Deep drawing segment

Abstract

The present invention relates to a method for producing a waterproof and vapor-permeable segment (5) having a three-dimensional profile, said segment being for a shoe upper, clothing or a backpack or for producing a shoe upper, clothing or a backpack, said segment being free of connection points in its surface, and the method for producing said segment (5) being a thermoforming method, wherein the resulting two-dimensional planar structure is fully laminated as a whole, and said segment is free of connection points in its surface. The present invention further relates to a waterproof and vapor-permeable segment for introducing into a three-dimensional functional laminate of a shoe or a shoe upper, clothing or a backpack, said segment being dimensionally stable under its own weight, being single-piece and being free of connection points in its surface.

Description

[0001] The present invention relates to a method for producing a waterproof and vapor-permeable segment having a three-dimensional contour, said segment being intended for introduction into a shoe shaft, clothing or a backpack or for forming such a contour, and also to such a segment.

[0002] The outer layer (upper) of a waterproof and vapor-permeable shoe shaft is generally composed of a water-permeable or water-repellent and breathable material, such as a leather or textile laminate. In order to render the shoe shaft waterproof, a waterproof and vapor-permeable laminate is used on the inner side of the upper, which can be, for example, a single sheet or a porous membrane. Such a waterproof and vapor-permeable laminate, which is generally referred to as a "functional layer", can have a protective or reinforcing laminate on one or both sides. The composite material of the "functional layer" and the protective or reinforcing laminate is generally referred to as a "functional laminate".

[0003] Waterproof and vapor-permeable top and bottom coverings are constructed in a completely analogous manner. The outer layer in clothing, for example, is generally made of a sturdy fabric and provides protection against wind and weather. Towards the inside, there is generally one or more wool or flannel layers, which, for example, protect the body against cold. In order to render the clothing waterproof, a waterproof and vapor-permeable laminate is still provided as a functional layer as one of the (inner) layers, which can be, for example, a single sheet or a porous membrane. As in shoes, the functional layer can also carry a protective or reinforcing laminate on one or both sides of the clothing in order to become a functional laminate.

[0004] Functional laminates as described above are also known in other textile applications, such as backpacks, where a laminated structure consisting of a soft functional layer and a protective or reinforcing laminate ensures a certain level of wearing comfort and an optimal load distribution.

[0005] A full range of materials for the functional layer are known to the person skilled in the art. Examples of functional layer materials are polyether esters (PEEST), polyurethanes (PU), polyether amides (PEA) and polyhaloolefins.

[0006] The specific challenge here is to adapt the functional laminate in an optimal manner to the contour of a body part, such as to the shape of the foot.

[0007] In this regard, it should be noted that the following description of the invention is given only by way of example of a shoe, but the embodiments should of course not be understood as being limited thereto, but can also be applied to other items of clothing (such as jackets, trousers, shirts or parts thereof) and accessories (such as hats, gloves, backpacks) - where an optimized three-dimensional or seamless or at least seam-reduced contour appears useful without departing from the intended scope of protection.

[0008] Functional laminates thus typically consist of several two-dimensional planar parts in order to obtain a three-dimensional structure with a reasonably precise fit. For example, in the case of a shoe, this three-dimensional structure is typically connected at the top of the shoe upper and at the sole. Since the functional layer no longer exhibits watertightness, or at least the watertightness is reduced, at the connection or seam points, the connection or seam points usually have to be subsequently sealed using a seam sealing tape. Seam sealing tapes known to those skilled in the art that cover the functional layer in the area of the connection or seam points are generally not vapor-permeable. This reduces the effective surface area available in the shoe upper area for removing moisture from the interior of the shoe and impedes the essentially desirable vapor passage in the sealed connection or seam area, thereby reducing the climatic comfort of the shoe.

[0009] Furthermore, in the production of a three-dimensional shoe that is waterproof and at the same time vapor-permeable, the steps of stitching or connecting the functional laminate and subsequently sealing the connection points thus obtained constitute a relatively complex and labor-intensive process, which is usually reflected in the higher production costs of such shoes.

[0010] As explained above, the same or similar considerations also apply to other application forms of the functional laminate, such as in the clothing or backpack mentioned above.

[0011] Furthermore, the functional laminate may be weakened due to the introduction of seams or connection points necessary at these locations, thereby prematurely losing its integrity under load.

[0012] Another known problem that occurs in shoes with a functional laminate introduced in this way is the lack of wearing comfort due to insufficient fit. By assembling a three-dimensional structure from two-dimensional, planar individual parts, the required three-dimensional contour can only be approximated. This causes wrinkles where there is too much material and pressure points where there is too little material, making the wearing comfort of, for example, a waterproof and vapor-permeable shoe significantly worse.

[0013] US 2015 / 0230553 A1 discloses a waterproof and vapor-permeable functional sock (bootie) made of expanded polytetrafluoroethylene (ePTFE), which is seamless but has connection points.

[0014] US 2015 / 0150335 A1 discloses a footware system that includes a waterproof functional sock (bootie). This functional sock (bootie) is made by a casting process and is not vapor-permeable.

[0015] EP 1 212 953 B1 discloses a shoe construction having a functional layer shaft. This functional layer shaft is waterproof and vapor-permeable and is obtained by enclosing a three-dimensional foot contour or a three-dimensional sock structure. US2017 / 0042280 A1 discloses a waterproof and vapor-permeable functional sock (ankle boot). This functional sock contains at least one textile laminate and a seamless and stretchable functional layer. The one or more textile laminates are provided as a three-dimensional sock and are applied to a shoe last together with the functional layer. These laminates are connected to each other, for example, with an adhesive to form a functional laminate, and then their shape is fixed by heat. The functional sock (ankle boot) made in this way surrounds the entire foot of the wearer.

[0016] One disadvantage of US 2017 / 0042280 is that the functional laminate surrounds the entire foot of the wearer, especially the sole part. Therefore, certain techniques for connecting to the sole, such as by means of a Strobel seam or pinching, are not easily achievable here.

[0017] Another disadvantage of US 2017 / 0042280 is that the method of producing such a functional sock (ankle boot) is rather cumbersome and time-consuming because the layers are applied to the shoe last successively.

[0018] In addition, the method of successively applying different layers to produce a functional sock (ankle boot) described in US 2017 / 0042280 involves the risk of wrinkling, which can limit the comfort of the shoe.

[0019] Document DE 39 37 106 A1 discloses a method for producing a one-piece seamless shoe lining shaft by thermoforming a laminate. The shoe lining shaft produced in this way exhibits a processing shrinkage rate of up to 10%.

[0020] The disadvantage of DE 39 37 106 A1 is that the laminate to be transformed into a three-dimensional contour by thermoforming must be manufactured in a previous (possibly multi-stage) process step by methods known to those skilled in the art for connecting textile laminates and functional layers, such as by using a dot or grid bonding of a reactive wet-crosslinked PU hot melt adhesive. This can increase the work involved in equipment engineering and logistics and thus have a negative impact on production costs.

[0021] In addition, in the upstream lamination step, especially when using highly stretchable materials, there is a risk that the individual material laminates have been stretched to different degrees during the connection process and these stretches are fixed in the laminated composite material. In the downstream thermoforming step, these different stretches can have a negative impact on the reproducibility of the deformation, etc.

[0022] Accordingly, the object of the present invention is to provide a method for producing a waterproof and moisture-permeable three-dimensional segment, such as for a functional shoe upper laminate, thereby at least reducing the disadvantages of the prior art. Furthermore, the object is to provide such a three-dimensional waterproof and moisture-permeable segment, such as for a functional shoe upper laminate.

[0023] The problem posed according to the invention is solved by a method for producing a waterproof and moisture-permeable segment having a three-dimensional contour, said segment being for or for forming a shoe upper, clothing or a backpack, and said segment being free of connection points in its surface, and the method comprising the following steps:

[0024] a. Providing a stack of at least one first and one second two-dimensional sheet structure arranged one on top of the other, whereby at least two sheet structures contained adjacent to each other in the stack and laid directly on top of each other are not connected to each other and whereby the first sheet structure forms a waterproof and moisture-permeable functional layer,

[0025] b. Providing a mold body comprising said three-dimensional contour,

[0026] c. In the case of heating the stack to a process temperature, thermoforming at least the stack of the first and second sheet structures by means of the mold body and simultaneously laminating the sheet structures contained in the stack, such that the adhesion between at least one first and one second two-dimensional sheet structure arranged one on top of the other and initially not connected to each other, measured with a specimen width of 25 mm according to DIN 53530:1981-02, is at least 1.0 N, whereby the process temperature should be set to obtain plastic deformation of the stack and lamination for planar connection of the two-dimensional sheet-like structures contained in the stack, thereby forming said segment.

[0027] The method according to the invention has at least the advantages over the prior art that

[0028] · The segment can be obtained by means of a simple forming process.

[0029] · By using several individual sheet structures instead of a prefabricated integral laminate, at least some of the originally necessary upstream process steps for connecting / laminating the individual sheet structures can be dispensed with.

[0030] · Using several individual sheet structures instead of a prefabricated integral laminate enables a more rapid response to the requirements of individual customers and, if necessary, can reduce the storage capacity that originally had to be kept available in order to be able to implement diverse lamination designs.

[0031] · The materials in the two-dimensional sheet structures can be combined more freely in terms of sequence and / or selection.

[0032] · The method results in a maximized moisture exchange surface.

[0033] · Improve wearing comfort by avoiding pressure points caused by seams and avoiding wrinkles.

[0034] · The stretching and deformation of the two-dimensional sheet structure and the functional layer improve the breathability of the individual material or the resulting integral laminate compared to a non-deformed integral laminate having the same structure in other aspects.

[0035] · By simultaneously deforming and laminating sheet structures that are not connected to each other, the elastic and restoring forces between the sheet structures are reduced or even prevented, and the resulting segments are more stable in size than segments of the prior art.

[0036] In the present invention, the following terms are defined and used throughout the specification:

[0037] The term "free of connection points" should be understood to mean that the surface of the segment does not have any connection points established by stitching, welding, gluing or other connection methods known to those skilled in the art.

[0038] "Plastic deformation of the stack" should be understood to mean at least plastic deformation of a part of the two-dimensional sheet structure contained in the stack at the process temperature set in the thermoforming step, such that after the stack cools, the resulting segment is fixed in its three-dimensional contour according to the present invention.

[0039] A "segment" can be introduced into a three-dimensional shoe upper or used to produce a three-dimensional shoe upper. In addition, the segment can also be introduced into clothing or a backpack or form clothing or a backpack. If the segment is introduced into a three-dimensional shoe upper or forms a three-dimensional shoe upper, the segment can include all the foot-facing parts of the shoe. These areas can include the sole under the foot, as well as sub-areas of the toe cap, toeblade, quarter and rear cap. These sections, except for the sole, are also referred to as the inner shaft. The segment may also only include some areas facing the foot, for example, the sole area may be excluded from the segment. In this case, the segment can be introduced into the shoe upper, but the segment does not belong to the shoe upper material (outer shaft) (e.g., leather) of the shoe, but is located in the inner shaft area inside the shoe.

[0040] In addition, in addition to the foot-facing sheet structure (inner shaft), the segment may also include the upper / outer material of the shoe upper, thereby forming at least a part of the entire shoe upper. This means that the segment can not only be introduced into the shoe as an inner shaft, but also form the entire shoe upper. The segment according to the present invention can completely surround the foot, but can also be open in the sole area, for example, in order to be connected to a suitable sole.

[0041] If this segment is introduced into a piece of clothing, it can form a single component of the body-facing clothing. For example, it is possible for this segment to replicate the shape of a glove, the shape of which includes the individual fingers, palm, and back of the hand. In addition, this segment can also form an entire piece of clothing. This segment can also be introduced into socks or headgear, such as hats, caps, or also caps, or completely form them. This segment can take the form of an entire headgear or only a part thereof. For example, in the case of a hat, the main part, the crown, contains this segment, while the brim does not. In addition, the segment according to the invention has a three-dimensional contour and is thus a three-dimensional segment.

[0042] The stack provided in the method according to the invention contains at least first and second two-dimensional sheet structures arranged one on top of the other. The laminae contained in the provided stack can be laminated, i.e., connected to each other. However, in any case, the stack contains two adjacent two-dimensional sheet structures that are not connected to each other. The two-dimensional sheet structures adjacent to each other and laid directly on top of each other are not connected to each other. However, the stack can also include other two-dimensional sheet structures that are not connected to their respective adjacent and directly superposed sheet structures. Finally, the stack can also consist entirely of two-dimensional sheet structures that are not connected to each other.

[0043] In the present invention, "laminated" is understood to mean that the two-dimensional sheet structures contained in the stack are connected to each other in a planar manner.

[0044] The term "connected in a planar manner" means that at least two two-dimensional sheet structures or laminae are connected to each other at the surface formed in their planar extension to form a two-dimensional planar laminate. The planar connection can be in such a way that the elements are connected over their entire surface, i.e., in a full-surface manner. The surfaces can also be connected at points, whereby the point connections form a pattern and can be adhesive points distributed in a grid pattern.

[0045] The term "lamina" describes a two-dimensional layer that can exist as an adjacent (continuous) layer or also as a non-adjacent (discontinuous) layer. An adjacent layer can be, for example, a textile lamina. A non-adjacent layer can be, for example, a pattern in the form of adhesive points, flakes, etc. Such a pattern can be printed, for example, on the side of the functional layer facing away from the foot. In textile technology, this is called a half-ply; in combination with the functional layer and the textile lamina facing the foot, it is called a 2.5-ply laminate.

[0046] The terms "bootie" and "functional sock" describe a shoe component that completely encloses the wearer's foot.

[0047] The term "textile laminate" describes a laminate consisting of textiles. Such textiles can take various forms, such as woven fabrics, knitted fabrics, crocheted fabrics, non-woven fabrics, braided fabrics, non-crimp fabrics or felt.

[0048] The term "functional layer" describes a laminate having at least one function, namely at least the basic functions of waterproofing and water vapor permeability. Such a functional layer can be a foil, film or membrane that is both waterproof and water vapor permeable. Preferably, the functional layer consists of one or more polymer materials, which include hydrophilic and hydrophobic polymers, as well as their combinations and mixtures.

[0049] In the present invention, the terms "polymer material" and "polymer" are used equivalently and interchangeably. Polymer materials or polymers are understood to mean any synthetic or natural polymer.

[0050] "Garment" within the meaning of the present invention includes gloves, headgear, socks, jackets, trousers, vests, etc.

[0051] The two-dimensional sheet structure of the present invention can comprise a single laminate or layer, or can comprise multiple laminates or layers. Possible laminates or layers are textile laminates, functional layers or adhesive layers. In the case of a sheet structure having several laminates or layers, these laminates and / or layers are connected in a planar manner to form a pre-laminate.

[0052] In a preferred embodiment of the method according to the present invention, the segment is introduced into a three-dimensional shoe upper, garment or backpack. Preferred garments are gloves, socks and headgear, such as hats, caps or bonnets, jackets, trousers and vests. Gloves can be designed such that each finger is surrounded by the glove, which is also known as finger gloves, or the thumb is surrounded separately from the other fingers, which is also known as mittens.

[0053] In a preferred embodiment of the method according to the present invention, at least one two-dimensional sheet structure comprises at least one thermoplastic laminate or contains at least a thermoplastic component.

[0054] The thermoplastic laminate can be formed as an independent two-dimensional sheet structure, or can be a laminate within a two-dimensional sheet structure that is a pre-laminate consisting of several laminates.

[0055] Furthermore, in a preferred embodiment, the thermoplastic component can be a component of a laminate of the two-dimensional sheet structure.

[0056] As explained, it is essential for the method according to the present invention that the stack is thermoformed into a three-dimensional shape to form a segment according to the present invention, and that the two-dimensional sheet structures contained therein are fully laminated together as a whole.

[0057] In the present invention, thermoforming refers to the forming of a stack of two-dimensional sheet structures. The stack may contain at least one thermoplastic laminate. The at least one thermoplastic laminate may be, for example, a thermoplastic film, a suitable textile containing a thermoplastic material, or a film or nonwoven fabric composed of a hot melt adhesive. In thermoforming, the two-dimensional sheet structure is heated to a temperature that allows the at least one thermoplastic laminate to plastically deform, and is transformed into a three-dimensional contour by means of a rigid mold or a mold that is itself movable during the thermoforming process and has a three-dimensional contour. At the same time, in the method according to the present invention, the at least one thermoplastic laminate must become sticky due to heating so that it laminates the two-dimensional sheet structures contained in the stack to each other in the three-dimensional segment or connects them to each other in a planar manner.

[0058] Preferably, the at least one thermoplastic laminate contains a thermoplastic material having a melting temperature of 80 to 270 °C measured according to DIN EN ISO 11357-1 and -3.

[0059] More preferably, the at least one thermoplastic laminate contains a thermoplastic material having a glass transition temperature of 0 to 220 °C measured according to DIN EN ISO 11357-1 and -3.

[0060] In a preferred embodiment of the method according to the present invention, the at least one thermoplastic laminate contains at least one material selected from polyurethane (PU), polyolefin (PO), polyester (PES), polyether ester (PEEST), polyacrylonitrile (PAN), polyamide (PA), polyacrylate (PAC), polyetherimide (PEI), polytetrafluoroethylene (PTFE), polysulfone (PSU), cellulose acetate (CA) and their block copolymers or random copolymers and / or mixtures thereof.

[0061] The mold with a three-dimensional contour may have a negative shape, such as a hollow body open on one side, or a positive shape, which may be a complete three-dimensional mold or a part thereof.

[0062] In a preferred embodiment of the method according to the present invention, the transformation of the stack of two-dimensional sheet structures into a three-dimensional contour and simultaneous lamination can be assisted by means of vacuum and / or compressed air and / or a counter tool. In a preferred embodiment of the method assisted by vacuum, a vacuum is applied between the mold and the stack of two-dimensional sheet structures.

[0063] In a further embodiment according to the present invention, thermoforming is assisted by applying a vacuum between the mold and the stack or the deformed stack.

[0064] After a stack of at least two two-dimensional sheet structures has been transformed into a three-dimensional contour and simultaneously laminated, it is cooled to fix the three-dimensional contour of the resulting three-dimensional segment. Cooling can also be carried out or supported by means of a cooled mold.

[0065] The mold and the resulting three-dimensional segment are then separated from each other. The three-dimensional segments obtained in this way can subsequently be subjected to further processing.

[0066] Despite the fixation achieved by cooling the resulting segments, the shape may still change slightly due to the elasticity or resilience of the materials contained. If, for example, the deviation of the contour of a deformed functional shoe laminate from the contour specified by a positive or negative mold is at most ±25%, the shape change associated with the method according to the invention is considered to be minor. Thus, if a three-dimensional segment undergoes a maximum change of ±25% of the specified contour under its own weight, it is considered dimensionally stable. In the method according to the invention, at least some of the two-dimensional sheet structures are not connected to each other, which is why the two-dimensional sheet structures can move relative to each other with a certain degree of freedom during the deformation applied as part of the method. Without being bound by theory, it is speculated that this will reduce the elastic and resilience forces and thus achieve a change in the specified contour of ±5% or less.

[0067] The method according to the invention offers the advantage that thermoforming can be carried out continuously with a specific timing of the individual process steps, for example using two-dimensional sheet structures pulled from a roll, which can consist of one or more laminae and / or layers.

[0068] Of course, it is also possible to carry out the procedure discontinuously.

[0069] In an advantageous embodiment of the method, thermoforming is assisted by applying a vacuum between the mold and the stack or the deformed stack.

[0070] In a further preferred embodiment of the method according to the invention, the thermoforming in step c. comprises the following sub-steps:

[0071] · Clamping the stack into a frame,

[0072] · Heating the two-dimensional sheet structures contained in the stack to the process temperature from at least one side,

[0073] · Forming the segment and laminating the two-dimensional sheet structures by transforming the stack into a three-dimensional contour by means of the mold and applying a vacuum between the two-dimensional sheet structures and the mold,

[0074] · Cooling the segment to fix the three-dimensional contour,

[0075] · Removing the vacuum,

[0076] · Removing the mold.

[0077] Thermoforming can be carried out using a suitable thermoforming machine, such as a thermoforming machine manufactured by Illig or Kiefel.

[0078] In the thermoforming method, a two-dimensional sheet structure is introduced into the thermoforming machine and heated here, for example, by means of an infrared radiator to a process temperature between 80 °C and 270 °C, preferably between 100 °C and 220 °C, and particularly preferably heated to a process temperature between 130 °C and 180 °C.

[0079] Instead of an infrared radiator, the stack can be heated by any suitable method, such as induction, microwave radiation, or hot air. However, it is preferred to heat the stack by means of an infrared radiator.

[0080] Preferably, the stack is heated for 5 to 60 seconds.

[0081] Particularly preferably, the stack of at least two two-dimensional sheet structures is heated on both sides. By heating the stack on both sides, the contained two-dimensional sheet structures are uniformly heated, which can lead to better lamination and better adhesion between the laminae. Therefore, the two-dimensional sheet structures laminated together can have a favorable adhesion force of at least 1.0 N, and thus the two-dimensional sheet structures preferably have an adhesion force of at least 3.0 N, more preferably at least 3.5 N, and particularly preferably at least 4.0 N measured according to DIN 53530:1981-02 with a specimen width of 25 mm. If at least one two-dimensional sheet structure tears before the laminae separate during the test, the upper limit of the adhesion force is obtained.

[0082] During or after heating, the heated pile can be re-tensioned. The re-tensioning can be carried out mechanically by fixing the stack in the thermoforming machine or by using an active medium, such as compressed air.

[0083] After heating and if necessary, re-tensioning, in one embodiment of the method, a mold with the desired three-dimensional contour can be moved, for example, from below through the plane of the heated stack to roughly predefine the three-dimensional contour.

[0084] At this time, as explained, in a preferred embodiment of the method, a vacuum can be created between the mold and the two-dimensional sheet structure so that the desired three-dimensional contour is fully formed by the two-dimensional sheet structures contained in the stack and these are laminated together to obtain a fragment of a three-dimensional functional laminate, which is used, for example, for introducing into a shoe upper, clothing, or a backpack, or for producing a shoe upper.

[0085] Preferably, the thermoforming carried out with the mold is carried out with a residence time of the stack on the mold of 1 to 30 seconds.

[0086] When a vacuum is used between the mold body and the two-dimensional sheet structure, a pressure of 0.001 to 0.95 bar is used, preferably a pressure of at most 0.8 bar, more preferably a pressure of at most 0.6 bar, particularly preferably a pressure of at most 0.4 bar.

[0087] The segment is then preferably cooled to fix the three-dimensional profile. Cooling can be achieved by a cooled mold body or by external cooling, for example by air or other suitable methods known to those skilled in the art. Preferably, cooling is carried out within 5 to 45 seconds.

[0088] The method may comprise the subsequent step of cutting or punching out segments from the formed sheet structure.

[0089] A preferred embodiment of the method consists in that the thermoforming and laminating comprises deep drawing by means of forming tools, deep drawing by means of active media, deep drawing by means of active energy or a combination thereof.

[0090] Deep drawing with the aid of a forming tool can also constitute an embodiment, in which a mold body with a three-dimensional profile is moved through the plane of the stack, for example from below. To assist the deformation, a counter tool can additionally be pressed onto the stack from the side of the stack facing away from the mold body. In this case, the counter tool has a three-dimensional counter profile adapted to the molded part.

[0091] In the case of active medium deep drawing, the thermoforming is assisted by an active medium, such as compressed air or a pressure-regulated fluid cushion.

[0092] In the case of deep drawing with active energy, forming can be achieved by magnetic forces. However, this requires the presence of sheets or wires that are well conductive.

[0093] A preferred embodiment of the method consists in that, during the thermoforming process, additional pressure is applied to the surface of the stack facing away from the mould body in order to assist the conversion into a three-dimensional contour.

[0094] As already explained, this additional pressure can be generated by a reaction tool, by compressed air or a pressure-regulated fluid cushion.

[0095] In a preferred embodiment, when additional pressure is used on the side of the stack facing away from the mold body, a pressure of 1.5 to 10 bar, particularly preferably a pressure of 3 to 8 bar, and more preferably a pressure of 5 to 7 bar is used.

[0096] In a preferred embodiment of the method according to the invention, the functional layer comprises one or more polymeric materials, preferably one or more thermoplastic materials.The functional layer may consist of a non-porous film, a microporous film or a combination thereof.

[0097] The waterproof and vapor-permeable functional layer preferably has a thickness of not more than 200 μm, particularly preferably not more than 30 μm.

[0098] In addition, the functional layer preferably has an elongation at break of at least 50%. Particularly preferably, the functional layer has an elongation at break of at least 200%.

[0099] Preferably, the waterproof and vapor-permeable functional layer comprises at least one material selected from polyurethane (PU), polyolefin (PO), polyester (PES), polyether ester (PEEST), polyacrylonitrile (PAN), polyamide (PA), polyetherimide (PEI), polytetrafluoroethylene (PTFE), polysulfone (PSU), cellulose acetate (CA) and block copolymers or random copolymers thereof and / or mixtures thereof.

[0100] In one embodiment, the microporous membrane can be an expanded polytetrafluoroethylene membrane. It is also conceivable to use a non-expanded polytetrafluoroethylene membrane before deep drawing, which is stretched by deep drawing, whereby the polytetrafluoroethylene membrane is microporous after the deep drawing process.

[0101] In a further embodiment of the method according to the invention, the functional layer comprises a microporous membrane and a non-porous membrane. Preferably, the microporous membrane comprises a hydrophobic polymer material, such as polytetrafluoroethylene, and the non-porous membrane comprises a hydrophilic polymer material, such as polyurethane. The functional layer can thus also exhibit a combination of a hydrophobic polymer material and a hydrophilic polymer material.

[0102] In a preferred embodiment, the waterproof and vapor-permeable functional layer consists in particular of thermoplastic polyurethane (TPU) or polyether ester (PEEST).

[0103] A non-limiting example of a waterproof and vapor-permeable functional layer in the form of a non-porous membrane is a membrane made of a polyether ester (PEEST) that is harmless to health and recyclable.

[0104] In a preferred embodiment of the method according to the invention, the first sheet structure comprises a functional layer.

[0105] According to the invention, the two-dimensional sheet structure can consist of a plurality of laminae. Preferably, the at least two two-dimensional sheet structures have at least one additional lamina.

[0106] The functional layer can have at least one additional lamina on its lower side and on its upper side within the two-dimensional sheet structure. These can already be connected in a planar manner before thermoforming, or only be connected in a planar manner until thermoforming. The functional layer can have the same or different numbers of laminae on its lower side and upper side. Preferably, the at least one additional lamina is a textile lamina.

[0107] In a preferred embodiment, the at least one additional ply is a textile ply, whereby such textile ply can be constructed continuously or discontinuously in its planar extension. In a further preferred embodiment, the textile ply is in the form of a woven fabric, a knitted fabric, a crocheted fabric, a nonwoven fabric, a braided fabric, a non-crimp fabric or a felt. Preferably, the stack comprises at least one textile ply.

[0108] In a preferred embodiment of the method according to the invention, the first sheet structure is a pre-laminate comprising a functional layer and at least one additional ply, which are joined by means of a hot-melt adhesive or a reactive adhesive, applying the adhesive continuously or discontinuously to the functional layer and / or the at least one additional ply.

[0109] In a further preferred embodiment, the at least one additional ply can be applied to the functional layer in flocked form. In yet a further preferred embodiment, the at least one additional ply is discontinuous and can for example have a pattern, such as adhesive dots applied in a grid pattern or flocking applied in a grid pattern, for example in the form of domains, whereby the individual dots or domains are not connected to one another.

[0110] Preferably, the textile ply can have different regions, which include for example local reinforcements and / or different degrees of stretchability. The textile ply can also have anisotropic regions, where different properties exist in the direction of extension of the textile ply. These local differences and / or anisotropies in the textile ply can be incorporated into the textile ply for example by certain weaving processes and knitting methods. The different regions obtained in this way can for example serve as reinforcements at the heel region, the toe or the lace elements, or for supporting the most precise possible imprint for forming the desired shape profile in a thermoforming process. In a preferred embodiment of the method according to the invention, the textile ply has regions of different properties and / or anisotropic regions.

[0111] In a further preferred embodiment of the method, the textile ply can consist of yarns or filaments. The yarns can be multifilament yarns or yarns made from staple fibres. In this case, the person skilled in the art understands that staple fibres are relatively short fibres with a length of 2 to 200 mm. On the other hand, filaments have a length greater than 200 mm, preferably greater than 500 mm, even more preferably greater than 1,000 mm. Filaments can also be almost endless if they are continuously extruded through a spinneret during the spinning process, for example.

[0112] The yarns or filaments of the textile ply can consist of a single polymer or several polymers. In the latter case, the yarn can be a blended yarn, where the individual filaments contain different polymers, or the filaments can be bicomponent filament yarns, where the individual filaments contain more than one polymer.

[0113] Such bicomponent filament yarns contain more than one polymer in a spatially restricted arrangement, for example as side-by-side, core-sheath or sea-island types.

[0114] Another embodiment of the method consists in that the filaments of the textile laminate consist of core-sheath bicomponent filament yarns, whereby the melting temperature T of the polymer in the sheath M,sheath is lower than the melting temperature T of the polymer in the core M,core .

[0115] In a preferred embodiment, the material of the textile laminate is selected from polymers, including polyolefins, polyesters, polyamides, polyurethanes and polyacrylonitriles or combinations thereof.

[0116] Preferably, the polymer has a glass transition temperature of 20 to 220 °C measured according to DIN EN ISO 11357-1 and -3.

[0117] More preferably, the polymer has a melting temperature of 80 to 270 °C measured according to DIN EN ISO 1 1357-1 and -3.

[0118] Furthermore, the two-dimensional sheet structure preferably has a breaking elongation at room temperature of 50 to 360% in the longitudinal and transverse directions measured according to DIN EN ISO 13934-1:1999. In a preferred embodiment of the method according to the invention, the two-dimensional sheet structure preferably has a breaking elongation at room temperature of at least 50%, more preferably at least 100%, even more preferably at least 250% in the longitudinal or transverse direction.

[0119] Furthermore, the two-dimensional sheet structure preferably has a tensile strength of 60 to 1700 N in the longitudinal and transverse directions measured according to DIN EN ISO 13934-1:1999.

[0120] Preferably, the functional layer can be connected to one of the at least one additional laminate by means of a hot melt adhesive or a reactive adhesive, whereby the adhesive can be applied continuously or discontinuously to the functional layer and / or the at least one additional laminate.

[0121] It is also possible to construct a continuous or discontinuous laminate consisting of a hot melt adhesive or a reactive adhesive, for example in the form of a nonwoven fabric or other structure.

[0122] In the case of the preferred application of the textile laminate, these can contain a hot melt adhesive or a reactive adhesive. For example, the textile laminate can consist entirely or partly of a hot melt adhesive or a reactive adhesive. This includes fabric laminate structures where the polymer or polymers contained in the fabric act as a reactive adhesive or a hot melt adhesive.

[0123] In this case, there is the possibility of establishing a connection between the functional layer and the textile laminate by converting such a polymer into its softening range or beyond its softening range. Of course, such a textile laminate can also be combined in this way with another continuous or discontinuous laminate.

[0124] In one embodiment of the method according to the invention, the at least one additional laminate is a textile laminate comprising a hot-melt adhesive or a reactive adhesive, by means of which the functional layer and the textile laminate are connected to one another in a planar manner.

[0125] Generally, any suitable polymer, copolymer or mixture thereof can be used as the hot-melt adhesive or the reactive adhesive. Preferably, a polymer selected from polyurethanes (PU), polyamides (PA), polyesters (PES), thermoplastic polyurethanes (TPU), polyacrylates (PAC) or block copolymers or random copolymers thereof and / or mixtures thereof is used as the hot-melt adhesive or the reactive adhesive.

[0126] In a preferred embodiment of the method according to the invention, the polymer of the reactive adhesive or the hot-melt adhesive has a melting temperature of 70 °C to 220 °C measured according to DIN EN ISO 11357-1 and -3.

[0127] In an equally preferred embodiment, the polymer of the reactive adhesive or the hot-melt adhesive has a glass transition temperature of 10 °C to 220 °C measured according to DIN EN ISO 11357-1 and -3.

[0128] The polymer of the reactive adhesive or the hot-melt adhesive for connecting the laminates in the pre-laminate is preferably selected such that the melting temperature is higher than the process temperature during the deep drawing process.

[0129] However, in some cases, it is also preferred to select the polymer of the reactive adhesive or the hot-melt adhesive for connecting the laminates in the pre-laminate such that the melting temperature is lower than the process temperature during the deep drawing process. By melting the adhesive during the deep drawing process, it is possible, for example, to achieve the co-sliding of the laminates initially connected in the pre-laminate and the reconnection of the laminates after shaping and cooling, thereby at least reducing any strain that might otherwise occur in the three-dimensional segments of the functional laminate.

[0130] The polymer of the reactive adhesive or the hot-melt adhesive for laminating the two-dimensional sheet structure during the deep drawing process is preferably selected such that the melting temperature is lower than the process temperature during the thermoforming process.

[0131] A preferred embodiment of the method consists in that, when providing the two-dimensional sheet, the covering foil is placed on the surface of the stack facing away from the die body during the thermoforming process and is removed after thermoforming.

[0132] The covering foil can be made of different materials, but it should preferably be removable from the three-dimensional segment after thermoforming without leaving any residue. In addition, the covering foil should preferably exhibit good thermal conductivity, as well as high temperature resistance and a high softening temperature range. Furthermore, the covering foil should be easily stretchable and exhibit a stretchability of at least the same order of magnitude as that of the two-dimensional sheet structure. An example of such a covering foil is a silicone foil.

[0133] The covering foil can be used to maintain a vacuum during the thermoforming process, i.e., to seal it off from the outside. This is particularly advantageous when an additional layer is used on the outside of the airtight functional layer or when a breathable microporous membrane is used as the functional layer. In addition, such a covering foil can act as a separator film to prevent the laminae of the two-dimensional multi-layer sheet structure from sticking to the reaction tool or the pressure regulating fluid pad after thermoforming.

[0134] In another preferred embodiment of the method, the material of the mold body is selected from wood, plastic, fiber-reinforced plastic, polymer resin, and aluminum casting resin, gypsum, metal, metal alloy, steel, clay, ceramic, glass, hard plastic, cast brass, and / or combinations thereof.

[0135] Particularly preferably, the material of the mold body is selected from wood, plastic, fiber-reinforced plastic, polymer resin, aluminum casting resin, and / or combinations thereof.

[0136] In a further advantageous embodiment of the method, the mold body presents the desired in-shoe contour or the desired hand or hat contour, for example in the form of a shoe last or a hand or head shape.

[0137] The above method is particularly suitable for producing a waterproof and breathable segment for a functional shoe upper laminate for insertion into a shoe upper, whereby the segment is simultaneously dimensionally stable, single-piece and free of connection points on its surface.

[0138] Therefore, the present invention further relates to a three-dimensional segment for a shoe upper, clothing or backpack or for forming a shoe upper, clothing or backpack that is waterproof and breathable, whereby the segment comprises a waterproof and breathable functional layer and at least one additional lamina, and the functional layer and / or the at least one additional lamina comprises a thermoplastic material, whereby the segment is dimensionally stable under its own weight, single-piece and free of connection points on its surface, characterized in that the segment consists of a stack of at least two two-dimensional sheet structures that are simultaneously laminated and transformed into a three-dimensional segment.

[0139] In a preferred embodiment of the segment according to the invention, such a segment forms the entire shoe upper.

[0140] Such a segment does not exhibit any connection points on its surface. Thus, the entire segment is waterproof and airtight, without any weak points that would require special sealing or reinforcement.

[0141] Furthermore, the preferred embodiments described above for the method according to the invention, for example with regard to the materials used, their properties and the structure of the segments obtained by means of this method, also apply accordingly to the waterproof and vapor-permeable three-dimensional segments of the functional laminate according to the invention.

[0142] Furthermore, the three-dimensional segment or the three-dimensional segment according to the invention may comprise the entire inner shoe upper, as well as the inner and outer shoe uppers, and thus comprise the entire shoe upper.

[0143] Preferably, a sole construction is provided for the segment made by the method according to the invention or the segment according to the invention. The shoe-making methods known to those skilled in the art can be used to provide a sole construction for the segment made by the method according to the invention or the segment according to the invention.

[0144] For example, the segment made by the method according to the invention or the segment according to the invention can be connected by joining methods such as gluing and / or stitching. Of course, the present invention also covers all other suitable joining methods, such as laser welding, ultrasonic welding, high-frequency welding and hot-wedge welding and combinations thereof.

[0145] The segment according to the invention or the segment made by the method according to the invention is preferably stitched to the Strobel sole or clamped to the insole and connected to the sole structure in a watertight manner using a sealing material and / or by means of an adhesive.

[0146] The Strobel method is a way of connecting the shoe upper to the midsole, mainly used for making lightweight hiking shoes and running shoes. The shoe upper is stitched to a textile insole made of wear-resistant fabric, for example using a so-called Strobel seam. The Strobel seam is an annular whipped seam between the shoe upper and the insole. The sole is glued or injected. The adhesive or the material for injection penetrates the Strobel seam and seals it.

[0147] In the case of clamping, the insole is attached to the underside of the shoe last, and then the shoe upper including the functional laminate is pulled over the last. A permanent connection is made between the shoe upper, the functional laminate and the insole using an adhesive.

[0148] Furthermore, a outsole can also preferably be provided for the sole construction by directly injecting a polymer such as polyurethane, whereby the polymer seals the segment to the sole construction.

[0149] During the injection process, the finished shoe upper including the functional laminate is placed in a sole mold. In this form, a suitable polymer / plastic, usually polyurethane, is injected. The polymer material penetrates the Strobel seam and seals it.

[0150] The present invention will be explained in more detail with reference to the following drawings and examples, although the drawings and examples should not be construed as limiting:

[0151] Figure 1A Schematically shows a cross-section of a mold body with a three-dimensional segment according to the present invention.

[0152] Figure 1B Exemplary photographic image showing a side view of the mold body / last, wherein the three-dimensional segment according to the present invention surrounds the mold body on its vamp side.

[0153] Figure 2 Schematically shows a cross-section of a two-layer functional vamp laminate according to the present invention.

[0154] Figure 3 Schematically shows a cross-section of a three-layer vamp functional laminate according to the present invention.

[0155] Figure 4A Schematic side view sketch showing a last commonly used in the shoe manufacturing industry.

[0156] Figure 4B Schematic top view sketch showing a last commonly used in the shoe manufacturing industry.

[0157] Figure 5 Schematically shows a cross-section of a three-dimensional segment of a functional vamp laminate connected to a sole structure according to the present invention.

[0158] Figure 6 Schematically shows a cross-section of a shoe containing a three-dimensional segment of a functional vamp laminate according to the present invention.

[0159] Figure 1A and 1B in cross-section ( Figure 1A ) or by means of an exemplary photographic illustration ( Figure 1B ) schematically illustrates the result of the deformation of a two-dimensional sheet structure using a mold body 10 or 10a providing the three-dimensional profile of segment 5 or 5a according to the method of the present invention to form a suitable three-dimensional segment 5 or 5a of a functional vamp laminate.

[0160] Figure 2 Schematically shows a cross-section of a section of a three-dimensional segment 20 formed and laminated according to the method of the present invention, which consists of a textile layer sheet 30, an adhesive layer 40, and a waterproof and moisture-permeable functional layer 50. In an advantageous embodiment, the functional layer 50 is made of polyether ester (PEEST), such as a film. In a preferred embodiment, the adhesive layer 40 can also be a non-woven fabric containing fibers or filaments with an adhesive. The segment in this embodiment can thus also be regarded as a three-layer functional vamp laminate.

[0161] As an example,Figure 3 Schematically shows a cross-section of a part of a three-dimensional segment 60 deformed and laminated according to the method of the present invention, which is composed of a first textile layer 30, a first adhesive layer 40, a waterproof and moisture-permeable functional layer 50, a second adhesive layer 70, and a second textile layer 80. The textile layers 30 and 80 can be the same or different. The same applies to the adhesive layers 40 and 70, regardless of the textile layers. As described for Figure 2 the adhesive layers 40 and 70 can also each be a non-woven fabric composed of fibers or filaments containing an adhesive. The segment in this embodiment can therefore also be regarded as a 5-layer functional shoe upper laminate.

[0162] Figure 4A and 4B Schematically shows an example of a shoe last 85 for replicating a foot contour known to those skilled in the art in a side view and a top view, respectively, which can be used as a mold in the method according to the present invention.

[0163] Figure 5 Schematically shows a three-dimensional segment of a functional shoe upper laminate 90 according to the present invention, which is connected to a sole structure 100 by an adhesive 95a or stitching 95b in an advantageous embodiment.

[0164] Figure 6 Schematically shows a cross-section of a three-dimensional segment of a functional shoe upper laminate 105 according to the present invention in a waterproof and moisture-permeable shoe, which has an outer material 110 (e.g., made of leather), an attached sole structure 115, and a outsole 120. The segment made according to the method of the present invention or the segment 105 according to the present invention replicates the shoe contour in an optimal manner so that there are no gaps or only small gaps between the outer material 110 and the segment 105 containing at least a part of the inner shoe upper. This ensures an optimal fit of the shoe.

[0165] Example 1:

[0166] The stack is composed of a pre-laminate, a thermoplastic adhesive layer, and a lining material. The composition of the pre-laminate is as follows:

[0167] 1. A knitted fabric of 81% by weight of polyethylene terephthalate and 19% by weight of elastic fibers, with a weight of 50 g / m 2 ,

[0168] 2. A reactive moisture-curing polyurethane adhesive applied in a grid pattern and having a weight of approximately 12 g / m 2 ,

[0169] 3. A polyether ester-based film with a film thickness of 10 μm,

[0170] The adhesive layer (adhesive nonwoven fabric) consists of a nonwoven fabric of a thermoplastic adhesive made of polyurethane with a melting range of approximately 115 °C and weighing 20 g / m 2 , and the lining material is a knitted fabric made of polyester weighing 265 g / m 2 .

[0171] The pre-laminate, the adhesive nonwoven fabric, and the lining material are unwound from the reels and placed on a thermoforming machine (Illig) so that the knitted fabric side of the pre-laminate and the lining material face the two infrared heaters of the machine, each set to 175 °C, and the stack is heated here for 16 - 18 seconds. Then, a male mold is used to move an upright shoe last upward through the plane of the stack. The lining material side of the stack faces the shoe last, and the knitted side faces away from the shoe last. After reaching the end position, a vacuum is created between the shoe last and the laminate. Here, the stack is formed into a 3D functional shoe upper laminate, and the pre-laminate and the lining material are connected to each other through the adhesive nonwoven fabric. After a cooling time of approximately 15 seconds, the vacuum is released, the shoe last is moved downward, and the finished 3D functional shoe upper laminate is removed from the machine.

[0172] The finished 3D functional shoe upper laminate has an adhesion of 2.3 N measured according to DIN 53530:1981 - 02 with a specimen width of 25 mm.

[0173] Example 2:

[0174] Repeat Example 1, with the modification that the adhesive nonwoven fabric is now part of the pre-laminate. Thus:

[0175] The stack consists of a pre-laminate and a lining material. The composition of the pre-laminate is:

[0176] 1. A knitted fabric of 81 wt% polyethylene terephthalate and 19 wt% elastane, weighing 50 g / m 2 ,

[0177] 2. A reactive moisture-curing polyurethane adhesive applied in a grid pattern and weighing approximately 12 g / m 2 ,

[0178] 3. A polyether ester-based film with a film thickness of 10 μm,

[0179] 4. A nonwoven fabric of a thermoplastic adhesive made of polyurethane with a melting range of approximately 115 °C and weighing 20 g / m 2 ,

[0180] The lining material is a knitted polyester fabric weighing 265 g / m 2 .

[0181] The pre - laminate and the lining material are unwound from the roll and placed on a thermoforming machine (Illig) such that the knitted fabric side of the pre - laminate faces the two infrared heaters of the machine, each set to 175 °C, and heated here for 16 - 18 seconds. Then, an upright shoe last is moved through the plane of the stack from below by positive mold forming. The lining material side of the stack faces the shoe last, and the knitted side faces away from the shoe last. After reaching the end position, a vacuum is created between the shoe last and the laminate. Here, the stack is formed into a 3D functional shoe upper laminate and the pre - laminate and the lining material are connected to each other by an adhesive non - woven fabric. After a cooling time of about 15 seconds, the vacuum is released, the shoe last is moved downwards and the finished 3D functional shoe upper laminate is removed from the machine.

[0182] The 3D functional shoe upper laminate has an adhesion of 4.0 N measured with a specimen width of 25 mm according to DIN 53530:1981 - 02.

[0183] Example 3:

[0184] Example 1 is repeated, with the modification that the lining material is made of recycled material. Thus:

[0185] The stack contains the pre - laminate from Example 1, the thermoplastic adhesive layer from Example 1, and the lining material, which is a knitted fleece of recycled polyester with a weight of 350 g / m 2 .

[0186] The pre - laminate, the adhesive non - woven fabric, and the lining material are unwound from the roll and placed on a thermoforming machine (Illig) such that the knitted fabric side of the pre - laminate and the lining material face the two infrared heaters of the machine, each set to 165 °C, and heated here for 16 - 18 seconds. Then, an upright shoe last is moved through the plane of the stack from below by positive mold forming. The lining material side of the stack faces the shoe last, and the knitted side faces away from the shoe last. After reaching the end position, a vacuum is created between the shoe last and the laminate. Here, the stack is formed into a 3D functional shoe upper laminate and the pre - laminate and the lining material are connected to each other by an adhesive non - woven fabric. After a cooling time of about 15 seconds, the vacuum is released, the shoe last is moved downwards and the finished 3D functional shoe upper laminate is removed from the machine.

[0187] The finished 3D functional shoe upper laminate has an adhesion of 2.1 N measured with a specimen width of 25 mm according to DIN 53530:1981 - 02.

[0188] Comparative Example 4:

[0189] Example 1 is repeated, with the modification that the adhesive layer is now an adhesive web. Thus:

[0190] The stack is composed of a prepreg from Example 1, a thermoplastic adhesive layer, and a lining material from Example 1. The thermoplastic adhesive layer consists of a web of thermoplastic adhesive, which is made of a polyurethane with a melting range of approximately 110 °C and has a weight of 35 g / m 2 .

[0191] The prepreg, the adhesive web, and the lining material are unwound from the reels and placed on a thermoforming machine (Illig) such that the knitted fabric side of the prepreg and the lining material face the two infrared heaters of the machine, each set to 175 °C, and are heated here for 16 - 18 seconds. Then, a male mold is used to move an upright shoe last upward through the plane of the stack. The lining material side of the stack faces the shoe last, and the knitted side faces away from the shoe last. After reaching the end position, a vacuum is created between the shoe last and the laminate. Here, the stack is formed into a 3D functional shoe upper laminate, and the prepreg and the lining material are connected to each other through the adhesive nonwoven fabric. After a cooling time of approximately 15 seconds, the vacuum is released, the shoe last is moved downward, and the finished 3D functional shoe upper laminate is removed from the machine.

[0192] In the finished 3D functional shoe upper laminate, delamination sometimes occurs within the laminated composite due to the non-uniform distribution of the thermoplastic adhesive. In the area of these points, the adhesion measured according to DIN 53530:1981-02 with a specimen width of 25 mm is < 1.0 N.

[0193] Comparative Example 5:

[0194] Example 1 is repeated, with the modification that the adhesive nonwoven fabric now has a lower melting point. Thus:

[0195] The stack is composed of a prepreg from Example 1, a thermoplastic adhesive layer of a nonwoven fabric of thermoplastic adhesive (adhesive nonwoven fabric), and a lining material from Example 1. The thermoplastic adhesive is made of a polyurethane with a melting range of approximately 50 °C and has a weight of 20 g / m 2 .

[0196] The prepreg, the adhesive nonwoven fabric, and the lining material are unwound from the reels and placed on a thermoforming machine (Illig) such that the knitted fabric side of the prepreg and the lining material face the two infrared heaters of the machine, each set to 140 °C, and are heated here for 16 - 18 seconds. Then, a male mold is used to move an upright shoe last upward through the plane of the stack. The lining material side of the stack faces the shoe last, and the knitted side faces away from the shoe last. After reaching the end position, a vacuum is created between the shoe last and the laminate. Here, the stack is formed into a 3D functional shoe upper laminate, and the prepreg and the lining material are connected to each other through the adhesive nonwoven fabric. After a cooling time of approximately 15 seconds, the vacuum is released, the shoe last is moved downward, and the finished 3D functional shoe upper laminate is removed from the machine.

[0197] In the finished 3D functional shoe upper laminate, delamination sometimes occurs in the laminated composite due to the non-uniform distribution of the thermoplastic adhesive. In the area of these points, the adhesion measured with a specimen width of 25 mm according to DIN 53530: 1981-02 is < 1.0 N.

[0198] The above comparative examples show that simultaneous deformation and lamination during the thermoforming process are crucial for achieving adhesion between the unconnected sheet structures in the functional laminate required according to the present invention.

Claims

1. A method for producing a waterproof and moisture-permeable segment having a three-dimensional contour, said segment being for a shoe upper, clothing or a backpack or for forming thereof, said segment being free of connection points in its surface, and said method comprising the following steps: a. providing a stack of at least one first two-dimensional sheet structure and at least one second two-dimensional sheet structure arranged one above the other, whereby at least two two-dimensional sheet structures contained adjacent to one another in the stack and laid directly on one another are not connected to one another and whereby the first two-dimensional sheet structure forms a waterproof and moisture-permeable functional layer, b. providing a mold having said three-dimensional contour, c. thermoforming at least the stack of the first two-dimensional sheet structure and the second two-dimensional sheet structure with the aid of the mold while heating the stack to a process temperature and simultaneously laminating the two-dimensional sheet structures contained in the stack, such that the adhesion between at least one first two-dimensional sheet structure and at least one second two-dimensional sheet structure arranged one above the other and initially not connected to one another, measured with a specimen width of 25 mm according to DIN 53530:1981-02, is at least 1.0 N, whereby the process temperature should be set to obtain plastic deformation of the stack and lamination for planar connection of the two-dimensional sheet-like structures contained in the stack, thereby forming said segment.

2. The method according to claim 1, wherein at least one two-dimensional sheet structure contains at least one thermoplastic ply or at least a thermoplastic component.

3. The method according to claim 1, wherein thermoforming is assisted by applying a vacuum between the mold and the stack or the deformed stack.

4. The method according to claim 2, wherein thermoforming is assisted by applying a vacuum between the mold and the stack or the deformed stack.

5. The method according to any one of claims 1 to 4, wherein said thermoforming comprises deep drawing with a forming tool, deep drawing with an active medium, deep drawing with an active energy or a combination thereof.

6. The method according to any one of claims 1 to 4, wherein said functional layer comprises a non-porous membrane, a microporous membrane or a combination thereof.

7. The method according to claim 5, wherein said functional layer comprises a non-porous membrane, a microporous membrane or a combination thereof.

8. The method according to claim 6, wherein said functional layer comprises at least one material selected from polyurethane (PU), polyolefin (PO), polyester (PES), polyether ester (PEEST), polyacrylonitrile (PAN), polyamide (PA), polyetherimide (PEI), polytetrafluoroethylene (PTFE), polysulfone (PSU), cellulose acetate (CA) and their block copolymers or random copolymers and / or mixtures thereof.

9. The method according to any one of claims 1 to 4, wherein said stack comprises at least one textile ply.

10. The method according to claim 8, wherein said stack comprises at least one textile ply.

11. The method according to claim 9, wherein said textile ply comprises regions having different properties and / or anisotropic regions.

12. The method according to claim 9, wherein the material of said textile ply is selected from polymers, including polyolefins, polyesters, polyamides, polyurethanes and polyacrylonitriles or combinations thereof.

13. The method according to claim 11, wherein the material of the textile laminate is selected from polymers, including polyolefins, polyesters, polyamides, polyurethanes, and polyacrylonitriles or combinations thereof.

14. The method according to any one of claims 1 to 4, wherein the first two-dimensional sheet structure comprises a functional layer.

15. The method according to claim 12 or 13, wherein the first two-dimensional sheet structure comprises a functional layer.

16. The method according to any one of claims 1 to 4, wherein the first two-dimensional sheet structure is a pre-laminated product comprising a functional layer and at least one additional laminate sheet connected by means of a hot-melt adhesive or a reactive adhesive, and the adhesive is applied continuously or discontinuously to the functional layer and / or the at least one additional laminate sheet.

17. The method according to claim 15, wherein the first two-dimensional sheet structure is a pre-laminated product comprising a functional layer and at least one additional laminate sheet connected by means of a hot-melt adhesive or a reactive adhesive, and the adhesive is applied continuously or discontinuously to the functional layer and / or the at least one additional laminate sheet.

18. The method according to claim 16, wherein the at least one additional laminate sheet is a textile laminate sheet comprising a hot-melt adhesive or a reactive adhesive, whereby the functional layer and the textile laminate sheet are connected to each other in a planar manner.

19. The method according to claim 17, wherein the at least one additional laminate sheet is a textile laminate sheet comprising a hot-melt adhesive or a reactive adhesive, whereby the functional layer and the textile laminate sheet are connected to each other in a planar manner.

20. The method according to any one of claims 1 to 4, wherein the two-dimensional sheet structure has an elongation at break of at least 50% at room temperature in its elongation direction as measured according to DIN EN ISO 13934-1:1999.

21. The method according to claim 19, wherein the two-dimensional sheet structure has an elongation at break of at least 50% at room temperature in its elongation direction as measured according to DIN EN ISO 13934-1:1999.

Images