Patent Application
20160295971
The present invention relates to a sole for a sports shoe, to a sports shoe comprising such a sole, and to a method of manufacturing such a sole.
Sports shoes usually comprise a shoe upper and a sole attached to the shoe upper. The upper is for example made from textile materials, such as woven fabrics, nonwoven fabrics, meshes, knit textile, or similar. Such textile materials are based on suitable yarns and fibers, such as polyester. In some applications, leather or artificial leather is used instead of textile materials. The sole is permanently attached to the upper and usually comprises an abrasion resistant, ground-contacting outsole, e.g. based on rubber or plastic, a cushioning midsole, e.g. based on ethylene vinyl acetate (EVA) or polyurethane (PU) foam, and optionally an insole providing comfort for the foot.
A disadvantage of such a conventional sole structure is its rather heavy weight due to the use of two rather thick layers (outsole and midsole) made from dense and heavyweight materials. Furthermore, manufacturing such a sole structure requires a considerable number of manufacturing steps, such as molding the outsole, molding the midsole, gluing the outsole to the midsole, optionally manufacturing the insole, and optionally attaching the insole to the midsole.
Therefore, it has been proposed to replace parts of a sole by textiles. For example, U.S. Pat. No. 2,391,594 relates to a sole comprising a platform made of fibrous, absorbent or porous material which is cut to the outline of the desired sole and has fled parallel top and bottom surfaces. Covering the platform is a member made of either woven, knitted or braided fabric.
US 2004/0107603 A1 provides an indoor cloth wrap sole by providing a bottom layer of cloth and an upper layer of rubber or plastic. The upper layer and the bottom layer are heat pressed together to form a compound structure. The bottom layer includes thick and compact knitting fabrics with a slight embossing structure.
U.S. Pat. No. 8,464,383 B2 relates to a method for making a shoe outsole comprising placing rubber against a coating of cured rubber cement on a segment of fabric, heating the rubber to a temperature below the melting points of the cured rubber cement and the rubber, but high enough to render the cured rubber cement and the rubber tackily adherent to each other and vulcanizing the rubber, thereby to adhere the segment of fabric to the rubber, and cooling the vulcanized rubber to form an outsole having an exposed ground-contacting surface that includes the segment of fabric.
DE 100 37 728 C1 relates to a shoe, in particular a running shoe, and a method for its manufacture. The shoe comprises a light upper for accommodation and support of the foot and a sole which is formed by a net-like structure, wherein vertical sub-portions of the net-like structure are embedded into the sole and wherein the net-like structure interacts with the ground. The net-like structure is formed by a three-dimensional knit fabric of fibers made of one or more different materials.
Soles comprising textile elements known in the prior art, however, have the disadvantage of having a lower friction and/or traction than shoes having a molded outsole made from e.g. rubber. It is therefore the object of the present invention to provide a lightweight sole having a high friction and/or traction and that can easily be manufactured.
This object is fulfilled by the sole according to claim 1, the shoe according to claim 31 and the method of manufacturing a sole according to claim 32.
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 sole for a shoe comprises a first sole element, and a second sole element comprising a textile material, wherein the second sole element is coupled to the first sole element and arranged to at least partially cover the first sole element. At least one of the first sole element and the second sole element comprise protrusions, wherein at least a portion of the second sole element is configured to contact an adjacent surface when the sole is attached to an upper. The portion of the second sole element that contacts the adjacent surface generates an amount of at least one of friction and traction between the sole and the adjacent surface, and the protrusions are configured to increase the amount of the at least one friction and traction generated between the sole and the adjacent surface.
In certain embodiments, the amount of the at least one friction and traction generated by the portion of the second sole element is greater than an amount of the at least one friction and traction generated by a portion of the first sole element when the adjacent surface is the ground or a sports ball.
In some embodiments, the second sole element is made from yarns. The yarns may be based on natural or manmade fibers including polyester, high tenacity polyester, polyamide, metal yarns, stretch yarns, carbon yarns, glass yarns, polyethylene or polyolefin yarns, bi-component yarns, PTFE yarns, Ultra-high-molecular-weight polyethylene yarns, liquid crystal polymer yarns, specialty decorative yarns or reflective yarns or any of these yarns coated with EVA hot melt, TPU, PU, rubber or otherwise coated with a polymer.
In certain embodiments, the second sole element may be made from a knit textile. In further embodiments, the second sole element is a braided material, a woven fabric, nonwoven fabric or created by tailor fiber placement.
According to some embodiments, the second sole element may comprise at least one first area with less stretch than an adjacent area. The second sole element may further comprise at least one second area with more stiffness than an adjacent area, and/or at least one third area with more fraction than an adjacent area, and/or at least one fourth area with a looser knit structure than an adjacent area, and/or at least one fifth area where the second sole element is thicker than in an adjacent area.
In some embodiments, the sole comprises a third sole element, which extends between the first sole element and the second sole element.
Some embodiments comprise a shoe comprising the sole as described above.
According to certain embodiments of the present invention, a method of manufacturing a sole comprising a first sole element and a second sole element comprising a textile material, wherein at least one of the first sole element and the second sole element comprise protrusions comprises coupling the second sole element to the first sole element so that the second sole element is arranged to at least partially cover the first sole element. At least a portion of the second sole element may be configured to contact an adjacent surface when the sole is attached to an upper. The portion of the second sole element that contacts the adjacent surface generates an amount of at least one of friction and traction between the sole and the adjacent surface, and the protrusions are configured to increase the amount of the at least one friction and traction generated between the sole and the adjacent surface.
The textile material of the second sole element may be attached to the first sole element without any glues or adhesives.
In some embodiments, the method further comprises injection molding the first sole element in midsole shape, heating the first sole element to 100-140° C., placing the first sole element together with the textile material of the second sole element in a mold at 120-150° C., pressing the first sole element and the textile material of the second sole element for 10-60 seconds, and removing the produced sole from the mold and cooling.
In certain embodiments, after injection molding the first sole element, the first sole element is washed to create a surface of the midsole that is slightly more porous. The first sole element may be made of EVA. At least one insert may be placed in the mold to prevent flattening the structured surface during the molding process, and the insert may be a silicone insert.
The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.
In the following detailed description, embodiments of the invention are described referring to the following figures:
According to a first aspect of the present invention, a sole for a sports shoe is provided, comprising: (a.) a first sole element; and (b.) a second sole element attached to the first sole element, wherein (i.) the second sole element is arranged to at least partially cover the first sole element, wherein (ii.) the second sole element is configured to be able to get into contact with a surrounding surface when the sole is attached to an upper (iii.) the second sole element is a textile material; and (c.) the first sole element and/or the second sole element comprise protrusions to increase the friction and/or traction of the sole to the surrounding surface.
Surrounding surface in the scope of this invention can be for example the surface of the ground or of a sports equipment good, especially a sports ball.
The sole according to the present invention is particularly lightweight because it dispenses with a heavy outsole. Instead, two sole elements are used, wherein the second sole element is a lightweight textile material being considerably lighter than a conventional outsole. The first sole element may be made from a conventional midsole material, such as EVA. Thus, in total, the weight of the sole according to the invention is less than that of a conventional sole.
The sole according to the present invention enables it to use just one tooling for manufacturing the complete sole. It is possible to manufacture the sole with one mold. For example it becomes possible, first to produce the first sole element and then combine the first sole element with the second sole element in one and the same mold.
To provide stability, support, and bending and torsional stiffness comparable to that of conventional soles, the second sole element is arranged to at least partially cover the first sole element. Thus, by “wrapping” the first sole element with the textile material of the second sole element, the sole becomes stable and stiff just like a conventional sole. It is possible that the first sole element is fully contained in the second sole element, by wrapping around the second sole element. It is also possible that the first sole element partially exposes through the second sole element.
To increase the friction and/or traction of the sole according to the invention to the surrounding surface, the first sole element and/or the second sole element comprise protrusions. Thus, the sole is provided with a tread-like and/or stud-like structure. In this way, friction and/or traction of the sole is considerably improved. The protrusions allow the first sole element and/or the second sole element to fulfil the function of a conventional outsole. It is possible that the first sole element comprises protrusions and the second sole element does not comprise protrusions. For example the second sole element could be a flat textile material, which is molded around a shaped first sole element, for example around a midsole. Vice versa the first sole element could not comprise protrusions and the second sole element does comprise protrusions. Further it is possible that both, the first sole element and the second sole element comprise protrusions.
The first sole element may partly extend through the second sole element. Thus, relative movements between the first sole element and the second sole element (for example during fast and abrupt changes in direction) may be avoided or a least minimized.
It is also possible that the sole comprises a third sole element. The third sole element could be arranged between the first sole element and the second sole element, for example as a mid-layer. The third sole element could be permanently attached to the first sole element, for example by stitching, gluing or welding. The third sole element could be for example designed as a rubber plate, as a plate made of any kind of polymer, as an arrangement of cleats or as another plate which could comprise protrusions. Further it is possible, that the third sole element is designed as a functional spike plate. It is possible that the first sole element comprises a flat bottom surface without protrusions, whereby the third sole element comprises protrusions. It is possible that the third sole element supersedes the first sole element and interacts with the second sole element.
It is possible that the sole is designed that second sole element and the first sole element are being able to get into contact with a surrounding surface when the sole is attached to an upper. This could be the case if protrusions are designed on the first sole element and/or the third sole element and extending through the second sole element.
A high friction and/or traction is a achieved by the inventive sole due to protrusions formed directly on the first sole element and/or protrusions formed on the third sole element and/or by the design of the second sole element (textile material).
The first sole element may be permanently attached to the second sole element. This provides a firm connection between both sole elements and the second sole element may provide a high degree of stiffness and stability to the first sole element.
The second sole element may provide a greater friction and/or traction with the surrounding surface compared to the first sole element. Thus, the second sole element not only improves stiffness and stability of the entire sole, but also improves friction and/or fraction.
The second sole element may be arranged on the side of the first sole element which faces the surrounding surface when the sole is integrated into a shoe. In this way, the second sole element will contact the ground when the sole is attached to an upper and may improve friction and/or traction of the shoe, e.g. by using suitable yarns, such as rubberized or rubber yarns.
The second sole element may be at least partially arranged on a lateral side of the first sole element. If the sole is attached to an upper of a shoe for ball sports, such as soccer, the lateral arrangement of the second sole element advantageously increases the friction with the ball, e.g. during kicks.
The second sole element may completely cover the side of the first sole element which faces the surrounding surface when the sole is attached to an upper. Thus, the second sole element provides stiffness and stability over the entire length of the sole.
The second sole element may be configured to at least partly cover an upper of a shoe to which the sole is attached. Thus, a strong connection is provided between the upper and the sole. This arrangement, where the second sole element extends from sole to upper, offers lateral stability. Furthermore, this arrangement may improve friction and/or traction of the upper, e.g. by using suitable yarns, such as rubberized or rubber yarns. This is in particular advantageous for sports shoes for ball sports, such as soccer.
The second sole element may be made from yarns. The yarns may be based on natural or manmade fibers including polyester, high tenacity polyester, polyamide, nylon, cordura, metal yarns, stretch yarns, spandex yarns, carbon yarns, glass yarns, polyethylene or polyolefin yarns, PTFE yarns, Ultra-high-molecular-weight polyethylene (UHMWPE) yarns, liquid crystal polymer yarns, specialty decorative yarns or reflective yarns. Any of these yarns may be coated with EVA hot melt, TPU, PU, rubber or otherwise coated with a polymer. These yarns may provide specific functions to the sole. For example, the use of rubber yarns increases friction and/or traction, whereas the use of reflective or decorative yarns improves the optical appearance of the sole.
It is also possible that the second sole element may be made from bi-component yarns, which are formed of at least two thermoplastic polymer materials arranged in a core-sheath relationship, whereby a first material forms a central portion and a second material surrounds the central portion. Bi-component yarns may be formed to have materials with different properties. For example the used materials may be selected that the first material has a higher melting temperature than the second material. Raising the temperature of such a yarn to a point above the melting temperature of the second material, but below the melting temperature of the first material, will cause melting only the second material. The first and the second material may both be for example polyester, e.g. with different melting temperatures. It is possible that the first material may be nylon and the second material may be polyurethane. In addition to the core-sheath relationship in bi-component yarns, materials may be arranged in a side-by-side configuration, or any other configuration wherein different distinct areas of yarns includes different materials.
The second sole element may be made from a knit textile. The knit textile may readily be manufactured on a corresponding machine in the desired shape of the second sole element, i.e. with almost no waste. Furthermore, the knit textile may be provided with specific functions and targeted locations by programming the knitting machine accordingly. The knit textile may be a warp knit or a weft knit. For example the weft knit could be flat knitted or circular knitted. For example the warp knit can be an engineered knit.
The second sole element may be a braided material, a woven fabric, nonwoven fabric or created by tailor fiber placement. These techniques can be performed by corresponding machines which may also provide specific functions at targeted locations by programming the machine accordingly.
The second sole element may comprise multiple textile layers. Different textile layers may add different functions to the sole. For example, one layer may improve the stiffness of the entire sole, whereas the other layer may improve traction and/or friction.
At least two textile layers may comprise different yarns. Different yarns may provide different properties to the layers. For example, a rubberized rubber yarn may be used in a first textile layer to improve friction and/or traction, whereas a rather inelastic yarn may be used in a second textile layer to improve the stiffness and stability of the sole.
The textile layers may cover each other at least partially. Thus, the functions of the textile layers may add in the overlap area.
The textile layers may be sandwiched, engineered from a single constructed fabric, highly stable/non stretch, 2-way stretch, or 4-way stretch. The use of sandwiched layers improves the stiffness of the sole. Engineered textile layers allow for specific functions at targeted locations of the sole. 2-way stretch material is rather inelastic in one direction and more elastic in an orthogonal direction. 4-way stretch material is rather inelastic in a first and a second orthogonal direction, but rather elastic in a third and fourth orthogonal direction. Thus, the elasticity of the sole may be predetermined by a corresponding orientation of the 2-way or 4-way stretch material relative to the first sole element.
The second sole element may comprise areas with different properties. Examples of areas with advantageous properties are given in the following.
The second sole element may comprise at least one first area with less stretch than a surrounding area. The first area may be located in a toe area and/or a heel area of the sole. Thus, stability is improved during the landing and push-off phase of the gait cycle.
The second sole element may comprise at least one second area with more stiffness than a surrounding area. The second area may be located in a midfoot region of the sole. In this way the midfoot region and in particular the arch of the foot is provided with stiffness, stability and support.
The second sole element may comprise at least one third area with more traction than a surrounding area. The third area may be located in a heel region of the sole. Thus, friction and/or traction is improved during the landing-phase of the gait cycle. Slippage of the sole is reduced.
The second sole element may comprise at least one fourth area with a looser knit structure than a surrounding area. The fourth area may be located in a region between a heel region and a midfoot region of the sole. Thus, the heel region may be decoupled from the remainder of the sole. This reduces the propagation of forces along the sole and may provide additional cushioning to the sole.
The second sole element may comprise at least one fifth area where the second sole element is thicker than in a surrounding area. The fifth area may be located in a midfoot region of the sole. Thus, additional support is provided to the arch of the foot. A further aspect of the present invention relates to a shoe, in particular a sports shoe, comprising a sole as described before.
A still further aspect of the present invention relates to a method of manufacturing a sole, comprising the steps of: (a.) providing a first sole element; and (b.) attaching a second sole element to the first sole element, such that the second sole element is arranged to at least partially cover the first sole element, and such that the second sole element is configured to be able to get into contact with a surrounding surface when the sole is attached to an upper, wherein the second sole element is a textile material; wherein (c.) the first sole element and/or the second sole element comprise protrusions to increase the friction and/or traction of the sole to the surrounding surface.
The textile material of the second sole element may be attached to the first sole element without any secondary glues or adhesives. Nevertheless, glues or adhesives may additionally be used.
The method according to the present invention enables it to use just one tooling for manufacturing the complete sole. It is possible to manufacture the sole with one mold. For example it becomes possible, first to produce the first sole element and then combine the first sole element with the second sole element in one and the same mold.
The method may further comprise the steps of injection molding of the first sole element in midsole shape, heating the first sole element to a temperature range of 100-140° C., which may further be in a temperature range of 110-115° C., placing the first sole element together with the textile material of the second sole element in a mold at a temperature range of 120-150° C., which may further be at a temperature range of 135-145° C., pressing the first sole element and the textile material of the second sole element for a range of 10-60 seconds, which may further be for a range of 25-40 seconds, and removing the produced sole from the mold and cooling. This sequence of steps and of parameters has shown to be particularly advantageous to produce a compound sole, wherein the textile material shows a very good bonding to the first sole element without unintentionally flattening the yarns of the textile material. It is also possible that the first sole element may be molded directly with the textile material of the second sole element immediately after removing from the compression or injection mold, by placing the textile material against the first sole element and moving the created sole to a second mold.
After injection molding of the first sole element, the first sole element may be washed to create a surface of the midsole which is slightly more porous.
The first sole element may be made of EVA.
At least one insert may be placed in the mold to avoid that the structured surface, i.e. a yarn radius, is flattened during the molding process.
The at least one insert may be a silicone insert. Silicone inserts have been shown to provide for good heat conduction while being sufficiently heat resistant.
A business model of the sole according to the invention could be that consumers design their own look for the textile element of the second sole element. For example it could be possible that consumers create via a web tool (online platform) a certain pattern or certain pictures which they want to have on the textile material of the second sole element. Afterwards the consumers can then send their designs to the shoe manufacturer. This could happen automatically, for example by the web tool. Afterwards in the factory it is possible to produce a shoe with a sole, which comprises a first sole element and a second sole element, whereby the second sole element is based on the creative design of the consumer. It is also possible that consumers design their own textile material (e.g. pattern, colored) and upload it on an online platform, where other consumers can buy the designed textile material. The tooling of the inventive method of manufacturing a sole enables it to combine a first sole element with an arbitrary amount of textile materials by using the same mold.
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.
The sole 10 according to the invention also comprises a second sole element 12. This second sole element 12 is attached to the first sole element 11 by molding the first sole element 11 and the second sole element 12 together in a mold under heat and/or pressure as will be described in more detail below. Alternatively, the second sole element 12 may be attached to the first sole element 11 by stitching, gluing or welding. Furthermore, it is also possible that the second sole element 12 is non-permanently attached to the first sole element 11, e.g. by a hook-and-loop fastener, snap buttons, etc.
In the exemplary embodiments of
It is also possible that the second sole element 12 is configured to at least partly cover an upper of a shoe (not shown in the
Coming back to
As shown in
In general, the yarns used for the textile material of the second sole element 12 may be based on natural or manmade fibers including polyester, high tenacity polyester, polyamide, nylon, cordura, metal yarns, stretch yarns, spandex yarns, carbon yarns, glass yarns, polyethylene or polyolefin yarns, PTFE yarns, Ultra-high-molecular-weight polyethylene (UHMWPE) yarns, liquid crystal polymer yarns, specialty decorative yarns or reflective yarns. Any of these yarns may be coated with EVA hot melt, TPU, PU, rubber or otherwise coated with a polymer. The yarns may be coated as in some of the mentioned examples, or may not be coated. The yarns may be chosen to provide greater friction and/or traction. Rubber or rubber-covered yarns, for example, may provide improved fraction. In general, the second sole element 12 may provide a greater friction and/or traction with the ground and/or sports ball compared to the first sole element 11. The yarns may be chosen to provide adhesion to the midsole in lieu of adhesives or in conjunction with adhesives or with adhesives and primers.
It is also possible that the second sole element 12 may be made from bi-component yarns, which are formed of at least two thermoplastic polymer materials arranged in a core-sheath relationship, whereby a first material forms a central portion and a second material surrounds the central portion. Bi-component yarns may be formed to have materials with different properties. For example the used materials may be selected that the first material has a higher melting temperature than the second material. Raising the temperature of such a yarn to a point above the melting temperature of the second material, but below the melting temperature of the first material, will cause melting only the second material. The first and the second material may both be for example polyester, e.g. with different melting temperatures. It is possible that the first material may be nylon and the second material may be polyurethane. In addition to the core-sheath relationship in bi-component yarns, materials may be arranged in a side-by-side configuration, or any other configuration wherein different distinct areas of yarns includes different materials. The first sole element 11 and the second sole element 12 comprise protrusions. Three of these protrusions are exemplary denoted with the reference numeral 13 in
The protrusions 13 increase friction and/or traction to the ground and/or a sports ball, because the contact surface of the sole according to the invention is smaller than the contact surface of a flat sole. Thus, the pressure exerted on the protrusions 13 is increased as is the friction. Furthermore, on rather soft ground or a rather soft sports ball, the protrusions 13 may penetrate the ground or surface of the ball at least partially, thereby improving traction or “grip”.
In the exemplary embodiments of
In general, only the first sole element 11 may comprise protrusions, only the second sole element 12 may comprise protrusions, or both the first sole element 11 and the second sole element 12 may comprise protrusions. In this way a high friction and/or traction is achieved.
In the exemplary embodiments of
In the exemplary embodiments of
The sole 10 shown in
The second sole element 12 comprises a second layer 42 comprising a mesh-like or lattice-like structure with openings of a few millimeters. The second layer 42 covers the bottom side, medial and lateral sides and the toe and heel portions of the first sole element 11. In particular, the second layer 42 covers the first layer 41 completely. However, it is also possible that the second layer 42 covers the first layer 41 only partially. Also, what has been said with respect to the arrangement of the second sole element 12 relative to the first sole element 11 in the context of
The first sole element 11 comprises protrusions, three of which are exemplary denoted with the reference numeral 13 in
The first layer 41 and the second layer 42 may have different colors. Thus, the invention allows to provide a lightweight sole with an appealing, iconic design. It should be noted that a different number of layers may be used, for example three layers. Thus, using multiple layers, the design possibilities are numerous.
Furthermore, the two textile layers 41 and 42 shown in
In the exemplary embodiments of
In the area 52 between the heel area 51 and the midfoot area 53 the knit textile comprises a loser knit structure to decouple the landing zone 51.
In the midfoot area 53 the knit structure is denser and more closed, or maybe also be thicker, than surrounding areas to provide a high torsional stiffness and more stability in this area. Thickness could for example range from 0.5 mm to 8.0 mm in different areas.
In the area 54 between the toe area 55 and the midfoot area 53 the knit textile comprises less knit than surrounding areas to allow for stretch. This supports the flexing of the toes during the push-off-phase of the gait cycle.
Finally, in the toe area 55 the knit textile comprises more yarns, a tighter knit and less stretch to support the toes during the push-off-phase. Furthermore, due to the knit structure, the area 55 comprises more traction than the adjacent area 54.
The second sole element 12 could also comprise a Jacquard circular knit textile. When a Jacquard circular knit textile is used, yarns could be selected for specific purposes and the pattern could be modified to create grip/traction in areas where they are needed. By this, different yarns can be placed at any place to create a certain color pattern. It is also possible to use more than three different yarns to create different patterns.
The shoe 70 comprises a sole 10 as described before and an upper 71. The upper 71 can be made from conventional textile materials, leather or artificial leather. The sole 10 can be stitched, glued, welded or otherwise be fixed to the upper 71. Also it is possible to mold the sole 10 to the upper 71. As the shoe 70 is a soccer shoe, the first sole element 11 (not shown in
The second sole element 12 comprises a knit textile, which may be a warp knit textile. The knit textile comprises protrusions of a size between 0 and 3 mm, three of which are exemplarily denoted with the reference numeral 13a in
The first sole element 11 as well as the second sole element 12 furthermore comprise protrusions in the form of studs, three of which are denoted exemplarily by the reference numeral 13b. These studs 13b provide for good traction on grounds which are usually used for playing soccer, such as turf and artificial turf. The studs 13b are provided on the first sole element 11 (not shown in
The shoe 80 comprises a sole 10 as described before and an upper 81. The upper 81 can be made from conventional textile materials, leather or artificial leather. The sole 10 can be stitched, glued, welded or otherwise be fixed to the upper 81. The first sole element 11 is designed as a midsole, for example an EVA midsole. The second sole element 12 comprises a knit textile as described above. A third sole element 83 is arranged between the first sole element 11 and the second sole element 12, for example as a mid-layer. The third sole element 83 could be for example designed as a rubber plate, as a plate made of any kind of polymer, as an arrangement of cleats or as another plate which could comprise protrusions 13. Further it is possible, that the third sole element 83 is designed as a functional spike plate. It is possible that the first sole element 11 comprises a flat bottom surface without protrusions, whereby the third sole element 83 comprises protrusions 13. Also it is possible that the first sole element 11 and the third sole element 83 comprise protrusions 13. It is also possible that the protrusions 13 extend through the second sole element 12, whereby the protrusions 13 would be visible from the outside. The third sole element 83 could be designed to penetrate the textile material of the second sole element 12.
The sole 90 comprises a first sole element 11, which is designed as a midsole, for example an EVA midsole. A second sole element 12 comprises a textile material as described above. A third sole element 93 is arranged between the first sole element 11 and the second sole element 12, for example as an intermediate layer. Additionally the sole 90 according to
The shoe 100 comprises a sole 10 as described before and an upper 101. The upper 101 can be made from conventional textile materials, leather or artificial leather. The sole 10 can be stitched, glued, welded or otherwise be fixed to the upper 101. The first sole element 11 is designed as a midsole, for example an EVA midsole. The second sole element 12 comprises a knit textile as described above. The fourth sole element 94 comprises rubber elements. According to the embodiments of
The sole 10 according to the present invention may be manufactured by attaching the second sole element 12 to the first sole element 11 prior to molding. Suitable molding methods comprise compression molding, injection molding or steam molding tooling. In the case of compression molding, the mold may be a steel mold. An example for a mold is shown in
The textile material of the second sole element 12 may be attached to the first sole element 11 without any glues or adhesives. Nevertheless, glues or adhesives may additionally be used. The material of the first sole element 11 may be EVA with an Asker C hardness of for example 55 to 65. The textile material of the second sole element 12 may be based on natural or manmade fibers including polyester, high tenacity polyester, polyamide, nylon, cordura, metal yarns, stretch yarns, spandex yarns, carbon yarns, glass yarns, polyethylene or polyolefin yarns, PTFE yarns, Ultra-high-molecular-weight polyethylene (UHMWPE) yarns, liquid crystal polymer yarns, specialty decorative yarns or reflective yarns. Any of these yarns may be coated with EVA hot melt, TPU, PU, rubber or otherwise coated with a polymer.
As mentioned above it is also possible that the second sole element 12 may be made from bi-component yarns.
In certain embodiments of the process, EVA is injection molded into a midsole shape. Afterwards the midsole is washed to create a surface of the midsole which is slightly more porous. Then the EVA midsole is heated to a temperature range of 100-140° C., which may further be in the temperature range of 110-115° C. Then the EVA midsole together with the textile material is placed in a silicone lined mold at a temperature range of 120-150° C., which may further be at a temperature range of 135-145° C., whereby the silicone comprises a temperature of about 115° C. Afterwards the EVA midsole and the textile material are pressed for a range of 10-60 seconds, which may further be for a range of 25-40 seconds. Afterwards the produced sole is removed from mold and cooled.
To avoid that the structured surface, i.e. a yarn radius, is flattened during the molding process, the mentioned silicone inserts are placed in the mold. An example for such an insert is shown in
In additional embodiments, the EVA material is injection molded into midsole shape and heated to 150-160° C. when removed from the injection mold. It would be possible that afterwards the EVA midsole could be immediately combined with the textile material and pressed into mold directly after removal from injection mold, or hot washed then combined with a textile material and immediately pressed into mold while still hot.
It could be further possible to use hot melt yarns with a low melt temperature, for example 90° C. So it would be possible to keep the EVA material at 70-90° C. without shrinkage.
Features of particular embodiments of the present invention may be incorporated into other embodiments. Specifically, all embodiments and examples described in this specification may be combined with each other, i.e. features of one embodiment and/or example together with features of another embodiment and/or example may yield a further embodiment and/or example, although the combination of these features is not explicitly mentioned herein.
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.
