Application of liquid polymer on sports goods product

Abstract

The invention relates to a method (100) for producing a component (240), preferably for a sporting goods (260), comprising the following steps: (a.) providing (110) a polymer (210); (b.) providing (120) a solvent (220); (c.) mixing (130) the polymer (210) with a solvent (220), thereby producing a liquefied polymer (230); and (d.) curing (170) the liquefied polymer (230), thereby producing the component (240). Other aspects of the invention relate to outsoles and sports shoes obtained by the methods of the invention.

Description

Technical Field

[0001] The invention relates to a method for producing a component, preferably for sports equipment, to an outer sole produced using this method, and to a method for producing a sports shoe having such an outer sole. Background Art

[0002] Manufacturing sporting goods, such as athletic shoes, involves multiple steps and processes. Various production methods are known in the art. For example, in the case of athletic shoes, the first step is to design the outsole, which includes determining its shape, size, tread pattern, and other features. This includes selecting the materials used in production. Today, outsoles are typically made from various types of rubber or synthetic compounds. The choice of material depends on factors such as the desired level of traction, durability, flexibility, weight, and specific performance requirements.

[0003] Outsoles, but also other sporting goods, are typically produced using injection molding. To this end, the material for molding is produced by mixing a selected rubber or synthetic compound with fillers, plasticizers, stabilizers, and colorants known in the art. The prepared material is then injected into a mold cavity using an injection molding machine. After the mold cools to solidify the material, the sole is further processed, for example by cutting the edges. In a further process step, the produced outsole is integrated into the shoe manufacturing process by attaching it to the midsole, upper, or other elements using adhesives, stitching, or other assembly techniques.

[0004] Some prior art documents, such as WO2005090062A1, CN216416187U and WO2019106837A1, relate to sporting goods, such as shoe outsoles manufactured using injection molding.

[0005] A different approach in this context is described in the prior art, particularly in prior art documents IT1402354, CN109228445, and US11278081. IT1402354 describes a method for reinforcing and waterproofing shoes, as well as shoes comprising a coating. CN109228445 discloses a method for producing a dipped sole. US11278081 describes a sole for an article of footwear comprising a continuously distributed component forming a first layer and a second layer.

[0006] However, a common disadvantage of these soles is that the final sole has a specific weight and thickness to provide the desired durability and performance of the shoe, which significantly affects the overall shoe weight. Another common disadvantage of these soles is that they are not sustainable, as the shoe is designed to be discarded after use. In addition, it is not easy to change the material properties during the manufacturing process to adapt the sole to the different requirements of sporting goods. Moreover, the sole is usually produced in several separate steps, which makes the process labor-intensive and inefficient.

[0007] The problem underlying the present invention is therefore to provide an improved method and sporting article that at least partially overcome the above-mentioned drawbacks of the prior art. Summary of the Invention

[0008] The above problems are at least partially solved by a method for producing a component preferably for sporting goods, comprising the following steps:

[0009] a.) providing a polymer; b.) providing a solvent; c.) mixing the polymer with the solvent to produce a liquefied polymer; and d.) solidifying the liquefied polymer to produce a part.

[0010] However, in the aforementioned prior art, components, such as outsoles for sporting goods, are typically produced by, for example, injection molding a first component onto a second component. This method cannot be flexibly adapted to the specific needs of the product. The present invention is based on a different approach, namely, preparing a liquefied polymer by mixing a polymer and a solvent, and applying and curing it onto the sporting goods. In this way, the liquefied polymer can be applied to the sporting goods more precisely and efficiently, because no material waste, such as that generated by cutting off excess material, is generated. Thus, the method according to the present invention provides an improved method for manufacturing components, such as those for sporting goods, by consuming only the required material and avoiding any waste.

[0011] Furthermore, no manual assembly is required and glue-free application can be performed, providing an efficient method with reduced material consumption and therefore lower overall costs, which is suitable for automated processes. Gluing may require complex pre-treatment of the components, and the adhesives used to glue plastic components are often hazardous or harmful to the environment.

[0012] According to this method, components can be provided and cured more than once, which allows strategic production of components with different thicknesses and weights, while significantly improving the performance and durability of sporting goods and maintaining or even increasing their cushioning properties. In this way, the method allows a moldless production method, while being able to flexibly address the different needs and requirements of the product. Therefore, the claimed invention significantly simplifies the overall process of producing components (preferably for sporting goods) and, since worn products can be updated, i.e., the components are re-coated and re-applied, the overall sustainability of the process is enhanced. This significantly helps to extend the life of sporting goods by updating the corresponding components. Finally, this further helps to reduce the total waste generation of consumers. By selecting sustainable starting materials (polymers, solvents) in this method, the components and sporting goods produced are recyclable and produced in a sustainable manner. In addition, the inventors have found that the component can provide a shiny and / or glossy appearance, which is considered to be advantageous from a visual perspective.

[0013] Therefore, the entire process of manufacturing sporting goods using the method of the present invention can be more efficient and sustainable. The method according to the present invention provides the possibility that the curing process provided to different parts of the sporting goods can be easily adjusted, so that the components can be cured on the sporting goods without wasting excessive energy and time. In addition, the method of the present disclosure allows the possibility of creating patterns and designs by using components, the design and shape of which can be varied. For example, the components can be transparent, opaque, single-color or multi-color, and personalized by the consumer.

[0014] A "component" according to the present disclosure is, but is not limited to, a unit or module that performs a specific function within a larger system. Components are, for example, components used in the manufacturing process of sporting goods, such as sole units, midsoles, outsoles, outsole elements, film or foil materials, sole plates, uppers, functional elements.

[0015] According to the present disclosure, "sporting goods" should be understood as (but not limited to) any equipment, equipment or product specifically designed and / or used for sports. Sports goods are, for example, sportswear, sports shoes, sports accessories and / or sports equipment.

[0016] A "polymer" according to the present disclosure is, but is not limited to, a macromolecule based on repeating subunits (monomers) that are bound together and form a network structure. Polymers can be classified as follows: synthetic polymers, natural polymers, biodegradable polymers, composite polymers.

[0017] A "solvent" according to the present disclosure is, but is not limited to, a compound that can dissolve, disperse, or extract other compounds. Solvents can be polar or non-polar. Solvents are typically in liquid form, but can also be gaseous or solid.

[0018] "Mixing" according to the present disclosure is to be understood as, but not limited to, the process of combining one or more substances to produce a mixture of the respective substances.

[0019] "Curing" according to the present disclosure is understood to be, but not limited to, a chemical and / or physical process of a substance that generally promotes the hardening, solidification and / or solidification of the substance. Curing is based on chemical reactions, thermal influences and / or other external or internal factors.

[0020] In some embodiments, the method may further include a deposition step in which the liquefied polymer obtained in the mixing step is deposited onto a second component of the sporting goods, and the liquefied polymer may be a first component of the sporting goods. The deposition step may be before the curing step. According to the present disclosure, "deposition" should be understood as, but not limited to, a process in which one or more elements are applied to one or more other elements. Such an embodiment can significantly simplify the process of producing parts. For example, the liquefied polymer can be deposited with different physical properties before the polymer is cured on the sporting goods, thereby improving the efficiency of the manufacturing process. In addition, these method steps can be performed in one device, or can be performed at different entities to provide a high degree of flexibility and automation in the production process.

[0021] The method may further comprise the step of texturing the liquefied polymer obtained in the mixing step, and this step may be prior to the curing step. "Texturing" or "structuring" according to the present disclosure is to be understood as, but not limited to, a process of manipulating the physical properties of an element by external influences, such as shape, pattern and / or surface. The inventors have found that adding texture and structure can significantly improve the performance and durability of sporting goods because the thickness of the applied layer can be adapted to product requirements, such as weight, wear resistance and design. Texturing can be performed using conventional texturing devices, such as pattern brushes and / or pattern rollers. The choice of texturing device depends on the desired pattern and / or the physical properties of the liquefied polymer.

[0022] In some embodiments, the sporting goods may be athletic shoes. Examples of athletic shoes include soccer shoes, basketball shoes, running shoes, tennis shoes, motorcycle shoes, hiking shoes, and the like. The inventors have discovered that the method of the present invention, when applied to athletic shoes, significantly improves their lifespan and durability, and reduces their overall weight.

[0023] The component can be a sole, preferably an outsole of a sports shoe. In this way, a sole is manufactured by the method of the present disclosure and allows for the same or even more durable properties by using one or more soles and / or outsoles that are lighter and thinner than conventional soles known in the art.

[0024] In some embodiments, the athletic shoe may be a soccer shoe. In this manner, the soccer shoe exhibits enhanced physical properties compared to soccer shoes known in the art. Specifically, the inventors have discovered that following this approach, the soccer shoe is lighter while maintaining the same or even better performance characteristics as conventional soccer shoes.

[0025] In some embodiments, the component may be a stud for an athletic shoe. Besides being lighter while maintaining the same or even better performance characteristics as a conventional athletic shoe with studs, it also allows each stud to be individually recoated and / or updated. The studs can be individually formed and textured to suit the needs of the product and / or the consumer. In this way, each athletic shoe including the studs can be strategically and conceptually designed, providing an improved approach.

[0026] In some embodiments, the liquefied component can be deposited on one or more parts of the athletic shoe. Such parts may include the toe portion, forefoot portion, heel portion, midsole portion, sidewall portion, and / or upper portion. "Liquefied component" should be understood as, but not limited to, a component having semi-solid physical properties and / or comprising the liquefied polymer of the present invention. In this way, the athletic shoe can have separate sole components that can be adapted and reapplied. The liquefied component can be deposited on predetermined portions of the sporting goods. For example, the liquefied component can include different physical properties on each predetermined portion. In this way, the sporting goods can be conceptually adjusted while allowing the overall weight of the sporting goods to be lighter and enhancing their durability and performance characteristics.

[0027] One or more predetermined portions of a sporting good can be determined using a torque map, a wear map, and / or a pressure map. The inventors have discovered that using this approach, components can be applied to defined areas where they are most needed. These predetermined or defined areas can be described, for example, as "areas of highest typical wear." By adjusting the physical properties, particularly the thickness of the liquefied polymer and / or the component, based on the areas derived from the map, the deposition application is adapted to each map. These areas are characterized, for example, by the occurrence of high pressure, adhesion, and / or wear. The liquefied polymer can be applied to the predetermined areas in varying thicknesses and weights to meet wear and adhesion requirements. Furthermore, in this way, the weight reduction, performance, lifespan, and / or durability of the sporting good are enhanced.

[0028] In some embodiments, the liquefied component can be deposited in a pattern on the second component. This method offers the advantage of individualized and adaptable application of the liquefied component, requiring less material and therefore being cost-effective. Furthermore, the liquefied component can provide a shiny and / or glossy appearance. The pattern can include layered and / or linear patterns. In this way, the method can be applied to both linear forms and designs, as well as to large, uniform layered designs. This has the advantage of creating islands with more or less liquefied components, tailored to the individual needs of the product and / or the consumer.

[0029] The first component can be deposited on the second component with a thickness of 1-10 mm, preferably 2-4 mm, and most preferably 3 mm. The inventors have found that when components with a specific thickness are applied, the performance of the sporting goods is enhanced compared to commercial components, and the same or even enhanced durability results are achieved.

[0030] The thickness of the first component after the curing step may be 0.3 mm - 0.7 mm, preferably 0.5 mm. A particular thickness of the component has the benefit that the component exhibits the same or even better performance and / or durability characteristics while having reduced weight and thickness.

[0031] In some embodiments, the depositing step can be performed by at least one of the following methods: brushing, coating, dipping, painting, automated dispensing, automated printing, and controlled dispensing. The inventors have discovered that these specific deposition methods represent optimal ways to deposit the liquefied polymer. The choice of deposition method depends on the characteristics of the liquefied polymer and the second component of the sporting article.

[0032] In some embodiments, the second component can be produced by 3D printing, preferably the midsole and / or upper, and / or portions thereof. A liquefied polymer can then be applied to the second component, preferably the outsole. 3D printing includes additive manufacturing methods such as stereolithography and laser sintering. With stereolithography, light causes chemical monomers and oligomers to crosslink together to form the layered polymers that make up the 3D-printed object. With laser sintering, heat from a laser causes powdered material to sinter. The laser is aimed at points in the space defined by the 3D model, binding the materials together to create a solid structure. Another example of an additive manufacturing method is fused deposition modeling, in which parts are produced by extruding small beads or streams of material that immediately harden to form layers. If both the midsole and upper are manufactured using a 3D printing process, the midsole and upper can be produced in separate 3D printing processes and subsequently joined, for example, by gluing, welding, or stitching. Alternatively, the midsole and upper can be manufactured together in a single manufacturing step.

[0033] In another embodiment, the second component is a midsole made of a polymer material, and a liquefied polymer is applied to the midsole to form the outsole. In this embodiment, the polymer material can be ethylene vinyl acetate (EVA), thermoplastic polyurethane (TPU), or supercritical foam. These materials provide good cushioning properties while being relatively lightweight.

[0034] In some embodiments, the liquefied polymer can be deposited in the first part of the sporting article at a dynamic viscosity of 30,000 to 50,000 mPa·s; and in the second part of the sporting article at a dynamic viscosity of 10,000 to 30,000 mPa·s. Different viscosities can be achieved by varying the solvent and polymer mixing ratio. In this way, materials of varying viscosities can be deposited on the second part using a single process step. This method allows for flexible adaptation of the process steps based on product needs.

[0035] The first portion may be the outer edge of the second portion of the sporting article.This feature allows a pattern to be quickly and easily deposited onto the second component using only one operating step for deposition onto the sporting article.

[0036] In some embodiments, the contact angle θ between the liquefied polymer and the second component is 30° to 110°, preferably 40° to 90°, more preferably 50° to 70°. The inventors have discovered that these wettability characteristics represent an optimal way to deposit the liquefied polymer onto the second component.

[0037] The curing step may be performed using radiation. Thus, the liquefied component deposited on the second component is cured on the second component while simultaneously removing the solvent and drying the deposited liquefied component.

[0038] In some embodiments, the polymer can be selected from the group consisting of polyurethane (PU), thermoplastic polyamide (TPE-A or TPA), thermoplastic polyester (TPE-E or TPE), thermoplastic styrene block copolymer (TPE-S or TPS), thermoplastic polyurethane (TPE-U or TPU), thermoplastic vulcanizate (TPE-V or TPV), rubber or ethylene-vinyl copolymer (EVA), preferably thermoplastic polyurethane (TPE-U or TPU), and / or combinations thereof. The inventors have found that the use of these polymers allows for a time-efficient and sustainable process in the production of components. Suitable polymer materials can be elastic foam materials, such as thermoplastic elastomers and / or elastomers. Preferred materials used in the present disclosure are thermoplastic elastomers. More preferred materials used in the present disclosure are urethane-based thermoplastic elastomers (TPU), polyester-based thermoplastic elastomers (TPE) and / or polyamide-based thermoplastic elastomers (TPA).

[0039] In some embodiments, the solvent is a mixture selected from the group of solvent-based and / or aqueous solvents, preferably selected from the group of solvent-based solvents, more preferably selected from the group of (C1-C6)ethers, (C1-C6) 10 ) esters, (C1-C8) ketones, (C1-C8) alkanes and / or combinations thereof. These solvents have shown the best compatibility with the production process of the component while allowing the physical properties of the polymer to be flexibly adapted to the requirements of the product and process.

[0040] The solvent may be a mixture of one or more of tetrahydrofuran (THF), methyl ethyl ketone (MEK), cyclohexane (CYC), ethyl acetate, butyl acetate, preferably THF and / or CYC. These solvents have the advantage that they can be removed in a time-efficient manner during the curing process and allow a production process that can be adapted to the various physical properties of the liquid polymer.

[0041] The ratio of the mixture can be in the range of 10 vol% to 90 vol%, preferably 20 vol% to 80 vol%, more preferably 30 vol% to 70 vol%. In some embodiments, the ratio of the mixture can be in the range of 10 wt% to 90 wt%, preferably 20 wt% to 80 wt%, more preferably 30 wt% to 70 wt%. The inventors have found that the ratio of the solvent mixture shows the best compatibility for both mixing polymers and changing / adjusting the physical properties of the liquefied polymer to meet the specific requirements of the product and process.

[0042] In some embodiments, the liquefied component may have a dynamic viscosity of 10,000 to 50,000 mPa·s, preferably 20,000 to 40,000 mPa·s. Using a liquid polymer with a specific dynamic viscosity allows it to be used in automated and / or manual deposition methods.

[0043] The polymer is characterized by a Shore A value and / or a Shore D value, wherein the Shore A value is in the range of 20 to 120, preferably 40 to 100, more preferably 60 to 80; and the Shore D value is in the range of 2 to 80, preferably 5 to 75, more preferably 8 to 70. The use of polymers having these Shore A and / or Shore D values ​​ensures durable performance of the final part. Suitable polymer materials are elastic foam materials, such as thermoplastic elastomers (TPEs) and / or elastomers.

[0044] The ratio of polymer to solvent in the mixing step may be in the range of 2:98 to 40:60 vol%, preferably in the range of 5:95 to 30:70 vol%, more preferably in the range of 10:90 to 20:80 vol%. The inventors have found that a specific ratio of solvent to polymer allows for convenient use during the deposition process and flexibility in adapting to product and / or process requirements.

[0045] In some embodiments, the liquefied polymer may further comprise pigments and / or fibers. This allows for increased stiffness and durability in selected areas of application. "Fiber" is understood to include, but is not limited to, threads or filaments based on natural and / or synthetic materials.

[0046] The liquefied polymer may further include particles. In this manner, the particles can enhance traction and grip in selected areas of the sporting article. "Particles" should be understood as, but not limited to, particles of varying sizes and shapes, which may possess specific physical properties based on natural and / or synthetic materials.

[0047] In some embodiments, the curing step may have a curing temperature of 20° C. to 150° C., preferably 30° C. to 100° C., more preferably 40° C. to 50° C., and a curing time of 2 minutes to 750 minutes, preferably 5 minutes to 390 minutes, more preferably 10 minutes to 30 minutes. The inventors have discovered that these curing conditions allow for a cost- and energy-efficient method for producing parts.

[0048] In another aspect, the present invention relates to a method for manufacturing a sports shoe, comprising the method of the present disclosure, wherein the first component is an outer sole of the sports shoe and the second component is a midsole of the sports shoe. The advantage of the method for manufacturing a sports shoe is that it avoids depositing the outer sole onto the midsole of the sports shoe, for example based on glue and injection molding.

[0049] In another aspect, the present invention relates to an outsole manufactured according to the method of the present disclosure. The inventors have found that this component can be particularly useful for manufacturing lighter and thinner outsoles while still allowing the same and / or even enhanced performance and durability.

[0050] The outsole can have a pattern. In this way, the outsole can be individually designed according to the needs and requirements of the product and / or the consumer.

[0051] In another aspect, the present invention relates to an athletic shoe comprising an outsole according to the present disclosure. The inventors have discovered that an athletic shoe comprising an outsole according to the present disclosure is lighter and thinner, making the overall athletic shoe more desirable. Furthermore, the athletic shoe exhibits the same and / or even enhanced durability and performance characteristics as athletic shoes known in the art.

[0052] The outsole can be arranged at least in the toe portion, the midfoot portion and / or the heel portion of the sports shoe. This has the benefit that the outsole can be placed in a specific portion of the sports shoe, thereby allowing weight reduction and material and cost savings.

[0053] In another aspect, the present invention relates to an athletic shoe comprising a first component and a second component, wherein the first component is manufactured according to the method of the present disclosure, and wherein the first component is disposed on an upper of the athletic shoe. The inventors have discovered that an athletic shoe comprising the components according to the present disclosure is lighter and thinner, making the overall athletic shoe more desirable, while exhibiting the same and / or even enhanced durability and performance characteristics as athletic shoes known in the art. BRIEF DESCRIPTION OF THE DRAWINGS

[0054] The following is a further detailed description of possible embodiments of the present invention with reference to the accompanying drawings:

[0055] Figure 1 : A flow chart illustrating an exemplary method for producing a component preferably for use in sporting goods.

[0056] Figure 2 : shows an exemplary sports shoe including components according to the present invention.

[0057] Figure 3 and 4 : Two exemplary embodiments of the component are shown, in particular as a shoe sole.

[0058] Figure 5 and 6 : An exemplary embodiment of the component is shown, in particular as a shoe spike.

[0059] Figure 7 : shows an exemplary embodiment of a sports shoe according to the present invention.

[0060] Figure 8-11 : Illustrative and exemplary areas for depositing liquefied polymer are shown. DETAILED DESCRIPTION

[0061] Below, with particular reference to sporting goods, particularly athletic shoes, possible embodiments and variations of the present invention will be described. However, the concept of the present invention is not limited to these embodiments. The methods described herein can be applied identically or similarly to the manufacture of any general sporting goods, such as sportswear or athletic equipment.

[0062] It should also be noted that various embodiments of the present invention are described in more detail below. However, it is clear to those skilled in the art that the structural possibilities and optional features described with respect to these specific embodiments may be further modified and combined with one another in various ways within the scope of the present invention, and that individual steps or features may be omitted if they appear unnecessary to those skilled in the art. To avoid redundancy, reference is made to the explanations in the previous sections, which also apply to the embodiments described in detail below.

[0063] Figure 1A flow chart showing exemplary method steps of a method 100 for producing a component 240 according to the present invention, preferably for a sporting good 260, is shown. The method 100 begins with a method step 110 of providing a polymer. The polymer is selected from an elastomer and / or a thermoplastic elastomer. Preferred materials among the elastomers are block foams, such as ethylene vinyl acetate (EVA), polyurethane (PU) and / or rubber. Thermoplastic elastomers (TPE) are bead foams, block foams, crosslinked and / or non-crosslinked and are classified using the following groups: TPE-O or TPO; TPE-V or TPV; TPE-U or TPU; TPE-E or TPE or TPC; TPE-S or TPS; TPE-A or TPA. The polymer material selected from TPE-O or TPO is polypropylene (PP), ethylene propylene diene rubber or ethylene propylene diene monomer rubber (EPDM). Preferred polymer materials of TPE-V or TPV are thermoplastic vulcanizates, such as Polymer materials from the TPE-U or TPU group are further classified as ester-based, ether-based or linear UP materials. For example, preferred ester-based TPU materials are Huntsman-H For example, preferred ether-based TPU materials are e.g. 11XX (BASF). Preferred polymer materials of the TPE-E or TPC group are, for example (DuPont), (LG) and / or (DSM). Preferred polymer materials from the TPE-S or TPS group are, for example (BASF). Preferred TPE-A or TPA group polymer materials are from polyether block amides, e.g. and / or The polymer in method step 110 is characterized by its Shore A and / or D value. The Shore A value is in the range of 20 to 120, preferably 40 to 100, more preferably 60 to 80; and the Shore D value is in the range of 2 to 80, preferably 5 to 75, more preferably 8 to 70.

[0064] The second step in the method 100 is the method step 120 of providing a solvent. Suitable solvents are mixtures selected from the group of solvent-based and / or aqueous solvents, preferably selected from the group of solvent-based solvents, more preferably selected from the group of (C1-C6) ethers, (C1-C6) 10The solvent is preferably a mixture of one or more of tetrahydrofuran (THF), methyl ethyl ketone (MEK), cyclohexane (CYC), ethyl acetate, and butyl acetate, preferably THF and / or CYC. The proportion of the solvent mixture is in the range of 10 vol% to 90 vol%, preferably 20 vol% to 80 vol%, and more preferably 30 vol% to 70 vol%.

[0065] In the third method step 130 of method 100, a polymer and a solvent are mixed to produce a liquefied polymer 230. During the mixing step, the polymer to solvent ratio is in the range of 2:98 to 40:60 vol%, preferably in the range of 5:95 to 30:70 vol%, and more preferably in the range of 10:90 to 20:80 vol%. During the mixing step, the polymer to solvent ratio is in the range of 10 wt% to 90 wt%, preferably 20 wt% to 80 wt%, and more preferably 30 wt% to 70 wt%.

[0066] like Figure 1 As shown, method 100 may include optional method steps 150 and 160. These steps precede curing step 170. In method step 150, liquefied polymer 230 is deposited onto second component 250. The liquefied component 230 is deposited onto second component 250 to a thickness of 1-10 mm, preferably 2-4 mm, and most preferably 3 mm. Furthermore, the liquefied component 230 is deposited onto one or more portions of the athletic shoe. These portions include the toe portion, forefoot portion, heel portion, midsole portion, sidewall portion, and / or upper portion. Specifically, the liquefied component 230 is deposited in predetermined locations determined using a torque map, wear map, and / or pressure map, as described in more detail below. The liquefied polymer is deposited in deposition step 150 by at least one of the following methods: brushing, coating, dipping, painting, automated dispensing, automated printing, or controlled dispensing. The second component 250 is preferably deposited by automated printing, wherein the second component is the midsole and / or upper, or portions thereof, preferably both. The second component, which serves as the upper and / or midsole, is deposited in a single process step, preferably by 3D printing. A liquefied polymer is then applied to the second component, which is the outsole 290. The deposition step is preferably automated. The liquefied component 230 used for deposition has a dynamic viscosity of 10,000 to 50,000 mPa·s, preferably 20,000 to 40,000 mPa·s.

[0067] Specifically, to accelerate the deposition process, the outer edges of the target sporting article areas during the deposition step are dispensed using a thinner nozzle and a liquefied polymer with a higher viscosity to create a stronger edge. Secondly, the areas within the edges are dispensed using a wider nozzle and a liquefied polymer with a lower viscosity, resulting in a faster process. Thus, the liquefied polymer is deposited in the first portion of the sporting article at a dynamic viscosity of 30,000 to 50,000 mPa·s; and in the second portion of the sporting article at a dynamic viscosity of 10,000 to 30,000 mPa·s. The second portion is the area located between the first portions. The first portion is the outer edge of the second portion of the sporting article 260.

[0068] In some embodiments, during deposition, the contact angle θ between the liquefied polymer 230 and the second component 250 is 30° to 110°, preferably 40° to 90°, and more preferably 50° to 70°. Preferably, the deposition is an automated deposition process. In some embodiments, the liquefied polymer includes particles. In addition, it may further include pigments and / or fibers. In some embodiments, as Figure 2 and 4 As shown in the embodiment of FIG, the liquefied component 230 is deposited on the second component 250 in a certain pattern. The pattern includes a layered and / or linear pattern.

[0069] After deposition, the liquefied polymer 230 can be textured in an optional method step 160. Texture is added to the deposited liquefied polymer 230 using texturing devices known in the art, such as patterning brushes and / or patterning rollers. Texture and structure can also be added by embossing a pattern in the deposited semi-dried liquefied polymer 230 with a patterning device.

[0070] In the last method step 170 of method 100, the liquefied polymer is cured. In this way, the liquefied polymer 230 that can be deposited on the second part 250 in some embodiments is cured, and the solvent present in the liquefied polymer 230 is removed. The solvent can be removed by condensation and the condensate can be recycled. The curing temperature in the curing step 170 is between 20°C and 150°C, preferably between 30°C and 100°C, more preferably between 40°C and 50°C, and the curing time is between 2 minutes and 750 minutes, preferably between 5 minutes and 390 minutes, more preferably between 10 minutes and 30 minutes. In some embodiments, the curing step 170 is carried out using radiation. Curing 170 is preferably carried out using infrared radiation (IR). However, other types of radiation are also suitable. The thickness of the part 240 after the curing step is 0.3 mm-0.7 mm, preferably 0.5 mm.

[0071] In some embodiments, in part by Figure 1The sports article 260 obtained by the method 100 shown in FIG. 2 is a sports shoe 260. Specifically, the component 240 is a sole, preferably an outer sole of a sports shoe. In addition, the sports shoe partially obtained by the method 100 is a football shoe. Here, the component is a spike of the sports shoe. The sports shoe 260 may include at least two components, a first component and a second component. The first component is a Figure 1 The second component is the midsole 350 of the sports shoe 260.

[0072] Figure 2 The sporting goods 260 described in FIG. 2 are sports shoes 260 . Figure 2 An exemplary outsole of a sports shoe 260 manufactured by a method according to the present invention according to certain aspects of the present invention is shown. For a better understanding of the present invention, three different views of the sports shoe 260 are shown, namely two side views (left and right views) and a view from below (center view). Figure 2 , it is shown that component 240 is the outsole 290 of sporting goods 260. Figure 1 The depicted method 100 manufactures a component 240 , namely an outsole 290 of a shoe.

[0073] Back to Figure 2 , the liquefied polymer 230 is deposited onto the second component 250 along a continuous distribution path. Thus, the outsole 290 comprises a linear arrangement. The liquefied polymer 230 is deposited onto the second component 250. Figure 2 In the embodiment, the second part is not directly connected to the upper. It is conceivable that the second part 250 on which the liquefied polymer 230 is deposited is directly connected to the upper. During the deposition of the liquefied polymer 230, a fine nozzle is used to obtain a Figure 2 , which follows the path indicated by the black line. In this way, the outsole 290 obtains Figure 2 The pattern 300 is visible in the outer sole 290, wherein the white areas do not carry any liquefied polymer.

[0074] exist Figure 2 In the embodiment of the present invention, the outsole 290 is made of a different material than the midsole. However, it is conceivable that the midsole and outsole have the same material and / or shape. In some embodiments, the midsole and upper are produced using the above-described method. In this manner, the entire athletic shoe 260 is produced using the method according to the present invention. In some embodiments, the outsole 290 according to various aspects of the present invention is attached to the midsole, which is produced in a single step along with the upper. Here, the deposition is performed using 3D printing.

[0075] Back to Figure 2 , the outsole 290 has a pattern 300. Figure 2As can be seen in FIG, the deposited component 240 has a linear pattern. The sports shoe 260 can be manufactured by using the above-described method for manufacturing the component 240 according to the present invention, which is thus arranged on the midsole 350 of the sports shoe 260. Figure 2 As shown, the outsole 290 is disposed in the toe portion 10, the midfoot portion, and the heel portion 20 of the athletic shoe.

[0076] exist Figure 3 , an exemplary embodiment of an outsole is shown. Figure 3 As can be seen in the figure, the outsole 290 has a layered pattern 300. In addition, the outsole 290 provides a shiny and glossy appearance. Figure 3 The outsole 290 in the shoe has two different colors, namely a dark color in the midfoot portion and the forefoot portion and a light color in the heel portion. It is conceivable that the outsole 290 includes only one color or more than two colors. In addition, as Figure 3 As can be seen in the figure, the outsole 290 is arranged in three sections, namely, one larger layered section located on the midfoot portion and the forefoot portion and two smaller layered sections located on the heel portion.

[0077] To obtain this pattern or appearance, the polymer is mixed with a solvent and a liquefied polymer 230 is obtained, which is deposited in a uniform manner on the second part 250 , ie the midsole.

[0078] The liquefied component 230 is deposited onto one or more different parts of the sporting article 260, such as the toe portion, forefoot portion, heel portion, midsole portion, sidewall portion, and / or upper portion. The liquefied polymer is deposited by at least one of the following methods: brushing, coating, dipping, painting, automated dispensing, automated printing, or controlled dispensing. The preferred deposition method is automated. In some embodiments, the second component 250 is the midsole and / or upper, or portions thereof, preferably both, and the second component can be manufactured using a 3D printing process. 3D printing includes additive manufacturing methods such as stereolithography and laser sintering. Using stereolithography, light causes chemical monomers and oligomers to crosslink together to form the layered polymers that make up the 3D printed object. Using laser sintering, a laser causes powdered material to sinter due to heat. The laser is aimed at a point in the space defined by the 3D model, bonding the materials together to create a solid structure. Another example of an additive manufacturing method is fused deposition modeling, in which parts are produced by extruding small beads or streams of material that immediately harden to form layers.

[0079] In a subsequent step, the liquefied polymer 230 used to produce the outsole 290 is applied to the 3D printed midsole and / or upper. If both the midsole and the upper are manufactured using a 3D printing process, the midsole and the upper can be manufactured in separate 3D printing processes and then connected, for example, by gluing, welding, stitching, etc. Alternatively, the midsole and upper can be manufactured together in a single manufacturing step.

[0080] exist Figure 3 In the embodiment of the present invention, the second component is a midsole made of a polymer material, and the liquefied polymer is applied to the midsole to form the outsole 290. In this embodiment, the polymer material can be ethylene vinyl acetate (EVA), thermoplastic polyurethane (TPU) or supercritical foam.

[0081] exist Figure 4 In the embodiment of the present invention, the outsole 290 has a linear pattern 300. To achieve this pattern, the liquefied polymer 230 is deposited in a continuous dispensing mode. The linear pattern is characterized in that it comprises a uniform width, which is achieved by using a dispenser nozzle to produce a uniform discharge during deposition. In this way, the liquefied polymer 230 is dispensed without interrupting the deposition process. Preferably, the liquefied polymer 230 has constant physical properties throughout the deposition process. The outsole 290 is formed according to Figure 1 The thickness of the component 240 after curing is 0.3 mm to 0.7 mm, preferably 0.5 mm.

[0082] Also in Figure 3 In the embodiment of the present invention, the second component is a midsole made of a polymer material, and the liquefied polymer is applied to the midsole to form the outsole 290. In this embodiment, the polymer material can be ethylene vinyl acetate (EVA), thermoplastic polyurethane (TPU) or supercritical foam.

[0083] exist Figure 5 and 6 In the embodiment, the component 240 produced according to the method of the present invention as described above is used as a spike 285 of a sports shoe 275. Figure 5 and 6 As shown, the studs 285 are arranged on the sole of the soccer shoe 275. Figure 5 In some embodiments, the studs 285 have a different shape and appearance than the sole of the soccer shoe 275. In some embodiments, the studs 285 and the sole of the soccer shoe 275 are produced in separate steps, for example, the studs and the sole are produced separately according to aspects of the present invention, and the studs 285 are subsequently deposited onto the sole. In this context, the studs 285 are made of a different material than the sole. In some embodiments, the sole of the athletic shoe 275 and the studs 285 are made of the same material. Figure 6 In more detail, Figure 6The shoe spikes 285 and the shoe sole are manufactured in a one-step process according to the method of the present invention.

[0084] In some embodiments, components 240 produced according to aspects of the present invention are used in transition areas of sporting goods 260. Figure 7 Component 240 is used in more than one part of sporting article 260. Figure 7 As shown, the sports shoe 260 includes an outsole 290 and a midsole 350, wherein the component 240 is arranged on two shoe elements, namely, on the sole 280 (i.e., on the midsole and outsole 290 of the sports shoe 260) and on the upper. In order to obtain this pattern, the liquefied polymer 230 is additionally deposited on the midsole 350 and the upper. Figure 7 In the embodiment of the present invention, the midsole 350 and the outsole 290 have the same shape and / or material. However, in some embodiments, the midsole 350 and the outsole 290 may also include different patterns 300 and / or materials. In this case, the liquefied polymer 230 is textured after deposition. Texture is added to the deposited liquefied polymer 230 using a known texturing device, such as a patterning brush and / or a patterning roller. Texture and structure can also be added by pressing a pattern into the deposited semi-dried liquefied polymer 230 using a patterning device. In addition, the component 240 is deposited in the transition zone of the outsole 290, and particularly in the heel portion 20 of the outsole 290. Using this method, the component 240 can be arranged to create the pattern 300 on multiple parts of the sporting article 260.

[0085] As discussed from the outset of this disclosure, the liquefied component can be deposited on a predetermined portion of the sporting article 260 using a torque map, a wear map, and / or a pressure map, such as Figures 8 to 11 In this manner, liquefied polymer 230 is applied to the area where maximum wear, traction, or torque is measured.

[0086] exist Figure 8In a method of measuring the wear pattern of a shoe sole 280 according to various aspects of the present invention, predetermined areas of the shoe sole 280 are measured using a wear pattern. Preferably, the wear pattern is used to determine the areas of the outsole 290 to which the liquefied polymer, as described herein, is applied. In this manner, the liquefied polymer 230 is applied to, for example, the sidewalls, toe box 10, and heel counter 20. The midfoot region 15 having the liquefied polymer 230 can be omitted. However, in some embodiments, the liquefied polymer 230 is also applied to the midfoot region 15. Using this method, the liquefied polymer 230 can be applied to predetermined areas with varying physical properties (e.g., thickness, weight, color, and / or viscosity). This allows each measurement area with its specific needs to be individually addressed during the deposition of the liquefied polymer 230 onto the second component 250 (e.g., midsole, upper, etc.). This method can be used, for example, to enhance the durability of sporting goods based on the varying traction, wear, and / or pressures applied to the goods during use. In some embodiments, the liquefied polymer 230 is deposited using a mask. In this manner, liquefied polymer 230 is deposited on the sporting article in desired areas and / or patterns.

[0087] It should be noted that the wear maps, traction maps, and / or pressure maps vary based on the sporting item and, in addition, based on the type of sport in which the sporting item may be used (e.g., basketball, football, tennis, etc.). For example, the sole, preferably the outsole, of a basketball shoe may be reinforced by applying component 240 to one or more areas where the greatest lateral traction is recorded. Similarly, component 240 is preferably applied to the sidewall areas of the sole of a tennis shoe to support these areas that exhibit the greatest traction and / or wear.

[0088] Now see Figure 9 , showing two maps of an outsole 290 including predetermined areas according to various aspects of the present invention. These predetermined areas are determined / measured using traction maps, wear maps, and / or pressure maps. In the first map (top), the outsole 290 specifically includes a thicker layer of component 240 in the "midfoot to forefoot" heel area. The thickness of component 240 arranged at the edges can vary compared to component 240 arranged in the middle area. In addition, the adjacent areas exactly surrounding these thicker areas can also include components 240 in layered form with different thicknesses. The edges of the "thickest" area and the "adjacent" areas can further vary, i.e., include components 240 of different thicknesses. The remaining areas can include thinner layers or layers that do not include component 240.

[0089] In the second diagram (below), the outsole 290 specifically includes thicker layers of component 240 in the "heel to sidewall" area and on the "midfoot to sidewall" area. As in the upper diagram, the thickness of the deposited component 240 can vary at the edges and in the middle areas. In addition, the adjacent areas surrounding these thicker areas can also include component 240 in layered form with different thicknesses. The edges of the "thickest" area and the "adjacent" areas can further include component 240 with a different thickness. The remaining areas can include thinner layers or layers that do not include component 240. Thus, component 240 reduces the overall weight of the outsole and the sporting article while increasing the durability of the sporting article.

[0090] Figure 10 An exemplary traction map for determining predetermined areas of an outsole 290 according to aspects of the present invention is shown. Using this method, component 240, particularly liquefied polymer 230, is applied to different areas of a second component 250, such as the toe box 10, the midfoot area 15, and / or the heel area 20, at different thicknesses and viscosities. These predetermined areas may be different from the areas measured by another map, such as Figure 11 Pressure diagram shown.

[0091] exist Figure 11 , an exemplary pressure map is shown that may be used to determine a predetermined area of ​​an outsole 290 according to aspects of the present invention. Figure 11 As shown, the figure is self-explanatory, with heel portion 20 exhibiting increased pressure compared to midfoot portion 15. This difference can be addressed by applying component 240 in these "high pressure" areas, i.e., depositing a thicker layer of liquefied polymer on these "high pressure" areas.

[0092] It is worth noting that the above embodiments and / or examples may be combined with further aspects described herein, and details of the embodiments and / or examples may be omitted, as understood by those skilled in the art. The scope of protection is determined by the claims and is not limited to the embodiments and / or examples disclosed in the above drawings.

Claims

1. A method (100) for producing a component (240), preferably for a sporting good (260), comprising the following steps: a. providing (110) a polymer (210); b. providing (120) a solvent (220); c. mixing (130) the polymer (210) with the solvent (220) to produce a liquefied polymer (230); as well as d. Curing (170) the liquefied polymer (230) to produce the component (240).

2. The method (100) according to the preceding claim, wherein: The component is a first component of the sporting good, and the method further comprises a step of depositing (150) the liquefied polymer (230) obtained in the mixing step (130) onto a second component (250) of the sporting good (260), wherein the depositing step (150) precedes the curing step (170).

3. The method (100) according to the preceding claim, further comprising a step of texturing (160) the liquefied polymer (230) obtained in the mixing step (130), wherein the texturing step (160) precedes the curing step (170).

4. The method (100) according to any one of the preceding claims, wherein: The sporting goods (260) are sports shoes (270).

5. The method (100) according to the preceding claim, wherein: The component (240) is a sole (280), preferably an outer sole (290) of the sports shoe (270).

6. The method (100) according to any one of claims 4-5, wherein: The sports shoe (270) is a soccer shoe (275).

7. The method (100) according to any one of claims 4 to 6, wherein: The component (240) is a spike (285) of the sports shoe (270).

8. The method (100) according to any one of claims 4 to 7, wherein: The liquefied component (230) is deposited on one or more portions of the athletic shoe (270), including a toe portion, a forefoot portion, a heel portion, a midsole portion, a sidewall portion, and / or an upper portion.

9. The method (100) according to any one of claims 2 to 8, wherein: The liquefiable component (230) is deposited on one or more predetermined portions of the sporting good (260).

10. The method (100) according to the preceding claim, wherein: One or more predetermined portions of the sporting article (260) are identified using the torque map, the wear map, and / or the pressure map.

11. The method (100) according to any one of claims 2 to 10, wherein: A liquefied component (230) is deposited on the second component in a pattern (300).

12. The method (100) according to the preceding claim, wherein: The pattern (300) includes layered and / or linear patterns.

13. The method (100) according to any one of claims 2 to 12, wherein: The first component (240) is deposited on the second component with a thickness of 1-10 mm, preferably 2 mm-4 mm, most preferably 3 mm.

14. The method (100) according to any one of claims 2 to 13, wherein: After the curing step, the thickness of the first component (240) is 0.3 mm to 0.7 mm, preferably 0.5 mm.

15. The method (100) according to any one of claims 2 to 14, wherein: The depositing step (150) is performed by at least one of the following methods: brushing, coating, dipping, painting, automatic dispensing, automatic printing, controlled dispensing.

16. The method (100) according to any one of claims 2 to 15, wherein: The second component (250) is produced via 3D printing, wherein, preferably, the second component (250) is a midsole and / or an upper and / or a part thereof.

17. The method (100) according to any one of claims 2 to 16, wherein: The liquefied polymer (230) is deposited in a first portion of the sporting article (260) with a dynamic viscosity of 30,000 to 50,000 mPa·s; and is deposited in a second portion of the sporting article (260) with a dynamic viscosity of 10,000 to 30,000 mPa·s.

18. The method (100) according to the preceding claim, wherein: The first portion is an outer edge of a second portion of the sporting article (260).

19. The method (100) according to any one of claims 2 to 18, wherein: The contact angle θ between the liquefied polymer (230) and the second component (250) is 30° to 110°, preferably 40° to 90°, and more preferably 50° to 70°.

20. The method (100) according to any one of the preceding claims, wherein: The curing step (170) is performed using radiation.

21. The method (100) according to any one of the preceding claims, wherein: The polymer (210) is selected from the group consisting of polyurethane (PU), thermoplastic polyamide (TPE-A or TPA), thermoplastic polyester (TPE-E or TPE), thermoplastic styrene block copolymer (TPE-S or TPS), thermoplastic polyurethane (TPE-U or TPU), thermoplastic vulcanizate (TPE-V or TPV), rubber or ethylene-vinyl copolymer (EVA), preferably thermoplastic polyurethane (TPE-U or TPU), and / or combinations thereof.

22. The method (100) according to any one of the preceding claims, wherein: The solvent (220) is a mixture (225) selected from the group of solvent-based and / or aqueous solvents, preferably selected from the group of solvent-based solvents, more preferably selected from (C1-C6) ethers, (C1-C 10 )esters, (C1-C8)ketones, (C1-C8)alkanes and / or combinations thereof.

23. The method (100) according to the preceding claim, wherein: The solvent (220) is a mixture (225) of one or more of tetrahydrofuran (THF), methyl ethyl ketone (MEK), cyclohexane (CYC), ethyl acetate, and butyl acetate, preferably THF and / or CYC.

24. The method (100) according to the preceding claim, wherein: The ratio of the mixture (225) is in the range of 10 vol% to 90 vol%, preferably in the range of 20 vol% to 80 vol%, and more preferably in the range of 30 vol% to 70 vol%.

25. The method (100) according to the preceding claim, wherein: The ratio of the mixture (225) is in the range of 10 wt% to 90 wt%, preferably in the range of 20 wt% to 80 wt%, and more preferably in the range of 30 wt% to 70 wt%.

26. The method (100) according to any one of the preceding claims, wherein: The liquefied component (230) has a dynamic viscosity of 10,000 to 50,000 mPa·s, preferably 20,000 to 40,000 mPa·s.

27. The method (100) according to any one of the preceding claims, wherein: The polymer (210) is characterized by a Shore A value (190) and / or a Shore D value (195), wherein the Shore A value (190) is in the range of 20 to 120, preferably 40 to 100, more preferably 60 to 80; the Shore D value (195) is in the range of 2 to 80, preferably 5 to 75, more preferably 8 to 70.

28. The method (100) according to any one of the preceding claims, wherein: In the mixing step (130), the ratio of the polymer (210) to the solvent (220) is in the range of 2:98 to 40:60 vol%, preferably, in the range of 5:95 to 30:70 vol%, and more preferably, in the range of 10:90 to 20:80 vol%.

29. The method (100) according to any one of the preceding claims, wherein: The liquefied polymer (230) may also contain pigments and / or fibers.

30. The method (100) according to any one of the preceding claims, wherein: The liquefied polymer (230) also includes particles.

31. The method (100) according to any one of the preceding claims, wherein: In the curing step (170), a curing temperature of 20°C to 150°C, preferably 30°C to 100°C, more preferably 40°C to 50°C is used, and the curing time is 2 minutes to 750 minutes, preferably 5 minutes to 390 minutes, more preferably 10 minutes to 30 minutes.

32. Method (1000) of manufacturing a sports shoe (270), comprising the method (100) according to any one of claims 2 to 31, wherein: The first component is an outer sole (290) of the sports shoe (270), and the second component is a midsole (350) of the sports shoe (270).

33. An outsole manufactured according to the method (100) of any of the preceding claims.

34. Outsole according to the preceding claim, wherein: The outsole has a pattern (300).

35. Sports shoe comprising an outsole according to any one of claims 33-34.

36. Sports shoe according to the preceding claim, wherein: The outer sole (290) is arranged at least in the toe portion (10), the midfoot portion (15) and / or the heel portion (20) of the sports shoe.

37. A sports shoe comprising a first component and a second component, wherein: The first component is manufactured according to the method of any one of claims 2 to 32, wherein the first component is arranged on the upper of the sports shoe.

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