranged at the rim, more precisely at the medial forefoot rim, of the outsole unit 130, and at this rim they each comprise a clearly defined edge 175. These edges 175 can, for example, facilitate treading on small landings, ledges or steps in the rocks. As seen in
Optionally, the shoe 100 further comprises a releasable insole 200. As already mentioned,
a-d show such an insole 200, as it may, for example, be used in combination with the embodiments of an inventive shoe 100 shown in
The insole 200 comprises a shell element 210 and a cushioning region 220, wherein the shell element 210 comprises a larger deformation stiffness than the cushioning region 220. In principle, the cushioning region 220 can, for example, comprise at least one of the following materials: (expanded) ethylene-vinyl-acetate, foamed ethylene-vinyl-acetate, (expanded) thermoplastic polyurethane, foamed polyurethane, (expanded) polypropylene, (expanded) polyamide, (expanded) polyetherblockamide, (expanded) polyoxymethylene, (expanded) polystyrene, (expanded) polyethylene, (expanded) polyoxyethylene, (expanded) ethylene-propylene-diene-monomer. The cushioning region 220 can, in particular, comprise randomly arranged particles, which may comprise at least one of the previously mentioned expanded materials. The particles may be connected to each other, for example by fusing of their surfaces.
In certain embodiments, the cushioning region 220 comprises randomly arranged particles of expanded thermoplastic polyurethane, which are fused at their surfaces. In further embodiments, the shell element 210 comprises EVA with a hardness of 55 shore C.
In still further embodiments (not shown), the insole comprises a shell element comprising EVA with a hardness of 55 shore C, but the cushioning region comprises EVA with a hardness of 40 shore C.
In some embodiments, different hardnesses (softer or harder) are possible, respectively. For example, for the shell element hardnesses in the range from 45 shore C (very soft)-70 shore C (very hard) are possible or values from individual subranges within this range, for example values in the range 45-55 shore C, 55-60 shore C or 60-70 shore C, and so forth.
In some embodiments, for the cushioning region, hardnesses in the range of 30 shore C (very soft)-55 shore C (very hard) are possible. In addition, values from individual subranges within this range, for example, values in the range of 30-40 shore C, 40-45 shore C or 45-55 shore C, and so forth are possible.
The skilled person realizes that by a variation of the materials the insole may be influenced and adjusted as desired with respect to properties like cushioning and protection of the joints, energy loss/-return, stiffness, transfer of forces, feedback from the ground to the foot, and so forth.
In certain embodiments, the shell element 210 further comprises a reinforcement wing 242 in the lateral region of the toe joints and a reinforcement wing 245 in the medial region of the toe joints. These may, for example, correspond to the corresponding side wings 142 and 145 of the outsole unit 130 of the shoe 100 and provide the foot of the user with the required stability with respect to forces acting in a sideward direction (i.e. forces primarily acting on the foot in the medial-lateral direction). Depending on the size and shape of the reinforcement wings 242, 245 and/or of the side wings 142, 145, the stability behavior of the shoe 100 or the insole 200 with respect to the impact of sideward forces may be influenced or controlled. In particular, the reinforcement wings 242, 245 may be provided with different heights, wherein they may both comprise the same height, in order to achieve, for example, a strong or not so strong reinforcement and/or stabilization. Furthermore, the reinforcement wing 245 on the medial side may have a different height/thickness/design than the reinforcement wing 242 on the lateral side, in order to selectively limit or influence/control sideward movements of the foot, for example in a direction to the lateral side or to the medial side. In addition, the reinforcement wings 242, 245 may also be partially elastic, in order to provide the foot of the user with a defined freedom of movement.
The insole 200 further comprises a reinforcement foil 250 on its bottom side in the forefoot region. First, it is explicitly pointed out that it is also possible to use other planar materials like, for example, carbon, carbon-fibers or different textiles and fabrics alternatively or in addition to the reinforcement foil 250. The reinforcement foil 250 may, for example, serve as a push-through protection, in order to avoid irritations of the foot and, in particular, the toes when treading caused by the profile elements 150 and/or 170 or stones/pointed objects lying beneath. In order to simultaneously not impair the freedom of movement in the forefoot region to an undesirable degree, the reinforcement foil 250 comprises a number of individual fingers or sections 255, which are separated from one another by recesses 257 in the reinforcement foil 250. These recesses 257 hence act as flex zones in order to further influence and adjust the freedom of movement of the foot in the region of the reinforcement foil 250. Instead of the elongated design of the flex zones 257 shown here, they may also be round, oval or rectangular or may comprise a different arbitrary shape.
The insole further comprises a reinforcement foil 260 in the heel region, which extends into the midfoot region. Also here, it is possible to use different planar materials like, for example, carbon, carbon-fibers or different textiles and fabrics alternatively or in addition to the reinforcement foil 260, and the reinforcement foil 260 may comprise flex zones as described above, too. For clarification, the dimensions of this reinforcement foil 260 are indicated by the dashed line 265 in
Furthermore, both the reinforcement foil 250 as well as the reinforcement foil 260 may contribute to increasing the stiffness of the insole 200.
In some embodiments, materials for the reinforcement foils 250, 260 comprise thermoplastic polyurethane, polypropylene, polyethylene, polyamide and in principle all thermoplastic materials, which may be extruded as a foil.
It is further also possible that the insole 200 comprises further functional elements like a heel support, a (separate) midfoot support or a recess for an electronic component (all of which are not shown here).
The insole 200 comprises dimensions, which lead to a stretching of the shoe upper 110 when the insole 200 is inserted into the interior of the shoe upper 110 of the shoe 100, such that the insole 200 is secured within the shoe upper 110 without additional securing devices or securing measures from the created restoring forces.
It is, however, pointed out that other possibilities and solutions for securing the insole 200 in the shoe upper 110 may also be considered, for example a connection of a hook and loop fastener or where the insole 200 is hooked into the shoe upper at certain places, and so forth.
a-b show a molding arrangement 300, which may be used for performing embodiments of an inventive method for the manufacture of an inventive shoe, for example the shoe 100 with outsole unit 130.
Such a method comprises a positioning of a mounting 310 in the molding arrangement 300, wherein a shoe upper of a shoe, for example shoe upper 110, and a textile two-dimensional region connected to the shoe upper, for example two-dimensional region 120, which extends beneath the foot of the user of the shoe, are arranged on the mounting 310.
The mounting 310 may, for example, be a heat resistant last 310 made from metal, for example from aluminum and/or steel, which withstands the temperatures occurring during manufacture. On this last 310, the shoe upper with the textile two-dimensional region may be pulled on.
Subsequently, at least one sole material, which comprises a rubber material, is positioned in at least one recess in the molding arrangement 300 and/or on the shoe upper and/or on the two-dimensional region, the molding arrangement 300 is closed, and the rubber material is connected to the two-dimensional region without the use of a bonding agent.
This connecting may, in particular, proceed by vulcanizing of the rubber material under the influence of pressure and/or under the provision or heat for the creation of an outsole unit, or example the outsole unit 130 of the shoe 100.
During the connecting, in particular during the vulcanizing, the profile elements 150, 160 and 170, as well as different contours of the outsole unit 130, may form due to the sole material filling corresponding mold contours within the molding arrangement 300.
The following conditions/parameters may be beneficial for the vulcanization process:
A temperature in the closed molding arrangement 300 of 150° C.-200° C., further in a range of 160° C.-190° C., and still further in a range of 165° C.-175° C.;
A closing force of the molding arrangement 300 of 100 kg-200 kg, further in a range of 140 kg-160 kg, and still further in a range of 145 kg-155 kg; and
A duration of the vulcanization process of 5 min-15 min, further in a range of 6 min-10 min, and still further in a range of 8 min.
In some embodiments, manufacturing parameters in different ranges or intervals are possible, for example temperatures in the closed molding arrangement 300 in the region of 150° C.-160° C., 160° C.-170° C., 170° C.-180° C., 180° C.-190° C., 190° C.-200° C., or even higher or lower temperatures, closing forces in the range 100 kg-110 kg, 110 kg-120 kg, 120 kg-130 kg, . . . , 190 kg-200 kg or even higher or lower closing forces as well as a duration of the vulcanization process in the range of, for example, 5 min-8 min, 8 min-12 min, 12 min-15 min or even longer or shorter process durations.
In certain embodiments, the molding arrangement 300 shown in
As shown in
For example, for the manufacture of the shoe 100, a two-dimensional piece 335 of a rubber material is positioned either on the two-dimensional region mounted on the last 310 or in a recess in the top plate 330, which in its shape approximately corresponds to the foot of the later user and (among other things) will form the bottom side of the outsole unit 130. Potentially, further pieces, strips or cubes of the rubber material are placed onto this two-dimensional piece 335, if this is necessary to provide enough base material in the respective regions for the manufacture of the tread surface/profile elements/heel cap/toe cap, and so forth. In a recess of the baseplate 320, a two-dimensional piece 325 of a rubber material is inserted, which will form (among other things) the toe cap 140 after the manufacture. In a recess of the heel slider 340, a two-dimensional piece 345 of a rubber material is inserted, which will form (among other things) the heel cap 148 after the manufacture. In respective recesses of the medial and lateral slider 350, 360, a two-dimensional piece 355, 365 of a rubber material is inserted each, which will form (among other things) the sidewalls of the outsole unit 130 after the manufacture.
It is to be noted that the two-dimensional pieces 325, 335, 345, 355 and 365 may well comprise different rubber mixtures/materials, in order to locally adjust the properties of the outsole unit 130 being manufactured to the wishes and requirements in this way.
For example, a particularly abrasion resistant rubber material at the rim of the sole may be combined with a rubber material providing particular good traction in regions in which the sole primarily contacts the ground, in order to avoid a fast wear of the rims of the sole and to improve the traction at the rim of the sole and at the same time prevent slipping or sliding of the user. In further embodiments, a particularly abrasion resistant rubber material in the forefoot region may be combined with a rubber material providing particular good traction in the heel region, in order to minimize the abrasion during push-off over the forefoot and during climbing and to prevent slipping when treading with the heel. Additionally, in partial regions of the outsole unit a partially or completely vulcanized rubber may be used in a mix with unvulcanized rubber. These are merely some possible examples of how to combine different rubber materials, and further possibilities are possible for the skilled person.
It is also pointed out that it is in principle possible that not only caoutchouc-based materials are used as rubber materials. A different material may also be used, which after conclusion of the manufacturing process comprises properties that are similar or equal to those of vulcanized rubber, in particular similar properties with regard to the abrasion resistance, elasticity and traction on different grounds. The rubber materials/mixtures may hence also be thermo-formable plastics or something similar.
Finally, it is mentioned that such a manufacturing method may produce shoes that are difficult or impossible to manufacture with a conventional gluing method. If, for example, an outsole unit is designed as a single integral piece together with a toe cap and a heel cap and shall be glued to a shoe upper, the shoe upper would initially have to be “crumpled together” in order to be inserted into the undercuts of the toe/heel cap and subsequently be “folded out” again there. The glue used for a gluing of rubber, however, is highly adhesive such that the shoe upper would probably come into contact with the glue and stick to the outsole unit in places where this is not intended.
Finally,
To this end, a respective material sample was fixed to a stamping element and pushed onto different substrates (rough or smooth, wet or dry) with a certain contact force. The contact area was approximately 4 cm2 in each case. The substrate was then pulled out from beneath the material sample and the acting horizontal friction forces were recorded by the device. It was possible to measure the static friction but also the dynamic kinetic friction during the sliding phase of the substrate. For determining the kinetic friction, the first and the last 20 mm of the sliding track where excluded from the determination in each case. The friction forces continually recorded during the sliding phase were then averaged over the relevant sliding phase in order to obtain an averaged value for the kinetic friction.
For the determination of the static friction and the kinetic friction, the average was taken over all test runs performed for given scenario, in order to obtain a final averaged value. These final averaged values are shown in
The following Table 1 summarizes the measurement conditions/scenarios underlying the results shown in
R13 or R10 designate the norm numbers according to DIN 51130, which describe the slip resistance of the respective substrate.
In each case, four vulcanized rubber materials were measured, which are designated as “materials M1, M2, M3 and M4” in
The results presented in
a shows the coefficients of kinetic friction for scenario 1. The measurement values 400a, 420a, 440a and 460a were determined on dry substrate, the measurement values 405a, 425a, 445a and 465a on wet substrate.
b shows the coefficients of kinetic friction 400b, 420b, 440b and 460b for scenario 2, which were determined on wet substrate.
c shows the coefficients of kinetic friction 400c, 420c, 440c and 460c for scenario 3 determined on dry substrate, and
From the measurement results, the following conclusions may be drawn with regard to the rubber materials tested by applicant: in scenario 1, the material M1 shows a 20% higher kinetic friction on dry substrate than materials M2 and M3. On wet substrate, the differences were smaller. In scenario 3 on dry substrate, material M3 performed best with a 38% higher coefficient of static friction than material M1. In scenario 2 on wet substrate, the material M3 had a 19% higher coefficient of kinetic friction than material M1.
Finally, further investigations showed that the rubber materials M1-M4 discussed here on average comprise a 52% improved traction compared to conventional abrasion resistant rubber materials.
To summarize, the investigated rubber materials comprise very good traction values and can hence desirably be employed for use in an outsole unit of an inventive shoe, for example in the outsole unit 130 of the shoe 100. The investigations have also shown in an exemplary manner how different rubber materials perform under different conditions and the skilled person will therefore understand how the properties of an inventive shoe may be adapted to the respective requirements and to the conditions typically occurring in the context of a certain activity through a suitable choice of the rubber material or different rubber materials for different regions of the outsole unit.
In the following, further examples are described to facilitate the understanding of the invention:
Different arrangements of the components depicted in the drawings or described above, as well as components and steps not shown or described are possible. Similarly, some features and sub-combinations are useful and may be employed without reference to other features and sub-combinations. Embodiments of the invention have been described for illustrative and not restrictive purposes, and alternative embodiments will become apparent to readers of this patent. Accordingly, the present invention is not limited to the embodiments described above or depicted in the drawings, and various embodiments and modifications may be made without departing from the scope of the claims below.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2014 213 303.3 | Jul 2014 | DE | national |
