Sole component for article of footwear, molded assembly and method of manufacture

Abstract

Embodiments herein disclose a first sole component (10) having a foot-facing surface (11) and a ground-facing surface (12). The first sole part (10) comprises a plurality of through-holes (14), wherein the plurality of through-holes extend in a vertical direction from a foot-facing surface (11) to a ground-facing surface (12). The foot-facing surface (11) is configured to receive an injection sole material for attaching the first sole component to the ground-facing surface (12) of the upper (1).

Description

[0001] This application is a divisional application of invention patent application 202110701996.9, entitled “Sole component, molding assembly and manufacturing method for footwear articles” filed on June 24, 2021. Technical Field

[0002] The present application relates to the field of footwear. The present application relates to a first sole component for a footwear article, the first sole component comprising a plurality of through holes. The present application also relates to a footwear article comprising the first sole component. The present application also relates to a sole molding assembly, comprising a first mold component, the first mold component comprising at least one protrusion configured to cooperate with a plurality of through holes of the first sole component. The present application also relates to a method for molding footwear, wherein the method comprises mounting the first sole component to the first mold component, such that the plurality of protrusions of the first mold component cooperate with the plurality of through holes of the first sole component, and injecting material into the footwear molding assembly, such that the injected material adheres to the first sole component. Background Art

[0003] In shoe production, there are many ways to make a pair of shoes, where the manufacturing method, the choice of materials, the form of the upper, the form and material of the midsole, and the form and shape of the outsole have a great influence on the performance of the shoe. There are many different types of shoes, such as hiking boots, sports shoes, golf shoes, running shoes, where the shoes have different characteristics, such as the stiffness of the upper, the stiffness of the outsole or midsole, where the characteristics of the shoe are controlled by different factors.

[0004] One of the important factors in producing a particular type of shoe that functions in a certain way is the design, shape and stiffness of the sole of the shoe. Traditionally this has been achieved by introducing items such as shanks or embedded reinforcement elements to increase the stiffness of the material in specific areas while maintaining a certain flexibility in other areas, or by applying reinforcements to the outer surface of the sole in order to change the properties of the sole.

[0005] In the direct injection molding technique for shoes, the sole (such as the midsole and / or outsole of the shoe) is injected directly onto the upper of the shoe, wherein a last holds the upper, and a mold having the shape of the sole is introduced onto the upper, and a thermoplastic material is injected directly onto the upper, fixing the midsole and / or outsole to the upper. This means that the outsole is injected directly onto the upper without the need to adhere or otherwise fix the midsole / outsole to the upper.

[0006] In direct injection molding techniques, changing the properties of the sole and / or outsole, or providing a more complex sole and / or outsole, where certain areas may be rigid and other areas flexible, may require multiple different injection molding steps, using multiple different molds to obtain the desired properties. This is both expensive and time consuming for manufacturing purposes.

[0007] US2018 / 0153252 discloses a method of injection molding a sole assembly, wherein the sole assembly can be molded to the upper in different steps. In the first step, the midsole core can be directly injection molded to the bottom of the upper, and in the second step, the outsole can be directly injection molded to the bottom of the midsole and around at least a portion of the midsole core. Such an operation requires at least two rounds of injection molding in a ring molding machine, and requires trimming of the injected material between each direct injection molding operation. Therefore, the machine and labor costs of such production may be relatively high, thereby increasing the manufacturing cost of footwear articles. Summary of the invention

[0008] Therefore, there is a need for a shoe construction and manufacturing technique that mitigates, alleviates or solves existing disadvantages and allows certain properties of the shoe to be obtained by simpler means.

[0009] According to the present specification, a sole molding assembly is provided, comprising: a first sole component having a foot-facing surface and a ground-facing surface, wherein the first sole component comprises a plurality of through-holes, wherein the plurality of through-holes extend in a vertical direction from the foot-facing surface to the ground-facing surface; wherein the foot-facing surface is configured to receive injected sole material for attaching the first sole component to the ground-facing surface of an upper; and a first mold component comprising a plurality of protrusions configured to cooperate with the plurality of through-holes of the first sole component.

[0010] In addition, an article of footwear is disclosed. The article of footwear includes the first sole component disclosed herein.

[0011] Since the first sole component must be durable, to withstand the friction between the surface facing the ground of the first sole component and the ground, the first sole component is usually made of a material with a higher density than, for example, the midsole of a shoe, wherein the increased density may help to improve durability, such as in an example, the first sole component is made of natural rubber or TPU (thermoplastic polyurethane), and the midsole is made of PU (polyurethane). By providing a through hole in the first sole component, the weight of the assembled footwear can be reduced and the user's comfort can be improved. However, this is usually achieved with adhesive shoes, that is, wherein the first component is adhered to the midsole, which is not feasible for directly injection molded footwear, because the injected material will enter the opening, wherein there is no sole material to prevent this situation. However, this has been solved by providing a mold component, which has a mating protrusion that prevents the sole material from entering the opening from the surface facing the foot. In addition, the through hole provided in the first sole component increases the flexibility of the first sole component. Therefore, during use, the first sole component can adapt to the shape of the foot of the user of the footwear, which further increases the comfort of the user of the footwear.

[0012] Traditionally, in the art of direct injection molding, the shoe component to be molded onto the shoe assembly is provided in such a way that the component is a continuous component, wherein the component provides a barrier between the inner surface of the mold and the injected material. The injected material is generally of a type that expands after it has been introduced into the mold, causing the material to expand into any cavity in fluid communication with it, and may also force itself into the area between the component and the mold, thereby producing material that has flowed out of the mold cavity, which must be cut or trimmed from the footwear after molding is completed. Therefore, the trimming operation of the footwear article increases the labor time that needs to be invested during production, which in turn increases the cost of production.

[0013] Providing an injection molded assembly according to the present application means that the weight and / or amount of material used for a shoe component (e.g., a first sole component) can be reduced because the opening in the shoe component reduces the area and / or volume of the material of the shoe component. The protrusion of the first mold component can be configured to block the injected material from entering the opening, so that the protrusion prevents the injected material from seeping out or forcing itself through the opening.

[0014] By providing an injection molded assembly according to the present application, a prefabricated component, such as a first sole component, can be provided in a sole molded assembly, wherein a midsole or injection material can be injected between the first sole component and the upper, thereby allowing the injected material to attach the first sole component to the sole assembly. Thus, the injected material can be a soft material that provides comfort to the footwear assembly, while the first component can be a different material with higher wear resistance, thereby improving the wear resistance of the sole assembly. In addition, the first sole component can have a plurality of through openings while maintaining a ground contact surface, thereby reducing the weight of the wear-resistant material compared to an uninterrupted material.

[0015] In addition, a method for molding footwear is disclosed, wherein the method includes mounting a first sole component as disclosed herein to a sole molding assembly as disclosed herein, such that a plurality of protrusions of the first mold component cooperate with and protrude through a plurality of through holes of the first sole component. The method also includes injecting material into the footwear molding assembly such that the injected material adheres to a foot-facing surface of the first sole component and defines a second sole component of the footwear.

[0016] By providing a first mold part with a plurality of projections, which are configured to cooperate with the through holes of the first sole component, the first sole component can be molded to the footwear article using an injection molding process. During the injection molding process, the injection material fills all cavities inside the footwear molded assembly and will also fill the plurality of through holes of the first sole component. By matching the plurality of projections with the plurality of through holes, the through holes can be closed to prevent the injected material from entering the through holes. Thus, the characteristics of the first sole component, such as light weight and flexibility, can be maintained throughout the injection molding process. Therefore, the footwear article including the first sole component can be manufactured in a single molding step, which is efficient in cost and time.

[0017] According to the present specification, a footwear article is provided, comprising: an upper having a first ground-facing surface; a first sole component having a first foot-facing surface and a second ground-facing surface, the first foot-facing surface comprising a plurality of openings, each opening defining a volume extending in a vertical direction from the foot-facing surface toward the ground-facing surface and having a closed end; and a second sole component having a second foot-facing surface and a third ground-facing surface, wherein the second sole component is arranged between the upper and the first sole component and extends into a plurality of volumes and / or openings in the first foot-facing portion of the first sole component.

[0018] Since the first sole component must be durable in order to withstand the friction between the surface of the first sole component facing the ground and the ground, the first sole component is usually relatively heavy. By providing a plurality of through holes in the first sole component, the weight of the first sole component and the assembled footwear including the first sole component can be reduced, which improves the comfort of the user of the footwear.

[0019] The present application may also relate to a first sole component having a foot-facing surface and a ground-facing surface, wherein the first sole component includes a plurality of through-holes, wherein the plurality of through-holes extend in a vertical direction from the foot-facing surface to the ground-facing surface; wherein the foot-facing surface is configured to receive injected sole material for attaching the first sole component to the ground-facing surface of an upper.

[0020] According to an exemplary embodiment of the present invention, the first sole component can be a prefabricated component. The first sole component can have a surface facing the foot, wherein the surface facing the foot of the first sole component can define a portion of the mold cavity for injecting material, and can optionally define a portion of the mold cavity for injecting material in combination with the first mold component. Therefore, the first mold component can define a first portion of the mold cavity, the first sole component can define a second portion of the mold cavity, and when the first sole component is attached to the first mold component, the first sole component and the first mold component can together define a portion of the mold cavity that is larger than the portion of the mold cavity defined by the first sole component or the first mold component itself.

[0021] The protrusion of the first mold component may be adapted to close the opening of the first sole component such that the first mold component closes the opening and prevents injected material from entering the opening of the first sole component.

[0022] The engagement of the first sole component and the first mold part can thus produce an uninterrupted portion of the mold cavity for the injection material, wherein the interrupted portion (opening) of the first sole component is closed using the protrusion of the first mold part. When the injection material solidifies, the protrusion can be removed from the first sole component, thereby exposing the internal volume of the opening from the ground-facing surface and inwardly toward the solidified injection material. Therefore, after injection molding, each opening can expose the injection material of the sole assembly through the opening, while the material between the openings serves as a wear-resistant part and is in contact with the ground. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The following is a description of exemplary embodiments with reference to the accompanying drawings, in which

[0024] Figure 1 showing a top view of a foot-facing surface of a first sole component,

[0025] Figure 2A-2Cshowing a top view of a foot-facing surface of a first sole component with various arrangements of through holes,

[0026] Figure 3 showing a top view of the foot-facing surface of the first mold part,

[0027] Figure 4A shows a longitudinal section through a first sole component,

[0028] Figure 4B shows a longitudinal cross-section of a first mold part,

[0029] Figure 5 shows a longitudinal cross-sectional view of a first sole component arranged on a first mould part, and

[0030] Figure 6 A longitudinal cross-section of an article of footwear is shown. DETAILED DESCRIPTION

[0031] Various exemplary embodiments and details are described below with reference to the accompanying drawings when relevant. It should be noted that the drawings may or may not be drawn to scale, and that elements of similar structure or function are represented by the same reference numerals throughout the drawings. It should also be noted that the drawings are intended only to facilitate the description of the embodiments. They are not intended to serve as an exhaustive description of the invention or as a limitation on the scope of the invention. In addition, the illustrated embodiments do not need to have all the aspects or advantages shown. An aspect or advantage described in conjunction with a particular embodiment is not necessarily limited to that embodiment, and may be implemented in any other embodiment, even if not so described or not so explicitly described.

[0032] A first sole component is disclosed. The first sole component has a foot-facing surface and a ground-facing surface. The first sole component includes a plurality of through holes. The plurality of through holes extend in a vertical direction from the foot-facing surface to the ground-facing surface. The foot-facing surface of the first sole component is configured to receive an injected sole material for attaching the first sole component to the ground-facing surface of an upper of an article of footwear, such as a shoe.

[0033] The plurality of through holes of the first sole component reduces the weight of the first sole component by removing solid material from the first sole component. Thus, the weight of the first sole component can be reduced compared to the solid first sole component that is usually used for gluing the sole assembly. The through holes of the first sole component further reduce the rigidity of the first sole component, which provides a flexible first sole that can follow the shape of the user's foot during the use of the footwear. By making the first sole component more flexible, the first sole component follows the natural foot movement of the user, which increases the comfort of the user wearing the footwear. Fitness walkers, for example, often need flexible, lightweight and flat shoes because they strike with their heels and turn with each step. By increasing flexibility, the first sole component can follow the natural foot movement, improving the comfort of the footwear user.

[0034] A plurality of through holes can be arranged to extend in the longitudinal direction of the first sole component in parallel rows. The through holes of the parallel rows can be offset relative to each other in the longitudinal direction of the first sole component. Each through hole in the first row of parallel rows can offset half of the longitudinal length of the through hole relative to the through hole in the adjacent second row of parallel rows. In some exemplary embodiments, each through hole can be offset relative to half of the distance between the corresponding center points of two through holes in the same row arranged in the adjacent second row of parallel rows. By offsetting each row of through holes from each other, each row of through holes can be moved closer while keeping a minimum amount of solid material between the holes to ensure the structural rigidity of the first sole component. Making each row of through holes move closer to each other means that more through holes can be assembled on a predetermined area, thereby further reducing the weight of the first sole component. The solid portion of the first sole component also provides a surface where the second sole component (e.g., injection material) can be attached to the first sole component.

[0035] The plurality of through holes of the first sole component may taper toward the foot-facing surface of the first sole component. The taper of the through holes toward the foot-facing surface of the first sole component facilitates mounting or releasing the first sole component to or from the first mold component.

[0036] According to the desired characteristics of the first sole component and / or the footwear article including the first sole component, the through holes can be distributed in different areas of the first sole component. In one or more exemplary embodiments, a plurality of through holes can be distributed in the heel area of ​​the first sole component. Thus, the flexibility of the first sole component in the heel area can be increased. In one or more exemplary embodiments, a plurality of through holes can be distributed in the forefoot area of ​​the first sole component. Thus, the flexibility of the first sole component in the forefoot area can be increased. In one or more exemplary embodiments, a plurality of through holes can be distributed in the midfoot area of ​​the first sole component. Thus, the flexibility of the first sole component in the midfoot area can be increased.

[0037] However, the plurality of through holes may also be distributed over the above one or more regions. In one or more exemplary embodiments, the plurality of through holes may be distributed over the heel region, the midfoot region, and the forefoot region of the first sole component. The plurality of through holes may thus be distributed, for example evenly distributed, from the heel end of the first sole component to the toe end of the first sole component.

[0038] A plurality of through holes can be arranged at a predetermined distance from each other. A plurality of through holes can be evenly distributed on the first sole component so that an open grid is formed on the first sole component. Evenly distributed here means that a plurality of through holes can be separated by a first predetermined distance in the longitudinal direction of the first sole component and / or separated by a second predetermined distance in the transverse direction of the first sole component. A plurality of through holes are separated by a first predetermined distance in the longitudinal direction, meaning that the distance between any two adjacent through holes in the same row is a predetermined first distance. A plurality of through holes are separated by a first predetermined distance in the transverse direction, meaning that the distance between any two adjacent through holes in adjacent rows is a predetermined second distance. The distance can be determined, for example, from the center point of the first through hole to the center point of the second through hole. The first and second predetermined distances can be equal for any adjacent holes. The first and second predetermined distances can be selected so that the through holes are separated by at least 1mm of solid material to ensure the structural rigidity of the first sole component. The first sole component can have a thickness in the range of 0.1 to 0.8cm. Reducing the thickness of the first sole component can reduce the weight of the first sole component and can further increase the flexibility of the first sole component. However, reducing the thickness of the first sole component also reduces the structural integrity of the first sole component. Therefore, the thickness of the first sole component can be selected within a range that meets different requirements for weight, flexibility and structural rigidity according to the type of footwear.

[0039] The plurality of through holes may be elongated and may be arranged on the first sole component such that a longitudinal direction of the through holes extends in a longitudinal direction of the first sole component.

[0040] In one or more example embodiments, a plurality of through holes can be elliptical. Here, the through hole is elliptical, meaning that when viewed in a direction perpendicular to the surface of the first sole component facing the foot and / or the surface facing the ground, the periphery of the through hole is elliptical. The hole with an elliptical shape means that the hole does not have any sharp edges, which removes the stress concentration around the through hole, thereby reducing the risk of cracks around the through hole in the first sole component. Thus, the risk of failure of the first sole component can be reduced. The elliptical shape of the through hole also allows each row of through holes to be positioned closer to each other when each row is offset from each other. Due to the elliptical shape, compared with the through hole of, for example, a rectangular shape, the amount of solid material between two through holes in adjacent rows is increased. Compared with the elliptical shape, the edge of the rectangular shape will cause the through holes in two adjacent rows to be closer to each other. In order to ensure that the first sole component has enough solid material between the through holes, if a rectangular hole is used instead of an elliptical hole, each row will have to be positioned farther from each other. Thus, the oval-shaped through holes allow the rows of through holes to be moved closer to each other, which in turn allows a greater number of through holes to be fitted to the first sole component within a predetermined area. Thus, the oval-shaped through holes allow further weight reduction of the first sole while maintaining the desired structural stability of the first sole component.

[0041] The radius of the through hole may be in the range of 0.2 to 1.2 cm. When the through hole is elliptical, the through hole may have two diameters, a first diameter extending through the shortest portion of the ellipse, which may be referred to as the semi-minor axis, and a second diameter extending through the longest portion of the ellipse, which may be referred to as the semi-major axis. In this case, the first and second radii are different, but both may be in the range of 0.2 cm to 1.2 cm.

[0042] The ratio of the through hole area to the solid area of ​​the first sole component is in the range of 30:70 to 60:40. Solid herein refers to the solid material of the first sole component.

[0043] In one or more embodiments, the first sole component can be an outsole, such as an outsole for an article of footwear. When the first sole component is an outsole, the ground-facing surface of the first sole component is the lowest portion of the article of footwear and therefore will be the ground-contacting surface during use of the article of footwear.

[0044] When the first sole component is an outsole, the material of the first sole component can be provided to be durable and able to withstand contact with the ground. The first sole component can include a thermoplastic polymer, such as thermoplastic rubber (TPR), thermoplastic polyurethane (TPU) or polyurethane (PU) or a combination thereof.

[0045] According to the present application, there is also provided an article of footwear comprising the first sole component as disclosed herein.

[0046] The article of footwear may also include a second sole component having a second surface facing the foot and a second surface facing the ground, and an upper having a third surface facing the ground. The second sole component may be arranged between the upper and the first sole component. The second sole component may include injected material. In some embodiments, the sole assembly of the article of footwear may include one or more additional sole components, such as the third sole component.

[0047] The first sole component can be any kind of sole component that can provide a footwear article with aesthetic appearance and / or functional properties, wherein the second sole component can provide functional properties for the footwear article, such as impact absorption between the surface of the upper facing the ground and the first sole component. The second sole component can provide a material layer between the first sole component and the upper, wherein the second sole component can improve the predefined characteristics of the footwear article, such as the weight and / or softness of the footwear article, and the material of the first sole component provides rigidity for the footwear article. Since the first sole component can be a ground contacting sole component, the first sole component can be provided as a material that is durable and can withstand contact with the ground, wherein the second sole component can be provided as a material that is lighter and / or provides a softer feeling to the footwear article. Therefore, the first sole component and the second sole component can be made of different materials with different properties.

[0048] The second sole component can be considered as a part of the footwear article, wherein the second sole component combines the first sole component to the ground-facing surface of the upper. The first sole component can have a first hardness, and the second sole component can have a second hardness, wherein the first hardness can be greater than the second hardness. The first hardness of the first sole material can be used to improve adhesion by providing an attachment (traction) element on the ground-facing surface of the first sole component, and improve durability by providing the first sole with a material that can withstand the friction between the ground and the ground-facing surface of the first sole component. The second sole component can be provided with a material having a second hardness lower than the first hardness, wherein the second sole component can be positioned between the wearer's foot and the first sole component and the ground when in use. Therefore, a softer material can improve the comfort of the footwear article by providing a shock-absorbing layer that can absorb the impact that occurs during gait.

[0049] In some exemplary embodiments, the second sole component extends from a first ground-facing surface of the upper to a first foot-facing surface of the first sole component, and / or wherein the second sole component defines a second foot-facing surface attached to the first ground-facing surface of the upper and a third ground-facing surface attached to the first foot-facing surface of the first sole component. The second sole component may be adapted to attach the first sole component to the upper, wherein the second sole component extends in a vertical direction between a ground-facing portion of the upper and a first foot-facing surface toward the first sole component. Therefore, the second sole component may be coupled to the first foot-facing surface and the first ground-facing surface. The second sole component may extend from the inner first sole component to the outer side of the first sole component, so that the first sole component is attached to the upper from the inner side and continuously toward the outer side.

[0050] The second sole component may be arranged to extend over the entire length of the sole assembly and / or the article of footwear extending from the toe end to the heel end. The sole assembly may include a first sole component and a second sole component. The second sole component may extend uninterruptedly so that the second sole component may provide shock absorption and / or impact absorption along the entire length of the sole assembly from the heel end toward the toe end. Optionally, the second sole component may extend the entire width of the sole assembly from the toe end toward the sole end, thereby forming a shock absorbing element between the first sole component and the second sole component along the entire width and length of the sole assembly.

[0051] In some exemplary embodiments, a sole for an article of footwear may be a layered structure, wherein a first sole component may be an outsole for the article of footwear, wherein the first sole component may define a portion of the footwear that contacts the ground during normal use.

[0052] In some exemplary embodiments, the sole assembly of the footwear article can be a layered construction, wherein the second sole component can be a midsole for the footwear article. The midsole can be primarily used to absorb shock and / or provide a layer for the footwear article that can cushion the contact between the wearer's foot and the ground.

[0053] By making the first sole component from a durable and strong material, the structural rigidity of the sole assembly including the first sole component and the second sole component can be ensured, while the injected material can be softer than the material of the first sole component, thereby improving the comfort of the footwear article by providing a shock-absorbing layer capable of absorbing impacts occurring during gait.

[0054] Articles of footwear can be manufactured using a direct injection molding apparatus, wherein an upper and a first sole component can be positioned in a molded assembly. The molded assembly may include side components, wherein the side components can form a peripheral portion of the molded assembly. The upper and the first sole component can be positioned at a distance from each other in the molded assembly so that a first volume is formed between the upper, the first sole component, and the side components of the molded assembly. Therefore, the injected material can expand and solidify in the molded assembly so that during the expansion of the injected material, the upper and / or the first sole component remain in their positions so that when the injected material solidifies, the injected material bonds the first sole component to the upper. When the injected material has expanded and solidified, the injected material can form a second sole component.

[0055] Using direct injection molding for forming the second sole component means that the second sole component will adapt to the form of the first sole component and the ground-facing surface of the upper. This means that the injected material will fill all open volumes. That is, the injected material will penetrate and expand into all parts of each open volume. In order to ensure that the injected material does not penetrate and expand into the multiple through holes of the first sole component, the present application also discloses a sole molding assembly for molding footwear including the first sole component as disclosed herein.

[0056] The sole molding assembly includes a first mold part configured to receive a first sole component as disclosed herein. The first mold part includes a plurality of protrusions configured to mate with a plurality of through holes of the first sole component. The first mold part may correspond in size and shape to an outer shape of a ground-facing surface of the first sole component.

[0057] The plurality of projections may correspond, for example, in shape and position to the shape and position of the plurality of through holes of the first sole component. The outer periphery of each of the plurality of projections of the first mold component may be equal to or greater than the inner periphery of the corresponding through hole in the first sole component, so that the injected material is prevented from entering or passing through the through hole during injection molding. The plurality of projections have outer peripheries that are equal to or greater than the inner peripheries of the corresponding through holes in the first sole component, meaning that the plurality of projections will fit tightly or snugly into the plurality of through holes, thereby closing the through holes during the molding process so that the injected material cannot enter the through holes. The molding process may, for example, be an injection molding process.

[0058] The plurality of protrusions may have an elongated shape having a length, eg a longest extension, in the longitudinal direction of the first sole component.

[0059] The height of each of the plurality of protrusions of the first mold part is equal to or higher than the height of the first sole component at the corresponding through hole of the first sole component. When the height of the protrusion is equal to the height of the first sole component at the corresponding through hole, when the first sole component is arranged on the first mold part, a flat surface is formed to receive the injected material. The flat surface can improve the flow of the injected material in the molded assembly, which reduces the possibility of forming air pockets in the injected material, which may cause stress concentration of the injected material. Thus, the risk of the second sole component being damaged during the use of the footwear can be reduced. In addition, by providing a flat surface to receive the injected material, the seam along the surface of the first sole component facing the foot and the injected material (which may be the midsole) can be reduced or completely eliminated. Thus, a seamless construction of the sole assembly can be provided, which eliminates uneven points on the sole, which may cause friction that may be uncomfortable for the user, or may even cause blisters on the user's feet. Thus, the comfort of the user of the footwear can be further improved.

[0060] In one or more exemplary sole molding assemblies, the plurality of protrusions may have a first height that is higher than the height of the first sole component, such that the protrusions protrude above the foot-facing surface of the first sole component. Thus, a recess may be provided in the injected material, such as in the second sole component, which increases the distance from the injected material to the ground when the article of footwear is in use. This may reduce the risk of the injected material being penetrated by external objects on the ground, such as sticks or stones. Objects penetrating the injected material may cause moisture to enter the second sole component, which may cause premature failure of the second sole component, thereby causing potential failure of the article of footwear.

[0061] In one or more exemplary sole molding assemblies, a plurality of protrusions may extend in a vertical direction perpendicular to the main surface of the first mold part, so that when the first sole component is disposed on the first mold part, the plurality of protrusions extend from the surface of the first sole component facing the ground to the surface of the first sole component facing the foot. In one or more exemplary sole molding assemblies, the plurality of protrusions of the first mold part may be tapered, so that the plurality of protrusions are wider toward the main surface of the first mold part and taper toward the top of the protrusions, which are toward the surface of the first sole component facing the foot. The tapered shape of the plurality of protrusions may correspond to the tapered shape of the plurality of through holes of the first sole component. By making the through holes and the protrusions tapered, it is advantageous to release the first sole component from the first mold part after molding. In other words, the tapered shape of the through holes and the protrusions makes it easy to release the first sole component from the first mold part after molding.

[0062] The sole molding assembly may be configured to receive an injected material, wherein the injected material defines a second sole component of the footwear. The footwear molding assembly may be configured to receive the injected material by a direct injection process. To be able to receive and contain the injected material, the sole molding assembly may include a first side frame and / or a second side frame defining at least a portion of one side of the molding assembly.

[0063] In addition, a method for molding footwear is disclosed. The method includes installing a first sole component as disclosed herein into a sole molding assembly as disclosed herein such that a plurality of protrusions of the first mold component cooperate with and protrude through a plurality of through holes of the first sole component. The method also includes injecting material into the footwear molding assembly such that the injected material adheres to a foot-facing surface of the first sole component and defines a second sole component of the footwear.

[0064] In one or more exemplary methods, a method includes injecting a material onto a sole molding assembly, the injected material defining a second sole component of the footwear, the second sole component being configured to be positioned between the first sole component and an upper of the footwear.

[0065] The article of footwear can be manufactured, for example, by prefabricating an upper and a first sole component. The upper can be positioned in the sole molding assembly relative to the first sole component so that a volume, which can also be referred to as a mold cavity, is formed between the surface of the first sole component facing the foot and the upper. The volume can be further closed by one or more side components of the mold assembly, wherein the side components can form the peripheral portion of the mold. The construction of the article of footwear can be completed by injecting the injected material into the volume generated between the upper and the first sole component and filling the volume, thereby producing a second sole component. The second sole component can include a thermoplastic polymer, such as thermoplastic rubber (TPR), thermoplastic polyurethane (TPU) or polyurethane (PU) or a combination thereof. In some exemplary embodiments, the second sole material can be polyurethane foam, which expands into the mold cavity.

[0066] In some exemplary embodiments, the plurality of protrusions of the first mold component and the top surface can define a first mold surface, such as a bottom mold surface of a mold cavity for a second sole component. Thus, the injected material and / or the second sole component can adhere to the foot-facing surface of the first sole component.

[0067] The method for molding footwear may further include, after the injected material has solidified, removing the footwear article from the sole molding assembly such that the first sole component is released from the first mold portion. Thereby, the plurality of through holes are released from the plurality of protrusions of the first mold portion.

[0068] The exemplary embodiments of the first sole component, the footwear molded assembly and the footwear article will be further described in detail with reference to the accompanying drawings. For clarity, the accompanying drawings are schematic and simplified, and they only show details that help understand the present application, and other details have been omitted. Throughout the text, the same reference numerals are used for the same or corresponding parts.

[0069] Figure 1 1 shows a top view of a first sole component 10 in the direction of a foot-facing surface 11 according to one or more exemplary embodiments herein. The first sole component 10 includes a toe end 2 and a heel end 3, which are adapted to surround the periphery of the first sole component 10. The foot-facing surface 11 is configured to face the upper ( Figure 1 The first sole component 10 includes a plurality of through holes 14. The plurality of open through holes 14 extend in a vertical direction from the foot-facing surface 11 to the ground-facing surface ( Figure 1 ). The foot-facing surface of the first sole component is configured to receive injected sole material for attaching the first sole component to a ground-facing surface of an upper of an article of footwear.

[0070] The plurality of through holes 14 may be arranged in parallel rows in the longitudinal direction of the first sole component 10 (eg Figure 1 The through holes 14 in parallel rows may be offset relative to each other in the longitudinal direction of the first sole component. The through holes 14 in parallel rows may be offset relative to each other, for example, in the longitudinal direction of the first sole component by a distance L1. The longitudinal direction extends along the axis Z. The distance L1 may depend on the implementation. In some example embodiments, the distance L1 may be half of the distance L2 between the center points of two through holes 14 arranged in the same row. In some example embodiments, the distance L1 may be half of the longitudinal length of the through hole 14 (e.g., the radius along the semi-major axis of the elliptical through hole) relative to the through holes in the adjacent second row of parallel rows. By offsetting the through holes 14 in each row, the through holes 14 in each row may be moved closer together while maintaining a minimum value of solid material between the holes to ensure the structural rigidity of the first sole component. Moving the through holes in each row closer to each other means that a greater number of through holes can be assembled to a predetermined area, thereby further reducing the weight of the first sole component.

[0071] The foot-facing surface 11 of the first sole component is configured to be joined to the upper by receiving injected material such that the injected material extends between the upper (e.g., the ground-facing surface of the upper) and the foot-facing surface 11 of the first sole component 10. The first sole component 10 may also include a solid portion 10A surrounding the plurality of through-holes 14 and / or the area where the plurality of through-holes 14 are arranged. The solid portion 10A provides rigidity to the first sole component 10 and also provides a contact and bonding surface for the injected material of the second sole component.

[0072] exist Figure 1 In the exemplary embodiment shown, a plurality of through holes 14 are oval. Here, the through holes 14 are oval in shape, meaning that the periphery of the through holes 14 is oval when viewed in a direction perpendicular to the surface 11 facing the foot and / or the surface of the first sole component facing the ground. The oval shape of the through holes 14 allows the through holes 14 in each row to be positioned closer to each other when the rows are offset from each other. Due to the oval shape, the amount of solid material between two through holes 14 in adjacent rows is increased compared to, for example, rectangular shaped through holes 14. Therefore, the oval shape of the through holes 14 allows the through holes 14 in each row to be moved closer to each other, which in turn allows a greater number of through holes to be assembled to the first sole component 11 within a predetermined area. The oval shape of the through holes 14 can further reduce the weight of the first sole 11 while maintaining the desired structural stability of the first sole component. Furthermore, the elliptical shape of the through-hole reduces the risk of crack formation around the perimeter of the through-hole 14, since the perimeter does not include any sharp edges or corners, which could otherwise lead to premature failure of the article of footwear.

[0073] Depending on the desired properties of first sole component 10 and / or an article of footwear including first sole component 10, through-holes 14 may be provided in different areas of the first sole component. Figure 2A-2C Different arrangements of through holes on the first sole component are shown. Figure 2A An exemplary embodiment of a first sole component 10 is shown, wherein a plurality of through holes 14 are distributed in a plurality of parallel rows extending in a transverse direction of the first sole component 1 on a forefoot region 4 of the foot-facing surface 11. Thereby, the flexibility of the first sole component 10 in the forefoot region 4 can be increased. Figure 2B An exemplary embodiment of a first sole component 10 is shown, wherein a plurality of through holes 14 are distributed over the midfoot region 6 of the first sole component 1. Thereby, the flexibility of the first sole component 10 in the midfoot region 6 can be increased. Figure 2C An exemplary embodiment of a first sole component 10 is shown, in which a plurality of through holes 14 are distributed over the heel region 5 of the first sole component 10. Thereby, the flexibility of the first sole component 10 in the heel region 5 can be increased.

[0074] Figure 3 A first mold part 30 is shown. The first mold part 30 is configured to receive the first sole component 10. The first mold part 30 includes a plurality of protrusions 31 that are configured to cooperate with the plurality of through holes 14 of the first sole component 11. In order to receive the first sole component 10, the first mold part 30 is shaped to the ground-facing surface of the first sole component and thus conforms to the shape of the ground-facing surface of the first sole component 10. The plurality of protrusions may correspond to the plurality of through holes 14 of the first sole component 10 in terms of shape and position, for example. Thus, the plurality of protrusions may also have an elongated shape, for example, as Figure 3 The plurality of protrusions 31 may therefore also be arranged in parallel rows extending in the longitudinal direction of the first mold component, corresponding to the arrangement of the through holes 14 of the first sole component. Similar to the rows of through holes 14 of the first sole component, the parallel rows of protrusions 31 may be offset relative to each other in the longitudinal direction of the first mold component. Figure 3 The first mold part in an embodiment is shown, wherein the through holes 14 of the first mold part 10 are distributed from the toe end to the heel end of the first sole component 10. In the case where the plurality of through holes 14 are distributed only on certain areas of the first sole component 10, such as on the heel area, the forefoot area and / or the midfoot area, the plurality of protrusions of the first mold part 30 can be arranged accordingly.

[0075] The outer periphery of each of the plurality of protrusions 31 of the first mold part 30 may be equal to or larger than the inner periphery of the corresponding through-hole 14 in the first sole component 10, so that when the first sole component 10 is mounted on the first mold part 30, the plurality of protrusions 31 fit tightly or snugly into the plurality of through-holes 14. The through-holes 14 are thereby closed during the molding process so that the injected material cannot enter the through-holes 14.

[0076] Figure 4A and 4B A cross-sectional view of first sole component 10 and first mold component 31 is shown, according to one or more embodiments herein. Figure 4A Shown along Figure 11 is a cross-sectional view of a first sole component 10 along a cutting line AA of FIG. The first sole component 10 has a first foot-facing surface 11 and a first ground-facing surface 9. A plurality of through-holes 14 extend from the foot-facing surface 11 to the ground-facing surface 9 of the first sole component in a vertical direction and are open toward both the foot-facing surface 11 and the ground-facing surface 9. The foot-facing surface 11 of the first sole component 10 is configured to receive injected sole material for attaching the first sole component 10 to the ground-facing surface of the upper of the footwear article. The first sole component 10 has a height h1, which can also be referred to as the thickness at the through-hole 14 area of ​​the first sole 10 component at the corresponding through-hole 14 of the first sole component 10. The plurality of through-holes 14 are configured to cooperate with the plurality of protrusions 31 of the first mold component 30 when the first sole component 10 is arranged on the first mold component 30, so that the plurality of protrusions 31 protrude through the plurality of through-holes 14.

[0077] Figure 4B A cross-sectional view of the first mold part 30 along the cutting line BB of FIG. 2 is shown. A plurality of protrusions 31 extend in a vertical direction perpendicular to the first surface 32 of the first mold part 30, such that when the first sole component 10 is disposed on the first mold part 30, the plurality of protrusions 31 extend from the ground-facing surface 9 of the first sole component to the foot-facing surface 11 of the first sole component 10. Each of the plurality of protrusions 31 of the first mold part 30 may have a height h2 that is equal to or higher than the height h1 of the first sole 10 component at the corresponding through hole 14 of the first sole component 10. The height h2 may be the distance from the first surface 32 of the first mold part to the top surface 31A of the plurality of protrusions 31. When the height h2 of the protrusions 31 is equal to the height h1 of the first sole component at the corresponding through hole 14, a flat surface is created to receive the injected material when the first sole component 10 is disposed on the first mold part 30. The flat surface may improve the flow of the injected material within the molded assembly.

[0078] Figure 5 1 shows a cross-sectional view of the first sole component 10 mounted to the first mold component 30 along the cutting axes AA and BB. Figure 5As can be seen in the figure, the plurality of protrusions 31 of the first mold part 30 cooperate with the plurality of through holes 14 of the first sole component 10, so that the plurality of protrusions 31 close the plurality of through holes 14. The plurality of protrusions 31 cooperate with the plurality of through holes 14 means that the plurality of protrusions 31 protrude into the plurality of through holes 14, so that the plurality of through holes 14 accommodate the plurality of protrusions 31. The plurality of protrusions 31 are configured so that they fit tightly or snugly in the plurality of through holes 14, thereby sealing the plurality of through holes 14. The combination of the first sole component 10 and the first mold part 30 can define a portion of the mold cavity of the second sole component. By closing and / or sealing the plurality of through holes 14 in the first sole component 10 with the protrusions 31 of the first mold part 30, the injection material of the second sole component is prevented from entering the plurality of through holes 14 during the injection molding process. When the first sole component 10 is mounted on the first mold part 30 so that the plurality of protrusions 31 cooperate with the plurality of through holes 14 and when the height h2 is equal to the height h1, the foot-facing surface 11 of the first sole component 10 can be aligned with the top surface 31A of the plurality of protrusions. Thus, a flat surface can be provided that defines the lower boundary of the mold cavity for receiving the injected material. After the injected material solidifies in the mold cavity and the first mold part has been removed, the second sole component 20 formed by the injected material is bonded to the foot-facing surface 11 of the first sole component 10 and can span the entire foot-facing surface 11. The second sole component 20 can therefore also span the plurality of through holes 14 without protruding into the through holes 14.

[0079] Figure 6 A cross-sectional view of an example article of footwear 1 taken along a longitudinal axis Z is shown, wherein the article of footwear includes a sole assembly including a first sole component 10, a second sole component 20, and an upper 8, as shown in FIG. Figure 5As shown. The sole assembly may include one or more additional sole components, such as a third sole component. The first sole component 10 extends from the toe end 2 of the footwear article 1 to the heel end 3 of the footwear article 1, wherein the upper 8 and the insole 7 are attached to the first sole component 10 through the second sole component. The second sole component 20 may extend from the toe end 2 to the heel end 3 without interruption, thereby forming a shock absorbing layer, which is arranged between the first sole component 10 and the upper 8 along the entire longitudinal length of the axis Z of the footwear article. A plurality of through holes 14 are arranged in a plurality of parallel rows from the heel end 3 of the first sole component 10 to the toe end 2 of the first sole component 10, extending in the longitudinal direction of the first sole component 10. Therefore, the flexibility of the first sole component 10 and the footwear article 1 can be increased. The weight of the first sole component 10 and the footwear article 1 can also be reduced. The weight reduction of the first sole component 10 and the footwear article 1 improves the comfort of the footwear article during use. The second sole component 20 may span across the plurality of through-holes 14 without protruding into the through-holes 14. The plurality of through-holes 14 in the first sole component 10 may also improve the grip of the first sole component 10 and the article of footwear 1 in the longitudinal direction during use. The inner side 14A of the plurality of through-holes 14, such as the inner side wall, forms one or more surfaces arranged perpendicularly relative to the ground-facing surface 9 of the first sole component 10. These perpendicularly arranged surfaces may be configured to withstand forces in the longitudinal and lateral directions of the article of footwear 1, and thus may improve the grip of the first sole component 10 during use of the article of footwear 1.

[0080] The first sole component 10 may have a first hardness, and the second sole component 20 may have a second hardness, wherein the first hardness may be greater than the second hardness. The first hardness of the first sole material may be used to provide and / or improve durability by setting the material of the first sole 10 to a material that can withstand friction between the ground surface and the surface 9 of the first sole component 10 facing the ground. This sole 20 component may be provided as a material having a second hardness lower than the first hardness, wherein the second sole component 20 may be positioned between the wearer's foot and the first sole component 10 and the ground when in use. Therefore, the softer material can improve the comfort of the footwear 1 by providing a shock absorbing layer that can absorb impacts occurring during gait. The second sole component may be arranged between the upper and the first sole component. The second sole component may further include an injected material. As Figure 3 As shown, during the injection molding process, the injected material may have been injected onto the first sole component 10 arranged on the first mold part 30 of the footwear molding assembly. Since during the injection process, the plurality of protrusions 31 of the first mold part 30 cooperate with the through holes, the injected material cannot enter the through holes 14 of the first sole component 10. Therefore, the second sole component 20 is also arranged flush with the foot-facing surface 11 of the first sole component 10 in the region of the through holes 14.

[0081] like Figure 5 As can be seen in FIG. 1 , the surface 9 facing the ground may include or may be a ground contact surface. The ground contact surface may be located in the heel region 5 and in the forefoot region 4, or may be as shown in FIG. Figure 5 This is shown over the entire surface 9 of the first sole component 10 that faces the ground.

[0082] The use of the terms "first," "second," "third," and "fourth," "primary," "secondary," "tertiary," etc. does not imply any particular order, but are included to identify individual elements. Furthermore, the use of the terms "first," "second," "third," and "fourth," "primary," "secondary," "tertiary," etc. does not indicate any order or importance, but rather the terms "first," "second," "third," and "fourth," "primary," "secondary," "tertiary," etc. are used to distinguish one element from another. Note that the words "first," "second," "third," and "fourth," "primary," "secondary," "tertiary," etc. are used herein for labeling purposes only and are not intended to indicate any particular spatial or temporal ordering.

[0083] Furthermore, the marking of a first element does not imply the presence of a second element and vice versa.

[0084] It should be noted that the word "comprising" does not necessarily exclude the presence of other elements or steps than those listed.

[0085] It should be noted that the word "a" or "an" preceding an element does not exclude the presence of a plurality of such elements.

[0086] It should also be noted that any reference signs used do not limit the scope of the claims.It should be noted that features relating to the first sole component may be combined with features of the mould assembly or the method of moulding a sole assembly.

[0087] Although features have been shown and described, it should be understood that they are not intended to limit the claimed invention, and it will be apparent to those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the claimed invention. Accordingly, the specification and drawings are to be regarded as illustrative rather than restrictive. The claimed invention is intended to encompass all alternatives, modifications, and equivalents.

[0088] Reference numerals

[0089] 1 Footwear

[0090] 2 Toe tip

[0091] 3 Heel end

[0092] 4 Forefoot area

[0093] 5 Heel area

[0094] 6 Mid-foot area

[0095] 7 insole

[0096] 8 Upper

[0097] 9 First surface facing the ground

[0098] 10. First sole component

[0099] 10A Solid portion of the first sole component

[0100] 11 First surface facing the foot

[0101] 12 Second surface facing the ground

[0102] 14 Through hole

[0103] 20 Second sole component

[0104] 21 Second foot-facing surface

[0105] 22 Third surface facing the ground

[0106] 30 First mold part

[0107] 31 protrusion

[0108] 31A Top surface of protrusion

[0109] 32 Main surface of the first mold part

[0110] h1 Thickness of the first sole component

[0111] h2 height of the protrusion

Claims

1. A sole molding assembly, comprising: - a prefabricated first sole component, which is part of an article of footwear, the prefabricated first sole component having a foot-facing surface and a ground-facing surface, wherein the prefabricated first sole component includes a plurality of through-holes, wherein the plurality of through-holes extend in a vertical direction from the foot-facing surface to the ground-facing surface; wherein the foot-facing surface is configured to receive injected material during a molding process for attaching the prefabricated first sole component to the ground-facing surface of an upper; as well as - a first mould part comprising a plurality of protrusions configured to cooperate with said plurality of through holes of said prefabricated first sole part during said moulding process, Wherein, the outer periphery of each of the plurality of protrusions of the first mold component is equal to or larger than the inner periphery of the corresponding through hole in the prefabricated first sole component, so that the injected material is prevented from entering the through opening during injection molding.

2. The sole molding assembly of claim 1, wherein the plurality of through holes are arranged in parallel rows extending in a longitudinal direction of the prefabricated first sole component.

3. The sole molding assembly according to claim 2, wherein the through holes in adjacent parallel rows are offset relative to each other in the longitudinal direction of the prefabricated first sole component.

4. The shoe sole molding assembly of claim 3, wherein each through-hole in a first of the parallel rows is offset relative to the through-holes in an adjacent second of the parallel rows by half of the longitudinal length of the through-hole.

5. The sole molding assembly according to any one of claims 1 to 4, wherein the plurality of through holes are elongated and are arranged on the prefabricated first sole component such that a longitudinal direction of the through holes extends in a longitudinal direction of the prefabricated first sole component.

6. The sole molding assembly according to any one of claims 1 to 4, wherein the plurality of through holes have an elliptical shape.

7. The sole molding assembly according to any one of claims 1 to 4, wherein the radius of the plurality of through holes is in the range of 0.2 to 1.2 cm.

8. The sole molding assembly according to any one of claims 1-4, wherein the plurality of through holes are evenly distributed on the prefabricated first sole component, thereby forming a grid of openings in the prefabricated first sole component.

9. The sole molding assembly of any one of claims 1-4, wherein the prefabricated first sole component is an outsole.

10. The sole molding assembly of any one of claims 1-4, wherein the sole molding assembly is configured to receive an injected material that defines a second sole component of the footwear.

11. The sole molding assembly according to any one of claims 1-4, wherein each of the plurality of protrusions of the first mold component has a height h2 that is equal to or higher than a height hi at a corresponding through hole of the prefabricated first sole component.

12. The sole molding assembly according to any one of claims 1-4, wherein each of the plurality of protrusions of the first mold member is tapered such that the plurality of protrusions are wider toward a lower end and thinner toward a top of the protrusion.

13. A method for molding footwear, wherein the method comprises: installing a sole molding assembly according to claim 10, wherein the plurality of protrusions of the first mold component cooperate with and pass through the plurality of through holes of the prefabricated first sole component, and injecting material into the sole molding assembly such that the injected material adheres to the foot-facing surface of the prefabricated first sole component and defines a second sole component of the footwear.

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