Soles for sports shoes

Abstract

Improved soles and insoles for shoes, especially sports shoes, are described. According to one aspect, a sole for a shoe, in particular for a sports shoe, is provided which has a first sub-area which has an expanded thermoplastic polyurethane (TPU) and a second sub-area which is free of expanded TPU, wherein the second sub-area laterally surrounds the first sub-area.

Description

1. Technical field

[0001] The present invention relates to soles for shoes, in particular soles for sports shoes. 2. State of the art

[0002] Soles give shoes a multitude of different properties, which can vary in intensity depending on the specific type of shoe. Primarily, shoe soles typically serve a protective function. Their increased stiffness compared to the upper protects the wearer's foot from injuries caused by sharp objects, for example. Furthermore, the sole's increased abrasion resistance usually protects the shoe from excessive wear. In addition, soles can improve a shoe's grip on the ground, thus facilitating faster movements. Another function of a shoe sole can be to provide a degree of stability. Finally, a shoe sole can act as a shock absorber, for example, to cushion the forces generated when the shoe comes into contact with the ground.Finally, a shoe sole can protect the foot from dirt or splashes of water, or provide a variety of other functionalities.

[0003] To accommodate this wide range of functionalities, various materials are known in the art for manufacturing shoe soles. Examples include soles made of ethylene vinyl acetate (EVA), thermoplastic polyurethane (TPU), rubber, polypropylene (PP), or polystyrene (PS). Each of these materials offers a specific combination of properties that make it more or less suitable for soles of certain types of shoes, depending on the specific requirements of each shoe type. For example, TPU is very abrasion-resistant and tear-resistant. Furthermore, EVA is characterized by high stability and relatively good cushioning properties.

[0004] A common disadvantage of the aforementioned materials is that shoe soles made from these materials must be manufactured separately and then attached to the shoe upper, e.g., by gluing or sewing. Expanded TPU, which can be used for manufacturing shoe soles, is known from WO 2008 / 087 078 A1, WO 2007 / 082 838 A1, WO 2010 / 136 398 A1, and WO 2005 / 066 250 A1. WO 2005 / 066 250 A1 describes how a shoe sole made of expanded TPU can be bonded to a shoe upper without additional adhesives. Furthermore, WO 2005 / 066 250 A1 discloses that the expanded TPU is foamed in a tool in contact with the shoe upper, thus providing a sole made of expanded TPU that adheres to the shoe upper. Furthermore, WO 2005 / 066 250 A1 describes the possibility of using an outsole made of thermoplastic elastomer (e.g.The outsole (PVC, thermoplastic rubber, TPU) is prefabricated, and after curing, a cavity between the outsole and the upper is filled with expandable TPU foam. This eliminates the need to glue the outsole to the upper.

[0005] However, the disclosure in WO 2005 / 066 250 A1 has the disadvantage that the properties of the sole are influenced across its entire surface by the expanded TPU material. Fine-tuning of the sole properties is not possible according to WO 2005 / 066 250 A1.

[0006] DE 11 2009 001 291 T5 discloses a shoe comprising an upper designed to receive a foot and an outsole attached to the upper, as well as a ground engagement side and a side defining at least one opening extending through the outsole. The shoe further comprises a midsole that can be removably inserted into the upper and has at least one projection extending away from the removable midsole section, which is designed to project at least partially into the at least one opening formed in the outsole for attaching the midsole to the outsole, wherein the midsole has several support sections, at least two of which are made of different materials. One embodiment provides a midsole with an instep support provided in the midsole, wherein the instep support is, for example,may be made of thermoplastic polyurethane.

[0007] DE 10 2005 050 411 A1 relates to a method for manufacturing a sole made of foamed thermoplastic polyurethane, in which the sole is produced in an open tool and pressed to form the sole, as well as a sole available according to such a method, and a shoe having such a sole.

[0008] DE 10 2011 108 744 A1 discloses a method for manufacturing a sole or sole part of a shoe, in particular a sports shoe. To obtain a lightweight shoe with good resilience, the invention provides the following steps: a) manufacturing plastic bodies whose dimensions in the three spatial directions are between 2 mm and 15 mm, preferably between 3 mm and 9 mm, wherein the plastic bodies consist of foamed thermoplastic elastomer based on urethane (TPU, E-TPU, TPE-U) and / or on polyether block amide (PEBA); b) inserting the plastic bodies into a mold having a cavity corresponding to the shape of the sole or sole part to be manufactured; c) joining the plastic bodies together in the mold, wherein a bonding agent is introduced into the mold and / or heat is applied to the plastic bodies for joining.

[0009] US 2011 / 0047720A1 relates to a process for forming a midsole. A first mold and a second mold are placed in contact with each other. A first material is injected into the first mold to form a first and second section of a midsole preform. The first and second sections are positioned in a third mold of a second mold assembly. A second material is placed in the third mold. The third mold and a fourth mold are placed in contact with each other. The second material and the first and second sections are subjected to heat to form a midsole preform. The midsole preform is placed in a fifth mold. The fifth mold and a sixth mold are placed in contact with each other. The midsole preform is subjected to heat and pressure to form a midsole.

[0010] US 2009 / 0013558A1 concerns a footwear article with an upper and a sole structure attached to the upper. The sole structure has a plurality of support elements, and each support element comprises a shell and a core. The shell defines an interior void and is formed from a polymer material that extends substantially around the entire void. The core has a shape corresponding to the void and is positioned within the void, with at least a portion of the core being a polymer foam material. The polymer foam material of at least two support elements may have different densities.

[0011] EP 2 055 204 A1 discloses an elastic shock absorption device comprising at least one layer of a composite unit (2, 2', 2a, 2b) with top and bottom surfaces (201, 201', 202, 202') and a plurality of adjacent and interconnected elastic elongated elements (21, 21', 21a, 21b) arranged between the top and bottom surfaces (201, 201', 202, 202'). Each of the elastic, elongated elements (21, 21', 21a, 21b) has an outer tube (211, 211', 211a) and a foam element (212, 212', 212a) arranged in the outer tube (211, 211', 211a) and extending along the length of the outer tube (211, 211', 211a).

[0012] DE 600 11 222 T2 describes a method for manufacturing shoes with foamed soles, comprising the steps of: (a) forming a foamable mixture, (b) heating and foaming the foamable mixture to form a foamed insole blank, (c) forming a sole, (d) forming a shoe last, (e) forming a sheet on the shoe last, (f) arranging the adhesive-coated sole, the adhesive-coated foamed insole blank, the sheet, and the shoe last in a mold to press and join these parts together, (g) locally heating the outer circumference of the foamed insole blank, and (h) pressing the outer circumference of the foamed insole blank such that ribbing is formed on the outer circumference of the foamed insole blank, thereby forming a finished shoe product.

[0013] DE 10 2004 001 204 A1 discloses a method for manufacturing shoes in which the shoe upper is bonded to a sole based on foamed thermoplastic polyurethane, characterized in that the expandable thermoplastic polyurethane is foamed in a tool in contact with the shoe upper.

[0014] DE 103 26 138 A1 discloses expandable thermoplastic polyurethanes, producible by mixing thermoplastic polyurethanes with expandable microspheres, characterized in that the expandable microspheres have a TMA density of less than 10 kg / m·3.

[0015] US 2011 / 0126422A1 describes a shoe sole assembly with at least one compressible protruding element extending downwards beyond the underside of the outsole, wherein the at least one protruding element imparts a natural instability to the wearer when the sole assembly first comes into contact with a supporting surface.

[0016] Based on the prior art, it is therefore an object of the present invention to provide better soles for shoes, especially sports shoes. A further object of the present invention is to provide improved possibilities for designing soles made of expanded TPU. 3. Summary of the invention

[0017] The object of the present invention is solved by the subject matter of the independent claims. In one embodiment, at least one aspect of the problem according to the invention is solved by a sole for a shoe, in particular a sports shoe, with at least a first and a second surface area, wherein the first surface area comprises expanded TPU and wherein the second surface area is free of expanded TPU.

[0018] The combination of a surface area made of expanded TPU with a surface area that is free of expanded TPU, e.g. made of other materials, makes it possible to provide the advantageous properties of expanded TPU in a targeted manner where they are desired and to combine them with other properties in another surface area.

[0019] Expanded TPU is characterized by particularly good elasticity and cushioning properties. Firstly, expanded TPU provides excellent cushioning. External shocks, such as those occurring when the sole impacts the ground, are effectively absorbed, resulting in comfortable wear. Secondly, expanded TPU offers high elasticity. This high elasticity allows the absorbed energy, which causes the sole to deform, to be released again. This energy is therefore not lost. For example, this energy remains available to a runner even after the sole impacts the ground, as the sole rebounds with virtually no energy loss.

[0020] Furthermore, expanded TPU exhibits high long-term stability, meaning it deforms only minimally even under continuous external forces. This makes it particularly well-suited for shoe soles. Moreover, it turns out that the mechanical properties of expanded TPU are essentially temperature-independent across a wide temperature range. Therefore, this material allows for the simultaneous optimization of a shoe sole's properties across a broad temperature spectrum. For example, sports shoes, such as running shoes, with a sole that incorporates an initial surface area made of expanded TPU can be used in both winter and summer temperatures, such as a range of 0°C to 30°C, without significant functional changes, such as altered cushioning. In contrast, EVA, which is widely used in shoe soles in the prior art, exhibits a considerably stronger temperature dependence.

[0021] For example, a first area of ​​the sole made of expanded TPU can provide particularly high cushioning in the heel area, while using a firmer material in the rest of the sole can achieve increased strength. The advantageous material properties of expanded TPU can be precisely tailored to the requirements of each individual sole, allowing for optimized design across its entire surface or in a modular fashion.

[0022] The use of expanded TPU for a sole comprising at least two surface areas proves particularly advantageous because this material can be bonded to a wide variety of other materials without additional adhesives. It thus allows for combination with second surface areas made of numerous materials, such as EVA, TPU, rubber, PP, PS, polyamide, etc. The design possibilities for the first and second surface areas are therefore virtually limitless. The present invention opens up a wealth of design possibilities for novel shoe soles.

[0023] A partial area of ​​a sole, as defined in this application, refers to any arbitrarily shaped partial area of ​​a sole. In contrast, a surface area refers to a specific partial area of ​​a sole, namely a partial area that extends continuously from the underside of the sole to the top side of the sole. The term partial area of ​​a sole encompasses surface areas of the sole, but also, for example, a sole layer, a surface area of ​​a sole layer, or other partial areas of the sole.

[0024] In one embodiment, the sole's surface areas are bonded together using a steam process for the expanded TPU. Surprisingly, this is possible with a variety of materials that can be used for the second surface area, such as those already mentioned. The resulting bond is strong enough to withstand the high forces typically exerted on a shoe sole. Therefore, the surface areas do not need to be additionally glued or stitched together. Joining the surface areas using the steam process thus allows for a faster, less labor-intensive, and therefore more cost-effective production process. Furthermore, the precision of the bond in a steam process is significantly higher and easier to automate compared to, for example, stitching or gluing.Since adhesives are usually hazardous to health and poorly suited to the environment, avoiding adhesives also provides a more environmentally friendly manufacturing process with improved occupational safety.

[0025] In another embodiment, the second surface area features expanded EVA. The combination with expanded EVA creates a second surface area that provides good cushioning and increases the stability of the sole.

[0026] In a preferred embodiment, the second surface area comprises a non-expanded TPU. A combination with non-expanded TPU is particularly advantageous because the expanded and non-expanded TPU bond exceptionally well. This results in a particularly durable sole. Furthermore, the use of non-expanded TPU allows the second surface area to be equipped with high tear resistance and good abrasion resistance. Particularly preferably, the non-expanded TPU serves as the outsole material.

[0027] In another embodiment, the second surface area is made of rubber. The use of rubber can, for example, give the second surface area a particularly high slip resistance.

[0028] In another embodiment, the second surface area comprises PP. Polypropylene allows for high hardness while maintaining a relatively low weight for the second surface area.

[0029] In another embodiment, the second surface area comprises a polyamide (PA). Using PA allows for a particularly rigid second surface area.

[0030] In another embodiment, the second surface area is made of polystyrene (PS). The use of PS allows second surface areas to be made particularly hard while simultaneously being lightweight.

[0031] In one embodiment, the second surface area is arranged at an edge of the sole. This can, for example, increase the sole's strength and / or slip resistance. It can also help prevent, for instance, ankle sprains. Arranging the second surface area at an edge of the sole allows for a minimization of the second surface area.

[0032] In another embodiment, the second surface area comprises a sole plate and / or a torsional support and / or an outsole and / or a recess for receiving functional elements. Functional elements can be, for example, a frame specifically adapted for sprint shoes and / or a unit for supporting the damping of shear forces and / or a pronation support element and / or an electronic unit. The use of these elements in the second surface area further enhances the functionality of the sole. In a preferred embodiment, the elements are also prefabricated. The elements are precisely bonded to the first surface area using the steam process for the first surface area.

[0033] In one embodiment, the first surface area has a varying thickness. This varying thickness allows for targeted control of the surface area's properties. For example, increased thickness in certain areas can provide greater cushioning. Furthermore, varying the thickness can create a specific sole profile. Expanded TPU makes it particularly advantageous to produce surface areas with varying thicknesses. Due to the durability of expanded TPU, the thickness variation remains constant even under heavy use of the sole.

[0034] Preferably, the thickness of the first surface area of ​​the sole increases from the forefoot to the heel. This allows for greater rigidity in the heel area, for example. Furthermore, this increases the weight of the sole towards the heel, resulting in a more natural feel.

[0035] In one embodiment, the first surface area has at least one recess. This means that the first surface area only needs to be provided to the extent that it is actually required. This reduces the weight and cost of the sole.

[0036] In another embodiment, the first surface area is arranged essentially at an edge of the sole. By arranging it at an edge of the sole, essentially the entire contact area of ​​the sole can be supported by the first surface area in a preferred embodiment. For this purpose, the first surface area does not necessarily need to be located in the inner area of ​​the sole. Thus, the area of ​​the first surface area can be minimized essentially without loss of functionality.

[0037] Preferably, the thickness of the first surface area at the edge of the sole is increased. Since higher loads occur at the edge of the sole, for example due to changes in direction while walking, a greater thickness there can provide correspondingly higher strength.

[0038] In one embodiment, the first surface area is located in the midfoot and / or forefoot area of ​​the sole. This allows for particularly good cushioning in the midfoot and / or forefoot area of ​​the sole. Since the primary ground contact of the sole often occurs in these areas / in one of these areas during rapid movements, increased cushioning in these areas / in one of these areas is particularly desirable for many types of shoes, e.g., basketball shoes.

[0039] In one embodiment, the first surface area is surrounded by the second surface area. This can, for example, increase the stability of the first surface area. Furthermore, the functionality of the first surface area can also be influenced in this way, for example by limiting the possible extent of the first surface area with the second surface area.

[0040] In another embodiment, the sole comprises a third surface area made of expanded TPU. The advantageous manufacturing process of the expanded TPU also makes it possible to incorporate a third surface area made of this material into the sole. This opens up further design possibilities with regard to the functionality and appearance of the sole.

[0041] Preferably, the first surface area is located in the heel area of ​​the sole, while the third surface area is located in the midfoot and / or forefoot area of ​​the sole. This allows for increased cushioning in both the midfoot and / or forefoot area and the heel area of ​​the sole without requiring the expanded TPU to be used throughout. Instead, an intermediate area can remain untouched, thus saving material, weight, and costs.

[0042] In a further embodiment, at least the first surface area is at least partially surrounded by a film, in particular a plastic film. The film can comprise TPU, PA, polycarbonate, and / or carbon fiber and / or other materials. Using films allows, firstly, the external appearance of the first surface area to be modified. The film can, for example, give the first surface area a specific color and / or a specific texture. Furthermore, the film can also modify a functionality of the first surface area. For example, the film can be designed such that its geometry restricts the expansion and thus the damping properties of the first surface area. In addition, the film can influence the surface properties of the first surface area, such as its water repellency or static friction. Furthermore, the film can serve as a decorative element, as an outsole, as a sole plate, and / or as a connecting element.

[0043] In one aspect, a sole for a shoe, particularly a sports shoe, is provided with at least one section comprising expanded TPU. The sole also has a surface area free of expanded TPU. This aspect can also be combined with embodiments described herein.

[0044] In another embodiment, a problem according to the invention is solved by a sole for a shoe, in particular a sports shoe, with a first sub-area comprising a first expanded TPU and a second sub-area comprising a second expanded TPU, wherein the first expanded TPU and the second expanded TPU are manufactured using a different vapor deposition process and / or from a different starting material.

[0045] Such a sole exhibits the advantageous properties of expanded TPU, which are also locally adapted to the specific requirements of a first and a second sub-area. The beneficial properties of expanded TPU, such as high cushioning and temperature independence, can therefore be utilized, while simultaneously enabling a flexible sole design with varying properties in at least one first and second sub-area.

[0046] Using different vapor deposition processes for the first and second expanded TPU makes it possible to produce two parts with different properties from a single starting material. By making gradual changes in the vapor deposition process (e.g., pressure, density, or temperature), the properties of each expanded TPU can be precisely controlled. This allows for the achievement of different properties without the need to keep separate materials on hand.

[0047] Using different starting materials for the first and second sections also allows for different properties of the respective expanded TPU. This means that the first and second sections can be designed differently without having to change any parameters of the vapor deposition process.

[0048] Preferably, the first expanded TPU has a first particle size, while the second expanded TPU has a second particle size that differs from the first. The different particle sizes lead, for example, to different damping properties of the first and second TPUs. The different particle sizes can be achieved by using different particle sizes of the starting material and / or by using different vapor deposition processes.

[0049] In a further embodiment, at least one of the first and second sub-areas is at least partially surrounded by a film, in particular a plastic film. The film is preferably bonded to the first and / or second sub-area in a vapor process. The use of the film allows for further differentiation of the properties of the first and second sub-areas. Furthermore, a film also enables further differentiation of the external appearance of the first and second sub-areas.

[0050] In one embodiment, the sections are joined together by a steam process for the first expanded TPU and / or the second expanded TPU. Even when using two sections with a first and a second TPU, the sole elements can be joined together in a labor-saving, quick, and cost-effective manner. Furthermore, the precision of the joint between two expanded TPU sections is particularly high, as the sections expand in almost identical ways, thus ensuring excellent alignment between them.

[0051] In another embodiment, the first section comprises a first sole layer and the second section a second sole layer. This allows for a sole to be provided with different functionalities in different sole layers. For example, it may be particularly advantageous to design a sole layer located close to the wearer's foot to be especially cushioning, while an outer sole layer can be designed to be firmer and / or more abrasion-resistant.

[0052] In a preferred embodiment, the sole comprises a third sole layer that is free of expanded TPU. This allows the sole to be combined with the specific properties of other materials. Preferably, the third sole layer is bonded to at least one of the first and second sole layers using a vapor deposition process. The third sole layer can, for example, be an outsole exhibiting high slip resistance and / or high abrasion resistance. The outsole can be made of non-expanded TPU, particularly transparent TPU. This opens up a wide range of design possibilities, as the transparent outsole can be printed, backed with films, or colored. Thus, a variety of designs and / or decorations can be applied to the outsole.

[0053] In another embodiment, the third sole layer is arranged between the first and second sole layers. For example, this allows for high cushioning in the first sole layer, which is positioned towards the upper of the shoe, for comfortable wear. Simultaneously, high elasticity can be provided in the second sole layer, which faces the base of the sole. Both sole layers can be stabilized by the third sole layer.

[0054] In one embodiment, the first sub-area has a first surface area and the second sub-area has a second surface area. Thus, the various potentially advantageous properties of expanded TPU can be advantageously combined in a first and a second surface area.

[0055] In a preferred embodiment, the first surface area is located essentially on the medial side of the sole. This can, for example, increase the elasticity in this area. This promotes rapid lateral foot movements, as this area of ​​the sole is often subjected to particularly high stress during such movements. Therefore, the return of energy expended during impact absorption, achieved through high elasticity, is especially desirable in this area.

[0056] In a further preferred embodiment, the first surface area is arranged essentially on the medial side of the sole and the second surface area essentially on the lateral side of the sole. This allows for particularly good support and / or compensation of lateral movements of the foot.

[0057] In another embodiment, a problem according to the invention is solved by an insole for arrangement in the upper of a shoe, in particular a sports shoe, wherein the insole comprises expanded thermoplastic polyurethane (TPU).

[0058] By incorporating expanded TPU into the design of an insole, insoles can be equipped with the unique properties of this material. Expanded TPU is particularly well-suited for insoles, as these require excellent cushioning and elasticity. Since the properties of expanded TPU are variable, as previously explained, insoles with different firmness levels can be provided and easily interchangeable. For example, a soft insole can be used for training and a firmer one for competition. The desired properties can be achieved simply by inserting a suitable expanded TPU insole. The insole's properties can be varied without altering its thickness.The largely temperature-independent properties of expanded TPU make it a particularly advantageous material for insoles. The insole's properties remain constant even as it warms up to the foot's body temperature over time.

[0059] For example, using expanded TPU for an insole can provide sufficient cushioning functionality to eliminate the need for an additional midsole. This simplifies shoe manufacturing. Furthermore, it allows the user to replace the insole with the functionality that would normally be provided by a non-removable midsole.

[0060] Furthermore, expanded TPU allows for the creation of a particularly elastic insole, which releases the energy used to compress the insole with minimal loss when it rebounds. Expanded TPU also enables the creation of a particularly lightweight insole.

[0061] In one embodiment, the insole is at least partially surrounded by a film, in particular a plastic film. As already explained, this allows the functionality of the expanded TPU, as well as its external appearance and texture, to be modified. In the context of insoles, the alteration of the insole's feel is particularly advantageous. The film's influence on the insole's interaction with, for example, water or dirt is also significant.

[0062] In a further embodiment, a problem according to the invention is solved by a shoe, in particular a sports shoe, which has a sole according to one of the aforementioned embodiments.

[0063] Preferably, the shoe has an upper to which the sole is bonded using a steam process without adhesives. This avoids the need to glue or sew the sole to the upper.

[0064] In a further embodiment, a problem according to the invention is solved by a method for manufacturing a shoe sole, in particular a shoe sole for a sports shoe. A mold is loaded with expanded thermoplastic polyurethane (TPU) for a first surface area. The mold is also loaded with a material free of expanded TPU for a second surface area. Furthermore, steam is supplied to the expanded TPU. This allows the expanded TPU to be melted and bonded to form a foam structure. This method enables the efficient production of an advantageous sole. In particular, the method allows for a high degree of automation while simultaneously providing design freedom. Any first surface area with expanded TPU and a surface area free of expanded TPU can be bonded together to form a sole in a single manufacturing process.No work steps such as cutting or gluing are necessary.

[0065] In another embodiment, a method for manufacturing a shoe sole, in particular a shoe sole for a sports shoe, is provided, comprising loading a mold with a first expanded TPU for a first partial area and loading the mold with a second expanded TPU for a second partial area. The first and second expanded TPUs have different densities and / or different starting materials. Furthermore, steam is supplied to the first and second expanded TPUs.

[0066] Thus, soles that allow the use of the advantageous material properties of expanded TPU and also permit a variation of the properties of the expanded TPU within the sole can be provided in an efficient production process.

[0067] In one embodiment, the expanded TPU and / or the first and second expanded TPUs comprise particles. These can be easily placed in a mold. They can be compacted in the mold and formed into a cohesive foam structure. The particle shape allows for the simple production of expanded TPUs with different properties.

[0068] In one embodiment, the method further comprises melting the surface of the particles. Preferably, the particles are heated by the introduction of steam, whereby the surface of the particles melts, allowing the particles to form a chemical bond with one another. This leads to a foam structure of the expanded TPU.

[0069] In one embodiment, the expanded TPU, or the first and / or second expanded TPU, is compacted after filling the mold. Compaction is preferably achieved by reducing the mold volume, for example, by closing the mold to a predetermined size. The density can be varied, allowing for different weights and strengths of the expanded TPU. For example, with the same geometry of the expanded TPU, the density can be varied by opening the mold to different degrees before filling. The more the expanded TPU is compacted, the stronger it will be in its finished state. Furthermore, the compaction can be varied locally. Thus, a desired locally variable strength of the expanded TPU can be achieved through compaction.This results in a great deal of design freedom and variability, with which different expanded TPUs can be provided, even with the use of a single starting material.

[0070] In another embodiment, the loading with the expanded TPU, or the first and / or second expanded TPU, is carried out under pressure. The expanded TPU is thus compressed and loaded into the mold. This allows for a faster production process.

[0071] In a further embodiment, a method for manufacturing a shoe sole also includes relieving the pressure on the expanded TPU or on the first and second expanded TPU. After filling the mold with compressed, expanded TPU, the pressure within the mold is relieved. Preferably, the compressed, expanded TPU particles expand back to essentially their original size. This allows a continuous foam structure to be produced.

[0072] In a further embodiment, a method for manufacturing a shoe sole also includes curing the expanded TPU or the first and second expanded TPU. A curing step can stabilize the structure of the expanded TPU. 4. Brief description of the characters

[0073] In the following detailed description, currently preferred embodiments of the invention are described with reference to the following figures: Fig. 1a-c: A comparison of the properties of expanded TPU and EVA with regard to long-term stability, elasticity and temperature dependence; Fig. 2a-c: Embodiments of a shoe with a sole having a first surface area and a second surface area, wherein the first surface area has expanded TPU, and wherein the second surface area is free of expanded TPU; Fig. 3a-b: Another embodiment of a shoe with a sole having a first surface area and a second surface area, wherein the first surface area has expanded TPU, and wherein the second surface area is free of expanded TPU; Fig. 4a-b: Another embodiment of a shoe with a sole having a first surface area and a second surface area, wherein the first surface area has expanded TPU, and wherein the second surface area is free of expanded TPU; Fig. 5a-b: An embodiment of a sole for a shoe, in particular a sports shoe, comprising a first surface area and a second surface area, wherein the first surface area comprises expanded TPU, and wherein the second surface area is free of expanded TPU; Fig. 6. Example of an expanded TPU with a functional element, wherein the expanded TPU surrounds at least two opposing surface areas of the element; Fig. 7a-b: Another embodiment of a shoe with a sole having a first surface area and a second surface area, wherein the first surface area has expanded TPU, and wherein the second surface area is free of expanded TPU; Fig. 8a-b: An embodiment of a shoe with a sole comprising a first sub-area which has a first expanded TPU and a second sub-area which has a second expanded TPU; Fig. 9a-b: Another embodiment of a shoe with a sole having a first sub-area comprising a first expanded TPU and a second sub-area comprising a second expanded TPU; Fig. 10a-b: Another embodiment of a shoe with a sole having a first sub-area comprising a first expanded TPU and a second sub-area comprising a second expanded TPU; Fig. 11a-b: An embodiment of a film which can at least partially surround at least a surface area and / or at least a partial area with expanded TPU; and an embodiment of a sole which comprises a film; Fig. 12a-c: An embodiment of an insole for arrangement in the upper of a shoe, wherein the insole comprises expanded TPU; Fig. 13a-d: Another embodiment of an insole for arrangement in the upper of a shoe, wherein the insole comprises expanded TPU. The insole is made entirely of expanded TPU; Fig. 14a-c: Embodiments of a method for manufacturing a sole for a shoe; Fig. 15a-e: Exemplary forms for use in different embodiments of a method for manufacturing a shoe sole; 5. Detailed description of preferred embodiments

[0074] The following detailed description currently outlines preferred embodiments of the invention with regard to sports shoes. However, it is emphasized that the present invention is not limited to these embodiments. For example, the present invention can also be applied to work shoes, leisure shoes, or other types of footwear.

[0075] The Fig. Figures 1a-c show a comparison of the properties of expanded TPU (eTPU) and foamed EVA.

[0076] Fig. Figure 1a illustrates the long-term stability of the two materials. It shows that expanded TPU compresses 60% less than foamed EVA under the same long-term stress of approximately 100,000 compression cycles. Expanded TPU therefore retains its shape for longer. Even under prolonged stress, it compresses only slightly and maintains its shape to a high degree. This makes it very suitable for soles subjected to such high long-term stress. The durability of expanded TPU also helps to reduce waste from worn-out shoes and shoe soles in the long run, thus enabling the production of more environmentally friendly footwear.

[0077] Fig. Figure 1b shows the energy loss of EVA and expanded TPU at different temperatures. The percentage energy loss indicates what proportion of the energy used to compress the material is lost during subsequent expansion, for example, as heat. This proportion of energy is not returned to a sprinter, for instance, when the sole of a shoe rebounds after impact with the ground, causing compression. Therefore, minimizing energy loss is generally desirable. Fig. Figure 1b shows that the energy loss in expanded TPU is significantly lower than that in foamed EVA across all common temperature ranges. At 25°C, the energy loss in expanded TPU is reduced by at least 25% compared to foamed EVA. At 0°C, it is reduced by at least 40%, and at -20°C, it is reduced by at least 28%.

[0078] Fig. Figure 1c shows the force required for a specific compression of expanded TPU and foamed EVA in a temperature-dependent comparison. It is evident that curve 110 for expanded TPU remains essentially constant over a temperature range of -20°C to +30°C. Therefore, the compressibility of expanded TPU is essentially independent of temperature.

[0079] Furthermore, it shows Fig. 1c, that expanded TPU remains softer than EVA in all temperature ranges (see curve 120 for EVA), meaning it can, for example, provide stronger damping. In particular, unlike EVA, expanded TPU avoids the disadvantage of becoming hard at low temperatures.

[0080] The largely temperature-independent mechanical properties of expanded TPU lead to a new range of applications as a sole material. In addition to the well-known areas of indoor and summer sports, new applications are emerging, for example in winter sports or new shoe concepts such as running shoes for winter. Expanded TPU can be used regardless of the winter or summer season or regional conditions. This allows for the development of significantly more versatile footwear.

[0081] Fig. Figure 2a shows a basic embodiment for a shoe 200, which comprises an upper 220 and a sole 210. The sole has a first surface area 211, wherein the first surface area 211 comprises expanded TPU.

[0082] The first surface area 211 is located in the heel area, specifically in the area beneath the calcaneus. The sole 210 also features a third surface area 2111, which is located in the forefoot area. In the heel and forefoot areas, the first surface area 211 and the third surface area 2111, respectively, provide enhanced cushioning. In these areas, particularly beneath the calcaneus, the initial contact with the ground is to be expected during normal running and walking movements. Therefore, enhanced cushioning is desirable in these areas to absorb the impact of the foot on the ground. Furthermore, the final contact of the sole with the ground often occurs in these areas, especially in the forefoot, before the foot lifts off the ground.Particularly elastic cushioning through the expanded TPU is therefore especially desirable in these areas, in order to return the energy released when the foot hits the ground to the foot when it lifts off. This way, the foot, and thus, for example, a runner while jogging, loses only minimal energy upon impact.

[0083] In other embodiments, a different arrangement of these surface areas 211, 2111 may be advantageous. In particular, in other embodiments, the sole 210 may also comprise only a first surface area 211 or more than two surface areas 211, 2111.

[0084] The sole 210 also features a second surface area 212, which is free of expanded TPU. This second surface area 212 is arranged around the outer edge of the sole and between the forefoot and calcaneus. The outer edge of the sole is subjected to higher loads, especially during rapid lateral movements. Depending on the wearer, very high loads can also occur on the medial or lateral side of the sole, for example, due to supination or overpronation. The second surface area 212 at the outer edge of the sole provides greater strength in this area. Furthermore, the overall stability of the sole can be increased by arranging this second surface area 212 between the forefoot and calcaneus. In other embodiments, a different arrangement of the second surface area 212 may be advantageous.

[0085] The second surface area 212 comprises EVA. In other embodiments, however, the second surface area 212 may also comprise other materials.

[0086] The second surface area 212 encloses the first surface area 211 and the third surface area 2111. This provides additional stability to surface areas 211 and 2111. Furthermore, the enclosing limits the extent of the first and third surface areas, thereby restricting their damping.

[0087] In one embodiment, the first surface area 211 and the third surface area 2111 can comprise a first and a second expanded TPU, respectively. This allows, for example, different functionalities to be provided in the forefoot and heel areas. For instance, the first surface area 211 can comprise an expanded TPU with higher strength, thus providing greater strength in the heel area.

[0088] Fig. Figure 2b shows a view of an embodiment of a shoe 201, which is only slightly modified compared to embodiment 200. In particular, the sole 210 here includes an additional outsole 213. In one embodiment, the outsole provides the sole 210 with improved slip resistance and / or abrasion resistance. In another embodiment, the outsole 213 comprises rubber or TPU. The outsole is preferably not arranged to cover the entire surface. This allows the abrasion resistance and / or slip resistance of the sole to be optimized while simultaneously minimizing the weight of the sole. In some embodiments, the outsole gives the sole a special profile. In other embodiments, no outsole or a differently designed outsole is included, which covers the first surface area 211 completely or partially.

[0089] In further embodiments, other and / or additional layers or even partial layers may be included. Furthermore, the sole 210 comprises, as shown in Fig. As shown in Figure 2c, a cavity 214 is provided for an electronic unit that can offer the user of the shoe 201 functionalities such as speed measurement or distance measurement. In another embodiment, the sole 210 comprises other and / or additional functional elements. In one embodiment, all components of the sole 210 are bonded together by the vapor deposition process for the expanded TPU. No additional adhesives are then required to assemble the components of the sole 210. Furthermore, the components can be assembled automatically and with exceptional precision. This enables fast, high-quality, and cost-effective production.

[0090] Fig. Figure 2c shows the area of ​​the first surface region 211, which is located under the calcaneus, from above. Due to the strong cushioning of the first surface region 211, it can be in direct contact with the foot. This can be achieved, for example, by means of an opening in a Strobel insole positioned above the first surface region. Fig. In 2c, the opening is circular. In other embodiments, however, it can also be ring-shaped or star-shaped, for example. It is also conceivable that slits are incorporated into the Strobel sole, which, like an opening, also minimize the tensile forces of the Strobel sole in the heel area. This allows for a comfortable feel on the foot. Furthermore, the largely temperature-independent nature of the cushioning of the first surface area 211 allows it to be in direct contact with the foot. There is no significant change in the cushioning due to the first surface area 211 warming to the body temperature of the foot. In one embodiment, a midsole or insole can therefore be dispensed with entirely.

[0091] Fig. Figure 3a shows a further embodiment of a shoe 300. This shoe comprises an upper 320 and a sole 310. The sole 310 has a first surface area 311, which is made of expanded TPU. In the toe area, the shoe 300 also has a second surface area 312, which is free of expanded TPU. This provides greater firmness in the toe area. This is particularly desirable because a sole that is too soft, especially in the toe area, and the resulting slippage of the shoe can be uncomfortable and may lead to blisters, for example. In the remaining area of ​​the sole, the first surface area 311 provides particularly high cushioning. The thickness of the first surface area 311 increases from the toe area to the heel area. This provides increased firmness in the heel area.This gives the sole increased stability. Furthermore, the cushioning properties of the first surface area 311 are adapted to the higher forces occurring in the heel area. These higher forces result in greater stress there compared to the forefoot. The increased thickness of the first surface area in the heel area ensures that the cushioning is evenly distributed across the entire surface of the first surface area 311.

[0092] Furthermore, the sole 310 optionally includes an outsole 313. In one embodiment, the outsole comprises rubber or non-expanded TPU. The outsole 313 provides the sole 310 with additional slip resistance and abrasion resistance. Preferably, the outsole 313 is bonded to the first surface area 311 in a vapor deposition process for the expanded TPU. In some embodiments, no outsole is included.

[0093] Compared to the sole 210 of the Fig. 2b is in Fig. 3a shows that it is not necessary to attach the second surface area 312 around the outer edge of the sole.

[0094] In the embodiment of the sole 310, the first surface area 311 comprises a large part of the outer edge of the sole. In this embodiment, the expanded TPU exhibits a strength that withstands the loads at the outer edge.

[0095] Fig. Figure 3b shows a top view of the first surface area 311. The midsole 314 is also visible. The first surface area 311 is designed to fit precisely into the midsole 314. In other embodiments, the midsole 314, which may contain EVA, for example, can have a different shape, and the first surface area 311 can be designed accordingly. Preferably, the first surface area 311 and the midsole 314 are bonded together by the vapor deposition process for the expanded TPU. The midsole 314 is particularly located in the second surface area 312, to which it provides increased stability. The midsole 314 is also located along the outer edge of the sole, thus increasing stability there as well. In one embodiment, the midsole is an intermediate element, preferably a frame.In one embodiment, it can comprise unexpanded TPU or consist essentially of unexpanded TPU, which optimizes the connection to the expanded TPU and also improves the connection to the shaft. In another embodiment, a shaft is sewn directly to the TPU intermediate element, thus eliminating the need for adhesives.

[0096] Fig. Figure 4a shows an embodiment of a sole 410 for a shoe 400. This sole comprises a first surface area 411, wherein the first surface area 411 has expanded TPU, and a second surface area 412, which is free of expanded TPU. The sole 410 also optionally includes an outsole 413. Furthermore, the sole 410 optionally includes a recess for an electronic unit. The sole 410 also optionally includes a third surface area 4111 and a fourth surface area 4112, which comprise expanded TPU.

[0097] The first surface area 411 is located in the forefoot area. The third surface area 4111 is located medially and laterally between the forefoot and heel areas. Additionally, the fourth surface area 4112 is located in the heel area.

[0098] This provides particularly high flexibility of the sole 410 in the forefoot, midfoot, and heel areas, thus ensuring a high level of wearing comfort. The second surface area 412 is located in the remaining area of ​​the sole 410. Specifically, its placement along the outer edge of the sole 410 in the forefoot and heel areas increases the stability of the sole to a functionally necessary level. The second surface area 412 comprises EVA, but may also include other and / or additional materials.

[0099] Preferably, the outsole 413 does not completely cover the first surface area 411. In some embodiments, the outsole 413 gives the sole a special profile. In some embodiments, the first surface area 411 is provided with a continuous outsole. In other embodiments, no outsole 413 or an outsole 413 of a different design is included. Particularly for indoor shoes, the expanded TPU already provides sufficient slip resistance, so this aspect does not require an additional outsole 413.

[0100] To increase the abrasion resistance and / or slip resistance of the surface of the first area, it can be modified with a suitable surface treatment instead of being provided with an outsole. The surface of an area and / or a sub-area made of expanded TPU can be melted and / or embossed and / or treated with a laser. Furthermore, the surface can be manufactured in a suitably shaped form that provides higher abrasion resistance and / or slip resistance. Other materials, such as particles of other materials, which increase abrasion resistance, can also be incorporated into the area near the surface of the expanded TPU during the manufacturing process.

[0101] Fig. Figure 4b shows the sole 410 on a shaft 420. This illustrates Fig. 4b, how the third surface area 4111 and the second surface area 412 are arranged along the outer edge of the sole. In the forefoot and heel areas, the second surface area 412 is arranged along the outer edge, where it increases the stability of the sole. In the area between, greater flexibility of the sole is desirable to support the natural rolling motion of the foot. Accordingly, the second surface area 412 is not arranged here. Instead, a surface area 4111, which has expanded TPU, is arranged there. Thus, greater flexibility can be provided in this area.

[0102] Additionally, the thickness of area 4111 increases from the forefoot to the heel. This allows the functionality of area 4111 to be gradually adapted to the different requirements in each area.

[0103] In one embodiment, surface areas 411, 4111, 4112 comprise only expanded TPU. In another embodiment, at least the first surface area 411 and the third surface area 4111 comprise a first and a second expanded TPU.

[0104] Fig. Figure 5a shows another embodiment of a sole 510. This comprises a first surface area 511, wherein the first surface area 511 has expanded TPU, and a second surface area 512, which is free of expanded TPU. The first surface area 511 is arranged along the outer edge of the sole, with the lateral outer edge between the heel and forefoot areas not being included by the first surface area 511. The first surface area 511 is optionally reinforced with an outsole 513, which increases the slip resistance and / or abrasion resistance of the sole 510. Preferably, the outsole 513 covers only a portion of the first surface area 511. In some embodiments, the outsole 513 comprises rubber or TPU. Optionally, the sole also includes a sub-area 514. In some embodiments, this provides increased stability to the sole 510. In some embodiments, the sub-area 514 comprises EVA.However, subsection 514 is not included in all embodiments. Due to the increased strength of the expanded TPU, subsection 514 can be omitted in one embodiment. In particular, this allows for a more material-efficient sole design, resulting in a lighter sole. At the same time, the high elasticity of the TPU ensures that energy is optimally returned to the runner / walker when the sole rebounds.

[0105] Compared to many materials, e.g., EVA, a first surface area 511 can be manufactured more precisely using expanded TPU, since it expands only to a small extent during the steaming process. This allows for the production of finer structures, resulting in better-tuned functionality overall. Furthermore, this enables a minimalist design, thus saving a significant amount of material, as only small quantities of expanded TPU, reduced to the absolute minimum, are applied. As shown in embodiment 510 (without the optional sub-area 514), a large second surface area 512 of the sole can remain unobstructed. In particular, the first surface area 511 can therefore have cutouts, preferably large-area cutouts.

[0106] In one embodiment, the first surface area 511 can also serve to modify the functionality of the sub-area 514. Preferably, the first surface area 511 is not arranged over the entire area of ​​the sub-area 514. This means that the functionality of the sub-area 514 is only changed locally. For example, the cushioning is increased locally. Conversely, the sub-area 514 can increase the stability of the first surface area 511, which comprises expanded TPU. In one embodiment, the sole 510 has a sole plate. This can provide the sole with additional stability. The sole plate can connect the sole to the upper. The first surface area 511 and the optional sub-area 514 can be arranged below the sole plate.

[0107] Fig. Figure 5b shows a slightly modified embodiment of a sole 501, which, like the sole 510, is manufactured on a sole plate 516. The sole plate 516 ensures basic stability of the sole and serves to distribute the forces acting on the sole. It can also serve as a carrier for a variety of functional elements, which are preferably bonded together using the vapor deposition process for TPU. The thickness of the first surface area 511 increases from the toe to the heel area. In this way, the strength of the sole is gradually adapted to the expected loads in the respective areas.

[0108] Furthermore, it shows Fig. 5b, that the first surface area 511 can also be designed such that the area 515 between the forefoot and heel areas can be free of the first surface area 511. This allows the flexibility of the sole to be optimized in this area to support the natural rolling motion of the foot. Depending on the foot type of the shoe wearer, the first surface area 511 can also include the medial or lateral outer edge of the sole to adapt the flexibility of the sole to supination or overpronation.

[0109] Fig. Figure 6 shows an example of expanded TPU 611. The expanded TPU 611 can form a surface area or a partial area of ​​a sole. A functional element 614, e.g., a frame element, is integrated into the expanded TPU 611. A frame element can serve to stabilize and / or optimize the fit of a shoe. Preferably, the functional element 614 is bonded to the expanded TPU 611 in a vapor deposition process. A portion of the functional element 614 is completely surrounded by the expanded TPU 611, i.e., embedded within it. Other portions of the functional element 614 protrude from the expanded TPU 611.

[0110] In some embodiments, a section of the sole is provided, comprising expanded TPU, with a TPU-free functional element integrated into the expanded TPU. In a preferred embodiment, the functional element is integrated such that it is surrounded by the expanded TPU on at least two opposing surface areas. In other embodiments, the functional element is completely surrounded by the expanded TPU. In further embodiments, the functional element is arranged on a surface of the expanded TPU. Preferably, the functional element is bonded to the expanded TPU in a vapor deposition process.

[0111] The described embodiment of an expanded TPU with an integrated functional element can also include a second or more additional expanded TPUs. For example, the functional element can be surrounded by a first and a second expanded TPU. The first and second TPUs can adjoin a first and second surface area of ​​the element, respectively. Furthermore, it can incorporate additional functional elements. Overall, this results in a high degree of design freedom. Almost any functional element can be combined with the advantageous properties of expanded TPU. Moreover, a wide variety of design options are available. By combining the elements in a vapor deposition process for one or more TPUs, a high degree of automation can be achieved. In addition, a labor-saving, fast, and waste-reducing manufacturing process is possible.

[0112] The Fig. Figures 7a-b show a further embodiment of a shoe 700 with an upper 720 and a sole 710. The sole 710 comprises a first surface area 711, which has expanded TPU. The sole 710 also comprises a second surface area 712, which is free of expanded TPU. The sole includes a midsole 714. The sole optionally includes an outsole 713.

[0113] The first area, 711, is located in the forefoot. This provides particularly high cushioning in that area. The second area, 712, which is free of expanded TPU, is located in the heel area. This second area, 712, can consist of EVA and / or non-expanded TPU and / or other materials. This allows for greater sole rigidity in the heel area. The sole can thus be designed to meet the stresses encountered during specific uses. The 700 shoe, for example, is designed for trail running. Increased rigidity in the heel area is necessary to counteract ankle sprains. Conversely, high cushioning is desirable in the forefoot area. This is provided there by the first area, 711, which features expanded TPU.The high elasticity of the expanded TPU also ensures optimal energy transfer. When the toes lift off the ground and the first surface area of ​​the 711 rebounds, the energy used to compress the sole is returned to the runner with minimal loss.

[0114] The first surface area 711 is also raised at the outer edge of the sole. It has an increased thickness there. Alternatively or additionally, the expanded TPU of the first surface area has an increased thickness at the outer edge of the sole. This provides greater strength in the first surface area 711 at the outer edge of the sole. This further counteracts ankle sprains. Furthermore, the thickness of the first surface area 711 increases from the toe area to the heel area and / or the midfoot area. This adapts the strength of the sole to the typical loads encountered. The expanded TPU allows for a particularly gradual adaptation. In other embodiments, the first surface area 711 and / or the second surface area 712 can also be arranged differently.In some embodiments, for example, it may be helpful if the first surface area 711 is located in the heel area and the second surface area 712 in the forefoot area. Basketball shoes, for instance, could be a suitable application, where increased firmness in the forefoot area might be desirable.

[0115] In one embodiment, the second surface area 712 of the shoe 700 is formed primarily by a portion of the midsole 714. The midsole 714 is substantially arranged above the expanded TPU of the first surface area 711 and its shape is adapted to the expanded TPU. Preferably, the midsole 714 is bonded to the expanded TPU in a vapor deposition process. In other embodiments, the midsole 714 can also be arranged such that it is positioned below the expanded TPU of the first surface area 711. In another embodiment, the midsole 714 is arranged next to the expanded TPU of the first surface area 711, or only partially above or only partially below it.

[0116] The shoe 700 also optionally features an outsole 713. This only partially covers the first surface area 711. The outsole 713 is also located in the second surface area 712. This area of ​​the outsole can be connected to the outsole over the first surface area 711 or designed as a separate outsole.

[0117] The Fig. 8a and Fig. Figure 8b shows a shoe 800 with an upper 820 and a sole 810, comprising a first section 811, which has a first expanded TPU, and a second section 812, which has a second expanded TPU. The first expanded TPU and the second expanded TPU are manufactured using different vapor deposition processes. For this purpose, at least one parameter is changed in the manufacturing process of the second expanded TPU compared to the first expanded TPU, e.g., density, temperature, pressure, duration of expansion, vapor saturation, cooling rate, curing time, curing temperature, etc. In a preferred embodiment, the first and the second expanded TPU can be manufactured simultaneously in the same mold, with the at least one different parameter being applied locally. In another embodiment, the first and the second expanded TPU are manufactured sequentially in the same mold.In another embodiment, the first and second TPUs can also be made from different starting materials – simultaneously or simultaneously. Furthermore, the first and second TPUs can also be manufactured separately in different shapes.

[0118] In one embodiment, the first and second expanded TPUs exhibit different properties. These differences can be functional in nature. For example, the strength of the second expanded TPU can be greater than that of the first. This can be achieved, for instance, by applying higher pressure during the manufacturing process of the second expanded TPU. This results in the second expanded TPU having a higher density and greater strength. Thus, the properties of an expanded TPU can be gradually varied and combined using a first and a second sub-section. The different properties can also be optical in nature, such as providing different colors.

[0119] The first sub-area 811 of the sole 810 extends over a larger surface area of ​​the sole 810. However, the sole 810 also has a surface area 815 where the first sub-area 811 is not located. In one embodiment, the sole 810 has no material in surface area 815. In another embodiment, the surface area has a material that is free of expanded TPU. In yet another embodiment, the sole 810 does not have such a surface area 815.

[0120] The second section 812 is located in the heel area of ​​the sole. The first section 811 has a corresponding recess for this purpose. This allows the thickness of the sole 810, and thus its strength, to be increased in the heel area by the second section 812. This is particularly desirable for running shoes like the 800 model, as the heel area is typically subjected to very high stress during running. Preferably, the second expanded TPU of the second section 812 is designed to provide greater strength than the first expanded TPU of the first section 811. This allows for a particularly significant increase in strength in the heel area. Furthermore, the desired strength can be achieved with a smaller amount of material. The sole is therefore lighter and more cost-effective. The second section can be bonded to the first section using a vapor deposition process for the first and / or second expanded TPU.However, other fastening methods can also be used.

[0121] In one embodiment, a first expanded TPU is up to approximately 25% softer than a second expanded TPU. In another embodiment, a first expanded TPU is approximately 25% to 100% softer than a second expanded TPU. In other embodiments, the hardness of a first expanded TPU compared to a second expanded TPU varies in the range of ±150%.

[0122] In some embodiments of the sole 810, an additional functional element 814 is arranged between the first sub-section 811 and the second sub-section 812. In some embodiments, this element provides damping of shear forces. In another embodiment, the element 814 may also increase the strength of the sole and / or serve purely aesthetic purposes. The sole 810 may additionally include an optional outsole 813 made of rubber or TPU. In other embodiments, the sole 810 includes no outsole or a different outsole.

[0123] In another embodiment of the sole 810, the second sub-area 812 comprises EVA. This provides increased stability in the heel area of ​​the sole 810. Furthermore, the second sub-area 812 can be free of expanded TPU.

[0124] The Fig. Figures 9a-b show a further embodiment of a shoe 900 with an upper 920 and a sole 910, comprising a first sub-section 911, which has a first expanded TPU, and a second sub-section 912, which has a second expanded TPU. The first expanded TPU and the second expanded TPU are made of different starting materials. The starting materials for the first and the second TPU differ by at least one parameter, e.g., the degree of admixture of a blowing agent, the admixture of other materials, or the particle size of the material. The first sub-section 911 is arranged over the second sub-section 912. The first sub-section 911 has a first sole layer, and the second sub-section 912 has a second sole layer. The first and second sole layers 911 and 912 each extend substantially over the entire sole surface.In other embodiments, a surface area of ​​the sole 910 can be free of expanded TPU. In one embodiment, the strength of the second sub-area 912 is increased compared to the first sub-area 911. This allows for high cushioning and a comfortable feel in the contact area with the foot. The increased strength in the contact area with the ground also ensures good stability of the shoe 900. In one embodiment, sub-areas 911 and 912 differ in color.

[0125] In both sub-areas 911 and 912, the thickness of the sole 910 increases from the toe to the heel area. The thickness also increases towards the outer edge of the sole 910. This provides increased strength at the outer edges of the sole 910 and in the heel area. In other embodiments, the thickness of the first and / or second sub-area can be constant or varied in another way. The sole 910 has an optional outsole 913 in the form of a continuous sole layer. The outsole 913 can increase the slip resistance and / or abrasion resistance of the sole 910 and / or its water-repellent properties. In other embodiments, the outsole 913 is not applied across the entire surface in order to minimize the weight of the sole 910. The outsole 913 can be bonded to the second sub-area 912 in a steam process for the second expanded TPU. In further embodiments, no outsole 913 is provided.

[0126] In other embodiments, the first expanded TPU and the second expanded TPU are manufactured using different vapor deposition processes. In further embodiments, the sole 910 can also have additional sections containing the first and / or second and / or further expanded TPU.

[0127] In one embodiment, the outsole 913 can represent a third sub-section comprising expanded TPU. In particular, the outsole 913 can comprise a particularly abrasion-resistant expanded TPU. Thus, the outsole can be manufactured and / or assembled in the same process as sub-sections 911 and 912. The sub-sections can be individually configured and exhibit different properties, depending on the requirements of the shoe or its sole. They can vary in their base material, their properties (which are determined by the manufacturing process), and their geometry. In one embodiment, the outsole 913 consists essentially of expanded TPU.

[0128] In a further embodiment, the sole 910 alternatively or additionally comprises a third sub-section, which includes a third sole layer free of expanded TPU, in addition to the outsole 913. This provides the sole 910 with additional stability. Preferably, the third sole layer is arranged between the first and second sole layers of the first and second sub-sections 911, 912. This allows for good separation of the first and second expanded TPU, enabling, for example, improved manufacturing of the first and second expanded TPU in a steam process.

[0129] In a preferred embodiment, the sole 910 is connected to the shaft 920 via a steam process for the first sub-section 911. No additional fasteners are required. In other embodiments, the sole 910 can also be attached to the shaft 920 by means of other fasteners.

[0130] The Fig. Figures 10a-b show a further embodiment for a shoe 1000 with a shaft 1020 and a sole 1010 with a first sub-area 10111 which has a first expanded TPU, and a second sub-area 10112 which has a second expanded TPU, and an optional third sub-area 10113 which has a third expanded TPU.

[0131] The first, second, and third expanded TPUs are each manufactured with a different starting material. The expanded TPUs differ in their particle size. Generally, the smaller the particle size, the higher the strength of the TPU. In other embodiments, the different particle sizes can also be achieved by using different vapor deposition processes.

[0132] Preferably, the individual sections are joined together in a steam process for the first and / or second and / or third TPU. Particularly preferably, the first, second, and third TPU are manufactured simultaneously. This allows different sections of a sole with various advantageous material properties to be manufactured and assembled in a single production step. A locally adapted sole can thus be manufactured quickly, precisely, and cost-effectively.

[0133] The sub-sections 10111, 10112, and 10113 are components of the sole element 1011. Optionally, the sole 1010 also includes an outsole 1013, which encloses the sole element 1011 from below and laterally. In other embodiments, the outsole may have a different design. The outsole 1013 may be directly connected to the upper 1020. The outsole may be a housing made of TPU, EVA, rubber, and / or film.

[0134] The sub-sections 10111, 10112, and 10113 are arranged longitudinally along the sole, with the first sub-section 10111 being laterally positioned, the third sub-section 10113 medially, and the second sub-section 10112 positioned in between. The stiffness increases from the first sub-section 10111 through the second sub-section 10112 to the third sub-section 10113. Thus, for example, the stiffness of the sole 1010 can be adapted to overpronation. In other embodiments, the stiffness of the sole can also be adapted to supination. In this case, the stiffness of the sole 1010 increases from medially to laterally. However, a multitude of other embodiments of the first sub-section 10111, the second sub-section 10112, and the optional third sub-section 10113 are also conceivable. Alternatively or additionally, further sub-areas may be provided which have a first and / or a second and / or further expanded TPU.The thickness of the sub-areas can also vary. As a further variation, sub-areas can also be arranged transversely, diagonally, or in zones, as well as overlapping.

[0135] Fig. Figure 11a shows a plastic film 1100 with which a partial or full area of ​​expanded TPU can be at least partially encased. This allows the expanded TPU to be given a special texture, feel, and / or color. Furthermore, the service life of the area or partial area can be increased. The plastic film 1100, for example, prevents water or dust from affecting the expanded TPU, thus reducing its degradation. Additionally, the plastic film 1100 can also influence the functionality of the expanded TPU. For example, the film 1100 can have a higher tensile strength than the expanded TPU. This allows the film to limit the expansion of the expanded TPU when it rebounds from impacts. Furthermore, if the film 1100 completely encases the expanded TPU, it can also limit its compression. The plastic film 1100 can be manufactured from a variety of materials.The film preferably comprises TPU. Such a film allows for an optimal chemical bond between the film and the expanded TPU. In one embodiment, the film consists essentially of TPU. In other embodiments, the film can comprise PA, polycarbonate, and / or carbon fiber.

[0136] In one embodiment, the film 1100 is bonded to an expanded TPU, e.g., a surface area or partial area, in a steam process. In another embodiment, the film is bonded to the expanded TPU after a steam process, e.g., by wrapping it around the TPU. In further embodiments, any other functional element of the sole can also be formed from such a film and integrated into the manufacturing process of the sole.

[0137] In one embodiment, the film 1100 serves for shaping. Expanded TPU can be applied inside, outside, or around the film. The film can serve as a carrier material for elements such as a torsion support or other elements that are to be in contact with or completely surrounded by expanded TPU. In one embodiment, the film is pre-formed in a thermoforming process. The film can be thermoformed, pressed, or injected.

[0138] Fig. Figure 11b shows an embodiment of a sole 1110. This sole has a first section which comprises expanded TPU. A surface area of ​​the sole in the toe area is free of expanded TPU. The sole 1110 also has an outsole 1113, which preferably comprises rubber or non-expanded TPU. Optionally, the sole 1110 also has a film by means of which the outsole 1113 is connected to the first surface area 1111. The film serves as a carrier material and / or composite material and / or stabilizing element. Furthermore, the sole 1110 optionally has a frame element 1114.

[0139] The Fig. Figures 12a-c show an embodiment of an insole 1200 for a shoe, wherein the insole comprises expanded TPU. The insole has a first sub-area 1201 with a first expanded TPU and an optional second sub-area 1202 with a second expanded TPU. The first sub-area 1201 is located in the ball of the foot area. The second sub-area 1202 is located in the area under the calcaneus. This provides a particularly cushioning insole in these areas, resulting in exceptional wearing comfort. The first and second expanded TPU in sub-areas 1201 and 1202 can be bonded or otherwise connected to the rest of the insole. In another embodiment, the first and / or second sub-area is bonded to the rest of the insole using a steam process.In other embodiments, the first sub-area 1201 and / or the second sub-area 1202 may be configured differently than in the . Fig. The arrangement is shown in Figures 12a-c. The first and second expanded TPU layers can be made from different base materials and / or using different vapor deposition processes. This results in a wealth of design possibilities for an improved insole. Since an insole can be easily replaced with, for example, a different type of insole, the cushioning properties of a sole can be significantly altered simply by changing the insole. Thus, one and the same shoe can be adapted for different sports by using differently designed insoles. For example, a running shoe that is actually designed for sprinting and therefore has a rather firm sole can also be used for long-distance running with an insole that incorporates expanded TPU. Expanded TPU is particularly well-suited for providing insoles with high cushioning due to its long-term durability.

[0140] The insole 1200 can be coated on its upper surface using known methods to provide a comfortable surface for contact with the foot. In one embodiment, the insole 1200 can be at least partially enclosed by a film, in particular a plastic film. This film can improve the functionality of the insole. In particular, it can reduce the effects of dirt and water on the insole and thus further increase the service life of the insole 1200. Furthermore, the film, similar to what has already been described, can modify other functional properties of the expanded TPU of the insole 1200, such as cushioning, and / or give the insole 1200 a desired texture, feel, and / or color.

[0141] The Fig. Figures 13a-c show a further embodiment 1300 of an insole 1300 for a shoe, wherein the insole comprises expanded TPU. The insole 1300 is preferably manufactured using a steam process for the expanded TPU. The expanded TPU of the insole 1300 can be designed differently depending on requirements. Thus, different functionalities can be achieved by changing the insole. For example, the cushioning of the sole can be varied by using different insoles. Advantageous in this context are, on the one hand, the high cushioning and long-term durability that can be achieved with expanded TPU. On the other hand, with the help of expanded TPU, an insole can be equipped with different properties while maintaining the same dimensions, especially the same thickness. Thus, for example, the cushioning of the sole can be changed without the foot having to adapt to a changed geometry of the shoe.

[0142] Furthermore, the weight or cushioning of the insole can be adjusted to the wearer's weight as needed. In one embodiment, the insole 1300 comprises a first and second sub-area with a first and second expanded TPU. It can also comprise more than two sub-areas with two or more expanded TPUs.

[0143] By using an insole made of expanded TPU, the shoe's sole can be made thinner, and therefore more cost-effective and lighter, since the insole already provides significant cushioning, thus reducing the demands placed on the shoe's sole. The thin sole and the resulting close contact with the ground create a particularly natural wearing experience.

[0144] In one embodiment, a shoe is provided with an insole made of expanded TPU. Due to the high level of cushioning provided by the insole, an additional midsole is unnecessary. This allows the wearer to change the functionality normally provided by a non-removable midsole simply by replacing the insole.

[0145] Furthermore, in one embodiment of a shoe, the outsole can be designed to be so minimalist that it comprises only a layer attached directly to the bottom of the shoe upper. This layer preferably consists of rubber or TPU and only partially covers the underside of the upper. This allows for a particularly flat shoe with a natural walking and running feel due to its proximity to the ground. Preferably, the layer is fused to the upper.

[0146] The 1300 insole can be precisely shaped using the steam process for expanded TPU. This allows the 1300 insole to have varying thicknesses. Furthermore, the shape of the 1300 insole can be anatomically optimized.

[0147] Particularly in the context of insoles, low temperature dependence of the material properties is desirable. An insole typically warms up to the body temperature of the foot during use. At the beginning of use, however, it is colder – at normal ambient temperatures. Thus, the temperature of the insole usually changes significantly with wear. Due to the low temperature dependence of the properties of expanded TPU, an insole can be provided that changes its properties only minimally over time. A shoe with an insole containing expanded TPU is therefore immediately available with the desired properties.

[0148] Fig. Figure 13d shows another embodiment of an insole 1201 for a shoe, wherein the insole 1301 comprises expanded TPU. The insole 1301 is manufactured from a block comprising expanded TPU. For example, the insole 1301 can be cut or die-cut. The insole 1301 represents a particularly simple and cost-effective way to provide an insole with high cushioning, long-term durability, and low temperature dependence. In one embodiment, the insole 1201 comprises a plastic film and / or another covering, such as sweat-absorbing textile.

[0149] In a further embodiment, one of the described insoles, or one of the described partial areas of a sole / insole, or one of the described surface areas of a sole / insole can comprise expanded TPU made from expanded TPU particles with different properties. For example, a first type of TPU particles with a first particle size and a second type of TPU particles with a second particle size can be used to manufacture expanded TPU. Alternatively or additionally, the first type of TPU particles can differ from the second type of TPU particles in one or more other properties, e.g., color.

[0150] Fig. Figure 14a discloses a method 1400 for manufacturing a shoe sole, in particular a shoe sole for a sports shoe. It comprises loading 1410 a mold with expanded TPU. It can also optionally include decompressing 1420 the TPU. The method further comprises supplying steam 1430 to the expanded TPU. The supply of steam heats the expanded TPU. The surface of the expanded TPU melts, causing the expanded TPU to bond into a closed fabric-foam structure.

[0151] Loading 1410 with expanded TPU preferably comprises loading with expanded TPU in the form of expanded particles. These can be in bulk form. The particle size is such that they have diameters of approximately 0.5 mm to 25 mm. Preferably, the particle diameters are 2 mm to 10 mm. Particularly preferably, the diameters are 3 mm to 8 mm.

[0152] In one embodiment, the loading process 1410 comprises steps 1411 and 1412. In step 1411, the particles are loaded into the mold at atmospheric pressure. Subsequently, in step 1412, they are pressurized within the mold. A variety of different methods can be used for this purpose. For example, this can be achieved by reducing the mold volume. In one embodiment, a movable part of the mold is moved to reduce the mold volume. In another embodiment, the mold is designed such that the pressure within the mold is varied locally.

[0153] In another embodiment, loading 1410 includes step 1413. The particles are already filled into the mold under pressure – optionally with locally variable pressure. This can accelerate the production process.

[0154] The pressure applied to the particles in process 1400 has a significant influence on the density and strength of the expanded TPU. The diameter of the particles decreases under pressure. The higher the pressure, the more the particles are compressed and densified. Upon release of the pressure (1420), the expanded TPU particles essentially return to their original diameter.

[0155] By introducing steam 1430 to the expanded TPU, it is heated. The surface of the particles is partially melted or completely molten. This allows the particles to form chemical bonds with each other. They combine to form a granular, but closed, plastic foam structure.

[0156] In one embodiment, the method further comprises loading the mold with a material free of expanded TPU for a second surface area, while the expanded TPU is provided for a first surface area. Thus, the expanded TPU can be bonded to a variety of other materials in a vapor deposition process without additional adhesives. Preferably, the material free of expanded TPU is loaded into the mold first, followed by the expanded TPU. In other embodiments, however, this sequence can be changed. Furthermore, multiple loading steps with expanded TPU or different expanded TPUs and / or multiple loading steps with material free of expanded TPU can be performed. The sequence can be optimized in various ways in different embodiments.

[0157] In another embodiment, the method comprises loading the mold with a second expanded TPU for a second sub-section, wherein the aforementioned first TPU is provided for a first sub-section. Furthermore, the supply of steam includes supplying steam to the second expanded TPU as well. The first and second expanded TPU are compressed differently or have different pressures and / or different starting materials. In this way, several sub-sections with different properties can be precisely manufactured in a single production process. Preferably, the sub-sections are joined together by supplying steam. Steam can be supplied to both sub-sections simultaneously. In another embodiment, steam can also be supplied first to the first sub-section and then to the second sub-section.The sequential introduction of steam, and thus the fusion of individual sections, can be carried out in a suitable manner. For example, after the melting of an initial section, the mold is opened in a designated area only to the extent necessary to allow the loading and further melting of additional expanded TPU particles, which can then form another section.

[0158] In one embodiment, pre-expanded sections of expanded TPU can also be loaded into a mold. These sections can then be joined together by introducing steam.

[0159] The described processes can be highly automated, enabling cost-effective and efficient production. Furthermore, the problematic use of adhesives, which can endanger the environment and workers in shoe production, can be avoided. Only steam is added during the production process. In one embodiment, the steam is essentially free of additives.

[0160] Fig. Figure 14b shows a further embodiment of a method 1450 for manufacturing a shoe sole, which involves loading a mold with expanded TPU under increased pressure. In step 1451, the mold is closed and pretreated with steam. This allows, for example, the mold to be cleaned. In step 1452, the mold is loaded with expanded TPU particles, the loading taking place under pressure. In step 1453, the pressure in the mold is released. In step 1454, steam is supplied to the expanded TPU, causing the surfaces of the particles to melt and the particles to form a chemical bond. Furthermore, in step 1455, the method includes cooling the mold with water and / or air, which is passed through the mold. This indirectly cools the expanded TPU via the mold. This stops the bonding process, and the expanded TPU assumes the closed plastic foam structure.Finally, in step 1456, the mold is reopened and the sole, which comprises expanded TPU, is removed from the mold.

[0161] Fig. Figure 14c shows a further embodiment of a method 1460 for manufacturing a shoe sole, which includes loading a mold with expanded TPU under atmospheric pressure.

[0162] In step 1461, the mold, which has a moving part, is opened to a predetermined extent. In step 1462, the mold is loaded with expanded TPU particles at atmospheric pressure.

[0163] In step 1463, the mold volume is reduced to the predetermined size of the element to be produced, which comprises expanded TPU, thus compressing the expanded TPU. The width of the mold opening, and therefore the amount of particles available for compression, is crucial for the mechanical properties of the element. This determines the weight, strength, and elasticity of the expanded TPU. The opening width is also adjusted according to the size of the molded part. In one embodiment, the mold is opened to a height of 14 mm for loading. This results in a medium weight and medium strength of the expanded TPU. If the goal is to reduce the weight of the expanded TPU—while maintaining the same geometry—and / or to make it softer, the mold is opened in a range of, for example, 10 mm to 14 mm in another embodiment.For a heavier weight and a harder element, the mold can be opened up to 20 mm in one embodiment. In other embodiments, the height of the mold opening depends on the shoe size for which the expanded TPU is intended. Larger shoe sizes tend to experience higher forces, so the expanded TPU can be made correspondingly stronger. Accordingly, a mold for larger shoe sizes is preferably opened wider.

[0164] In step 1464, steam is introduced into the expanded TPU. The expanded TPU is melted. Preferably, steam is introduced into the expanded TPU while the mold is being closed. In other embodiments, steps 1463 and 1464 can also be performed sequentially. In step 1465, the mold is cooled using water and / or air, thereby indirectly cooling the expanded TPU. Finally, in step 1466, the mold is opened and the base is removed from the mold.

[0165] In other embodiments, the steps of the aforementioned methods for manufacturing a shoe sole can be combined. However, individual process steps can also be omitted or carried out in a different order.

[0166] The Fig. Figures 15a-e show exemplary embodiments of shapes which can preferably be used for one of the aforementioned methods for manufacturing a sole for a shoe, in particular a sports shoe.

[0167] Fig. Figure 15a shows an example of a mold 1510 in an open and a closed state. The mold 1510 has a fixed element 1511 and a movable element 1512. In one embodiment, the mold is opened to a predetermined extent and loaded with expanded TPU. Subsequently, the movable element 1512 is moved towards the fixed element 1511, compressing the expanded TPU. The mold is closed to a predetermined extent, which determines the thickness of the formed element containing the expanded TPU. Preferably, steam is supplied to the expanded TPU during closing. The two elements 1511 and 1512 are designed such that their shape determines the geometry of the formed element containing the expanded TPU.

[0168] Fig. Figure 15b shows another example of a form 1520. In addition to the fixed element 1511, form 1520 has a first movable element 1522 and a second movable element 1523. The number of two movable elements in the Fig. 15b-c is merely an example, and other molds can also have more than two movable elements. The various movable elements 1522 and 1523 allow the mold to open to different degrees in different areas. For example, in the area under element 1522, which opens further than element 1523, a higher density can be provided after the mold is closed than in the area under element 1523. For example, a surface area or section of a sole in the heel area can thus be made with a higher mass and greater strength than a section or area in the toe area.

[0169] Fig. Figure 15c shows a mold 1530 which, in addition to the fixed element 1511, also has two movable elements 1532 and 1533. Furthermore, the mold 1530 includes a separating element 1534, which separates the areas under the elements 1532 and 1533. Thus, the areas under the elements 1532 and 1533 can be advantageously loaded with different starting materials, e.g., a first expanded TPU 1535 and a second expanded TPU 1536. The first and second expanded TPU can, for example, have different particle sizes and / or colors and / or compositions. The separating element 1534 prevents the first and second TPU 1535 and 1536, respectively, from mixing during loading. In one embodiment, the separating element 1534 is removed before compression to bring the areas under the elements 1532 and 1533 into contact. In another embodiment, the separating element is removed after compression.In both embodiments, the first and second TPUs 1535 and 1536, respectively, can be fused together, thus creating a bond between them. In some embodiments, the movable elements 1532 and 1533 can also be opened to different extents before loading.

[0170] Fig. Figure 15d shows another example 1540 of a mold comprising a fixed element 1511 and a movable element 1542. In addition to expanded TPU 1546, the mold can also be loaded with a material 1547 that is free of expanded TPU. This material can, for example, be a functional element, such as a torsion support. Molds 1510, 1520, and 1530 can also be loaded with such elements. Preferably, the TPU-free material is loaded into the mold before the expanded TPU. In some embodiments, several materials or elements free of expanded TPU can also be loaded into the mold. After melting, the mold can be opened and reloaded. One or more further vapor deposition processes can be carried out sequentially to deposit further sections, either containing expanded TPU or free of it, on top of each other.

[0171] Fig. Figure 15e shows a three-dimensional view of a shape 1550. This includes a fixed element 1551 and a movable element 1552. Furthermore, it shows Fig. 15e the sole 1110 manufactured in mold 1550. The sole comprises a first section 1111, which includes an expanded TPU, an outsole 1113, and a frame element 1114, as well as optionally a film 1101. In one embodiment of a method, the outsole 1113, optionally the film 1101, and then the frame element 1114 are first loaded into a mold. The mold is then loaded with an expanded TPU. The mold is closed, and steam is supplied to the expanded TPU, causing it to melt and bond with the frame element 1114, the outsole 1113, and / or optionally the film 1101.

[0172] The features of forms 1510, 1520, 1530, 1540, 1550 and the associated process steps can also be combined arbitrarily in some embodiments.

[0173] Each of the aforementioned methods for manufacturing a shoe sole can also include curing an expanded TPU. This can improve the properties of the expanded TPU. In particular, curing can stabilize the structure of the expanded TPU.

[0174] The properties of expanded TPU can be influenced by the following parameters: The temperature of the supplied vapor affects the degree of melting of the particle surface. The higher the temperature, the stronger the bond between the particles. The more the particles are melted, the lower the strength tends to be. Additionally, the bond strength can be controlled by the duration of the vaporization process.

[0175] In one embodiment, the process takes approximately 3-15 minutes. Preferably, the duration is 3-6 minutes for less complex processes using only a few different materials and / or elements. For processes involving a plurality of materials and / or elements, the duration is up to approximately 15 minutes.

[0176] A higher initial pressure to which the expanded TPU particles are compressed tends to lead to a higher density of the expanded TPU. Densities of the expanded TPU are preferably in the range of 30–300 grams / liter. Particularly preferably, they are in the range of 70–250 grams / liter.

[0177] Slower cooling of the expanded TPU can stabilize its structure, resulting in greater long-term stability. Curing the expanded TPU can also stabilize its structure, with the curing temperature and duration influencing the degree of structural stabilization.

[0178] The properties of expanded TPU can also be influenced by the choice of starting material. For example, expanded TPU particles of varying sizes can be used. The larger the particles, the more porous the foam structure of the expanded TPU tends to become. Furthermore, with increasing particle size, it tends to become less dense, lighter, and softer. A wide variety of additives can also be mixed with the expanded TPU starting material, which can control the properties of the expanded TPU. For example, another expanded material can be added to the expanded TPU as the starting material. To make the material lighter, expanded PP or expanded PS can be added, for instance. To make the material stronger, expanded PA can be added, for example. Various materials can be combined for special applications.This allows the properties of the expanded TPU to be specifically modified in order to provide certain predefined properties.

[0179] Overall, this results in great flexibility in controlling the properties of the expanded TPU, both by changing the starting material and by modifying the manufacturing parameters, as well as by coordinating the starting material and the manufacturing parameters. In particular, the manufacturing parameters, such as the width of the mold opening, temperature, and pressure, can be changed very easily and quickly, allowing for a highly flexible and rapidly adaptable manufacturing process.

[0180] Further exemplary embodiments of the present invention are briefly described below to promote understanding of it: 1. Sole for a shoe, especially a sports shoe, with a. at least a first and a second area, b. wherein the first surface area comprises an expanded thermoplastic polyurethane (TPU) and c. wherein the second surface area is free of expanded TPU. 2. Sole according to example 1, wherein the surface areas are connected to each other by a vapor process for the TPU. 3. Sole according to one of Examples 1 or 2, wherein the second surface area comprises a foamed ethylene vinyl acetate and / or non-expanded TPU and / or rubber and / or polypropylene and / or polyamide and / or polystyrene. 4. Sole according to one of the preceding examples, wherein the second surface area is arranged at an edge of the sole. 5. Sole according to one of the preceding examples, wherein the second surface area comprises a sole plate and / or a torsion support and / or an outsole and / or a recess for receiving functional elements. 6. Sole according to one of the preceding examples, wherein the first surface area has a varying thickness. 7. Sole according to example 6, wherein the thickness of the first surface area increases from the forefoot area of ​​the sole towards the heel area. 8. Sole according to one of the preceding examples, wherein the first surface area has at least one recess. 9. Sole according to one of the preceding examples, wherein the first surface area is arranged at an edge of the sole. 10. Sole according to Example 9, wherein the thickness of the first surface area is increased at the edge of the sole. 11. Sole according to one of the preceding examples, wherein the first surface area is located in the midfoot and / or forefoot area of ​​the sole. 12. Sole according to one of the preceding examples, wherein the first surface area is surrounded by the second surface area. 13. Sole according to one of the preceding examples, wherein the sole includes a third surface area which has an expanded TPU. 14. Sole according to Example 13, wherein the first surface area is arranged in the heel area of ​​the sole and wherein the third surface area is arranged in the midfoot and / or forefoot area of ​​the sole. 15. Sole according to one of the preceding examples, wherein at least the first surface area is at least partially surrounded by a film, in particular a plastic film. 16. Sole for a shoe, especially a sports shoe, with a. a first sub-area which has a first expanded thermoplastic polyurethane (TPU), b. a second sub-area which has a second expanded TPU, c. wherein the first expanded TPU and the second expanded TPU are manufactured using a different vapor deposition process and / or from a different starting material. 17. Sole according to Example 16, wherein the first expanded TPU has a first particle size and wherein the second expanded TPU has a second particle size which differs from the first particle size. 18. Sole according to one of Examples 16 or 17, wherein at least one of the first and second sub-areas is at least partially surrounded by a film, in particular a plastic film. 19. Sole according to one of Examples 16 - 18, wherein the sub-areas are joined together by a steam process for the first expanded TPU and / or the second expanded TPU. 20. Sole according to one of Examples 16 - 19, wherein the first sub-area has a first sole layer and the second sub-area has a second sole layer. 21. Sole according to Example 20, wherein the sole comprises a third sole layer that is free of expanded TPU. 22. Sole according to Example 21, wherein the third sole layer is arranged between the first and second sole layers. 23. Sole according to one of the examples 16 - 19, wherein the first sub-area has a first surface area and / or the second sub-area has a second surface area. 24. Sole according to Example 23, wherein the first surface area is substantially located on the medial side of the sole. 25. Sole according to Example 24, wherein the second surface area is substantially located on the lateral side of the sole. 26. Insole for arrangement in the upper of a shoe, in particular a sports shoe, wherein the insole comprises an expanded thermoplastic polyurethane (TPU). 27. Insole according to Example 26, wherein the insole is at least partially surrounded by a film, in particular a plastic film. 28. Shoe, in particular sports shoe, with a sole according to one of the preceding examples. 29. Shoe according to Example 28 with an upper, wherein the sole is bonded to the upper in a steam process without adhesives. 30. Method for manufacturing a shoe sole, in particular a shoe sole for a sports shoe, comprising: Loading a mold with an expanded thermoplastic polyurethane (TPU) for a first surface area; Loading the mold with a material that is free of expanded TPU for a second surface area; Supplying steam to the expanded TPU. 31. Method for manufacturing a shoe sole, in particular a shoe sole for a sports shoe, comprising: Loading a mold with a first expanded thermoplastic polyurethane (TPU) for a first sub-area; Loading the mold with a second expanded TPU for a second sub-area; Supplying steam to the first and second expanded TPU; where the first and second expanded TPU have different densities and / or different starting materials. 32. Method according to one of Examples 30 or 31, wherein the expanded TPU or the first and / or the second expanded TPU comprises particles. 33. Procedure according to Example 32, further comprehensive: Melting of the particle surface. 34. Procedure according to one of the examples 30-33, further comprising: Compacting the expanded TPU or the first and / or the second expanded TPU. 35. Method according to one of Examples 30 - 33, wherein the loading with the expanded TPU or the first and / or second expanded TPU is carried out under pressure. 36. Procedure according to one of the examples 30 - 35, further comprising: Relaxing the expanded TPU or the first and second expanded TPU. 37. Procedure according to one of the examples 30 - 36, further comprising: Cooling of the expanded TPU or of the first and second expanded TPU. 38. Procedure according to one of the examples 30 - 37, further comprising: Curing of the expanded TPU or the first and second expanded TPU.

Claims

[1] Sole (210) for a shoe (200), in particular a sports shoe, comprising: a. a first sub-area (211) comprising an expanded thermoplastic polyurethane, TPU, and b. a second sub-area (212) that is free of expanded TPU, c. wherein the second sub-area laterally borders the first sub-area, and d. wherein the first sub-area comprises expanded TPU in the form of particles which are bonded to form a granular but closed plastic foam structure. [2] Sole according to claim 1, wherein the first part is arranged in a heel area of ​​the sole, in particular in an area under the calcaneus. [3] Sole according to one of claims 1-2, wherein the first part is designed as an insert. [4] Sole according to claim 1, wherein the particles in the first sub-area have been bonded to form the granular but closed plastic foam structure by applying heat to their surfaces. [5] Sole according to claim 4, wherein the heat has been supplied in the form of steam. [6] Sole according to one of claims 1-5, wherein the second part comprises ethylene vinyl acetate, EVA. [7] Sole according to one of claims 1-6, wherein the first sub-area and / or the second sub-area are designed as surface areas, i.e. as sub-areas of the sole which extend continuously from an underside of the sole to an upper side of the sole. [8] Sole according to one of claims 1-7, further comprising a third sub-area which also comprises an expanded TPU, and wherein the second sub-area also laterally surrounds the third sub-area. [9] Sole according to claim 8, wherein the third part is arranged in a forefoot area. [10] Sole according to one of claims 8-9, wherein the third part is designed as an insert. [11] Sole according to one of claims 8-10, wherein the second part is arranged around the outer edge of the sole and between the forefoot area and the calcaneus. [12] Sole according to one of claims 8-11, wherein the third sub-area also comprises expanded TPU in the form of particles which are connected to form a granular but closed plastic foam structure. [13] Sole according to claim 12, wherein the particles in the third sub-area have been bonded to form the granular but closed plastic foam structure by applying heat to their surfaces. [14] Sole according to claim 13, wherein the heat has been supplied in the form of steam. [15] Sole according to one of claims 8-14, wherein the first sub-area and the third sub-area comprise a first expanded TPU and a second expanded TPU respectively, which provide different functionalities. [16] Sole according to claim 15, wherein the first expanded TPU in the first sub-area provides a higher strength than the second expanded TPU in the third sub-area. [17] Sole according to one of claims 15-16, wherein the first expanded TPU in the first sub-area has a higher density than the second expanded TPU in the third sub-area. [18] Sole according to one of claims 8-17, wherein the third sub-area is designed as a surface area, i.e. as a sub-area of ​​the sole which extends continuously from an underside of the sole to an upper side of the sole. [19] Shoe (200), in particular sports shoe, with a sole (210) according to any one of claims 1-18.

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