Footwear component

Abstract

The present invention relates to a component of an article of footwear, the component comprising a fabric element wherein the fabric element comprises continuous threads arranged in a thread pattern. The line pattern includes a plurality of line rows. The component also comprises a polymeric material, wherein the fabric element is at least partially embedded in the polymeric material. The invention also relates to an article of footwear comprising the component and a method of manufacturing the component.

Description

Technical Field

[0001] The present invention relates to a component for an article of footwear, the component comprising continuous threads arranged in a thread pattern, and to a method of manufacturing the component. Background Art

[0002] Footwear articles generally include a sole and an upper made of multiple components. Each of these components is generally required for the sole and the upper in order to provide the footwear with various desired properties, such as cushioning, stability, moisture management, traction, wear resistance, etc. In recent years, footwear manufacturers have developed a new technology in which parts of footwear articles, such as parts of the upper, are manufactured by winding one or more wires or ropes around predetermined anchor points. Thus, various desired properties can be provided and individually adjusted based on the winding pattern of the wires or ropes.

[0003] For example, document US2022 / 0104588A1 discloses a method for manufacturing an upper of a footwear article, the method comprising: providing a frame and a support component, and defining a plurality of anchor points on the frame. The method further comprises: winding a first continuous line around the plurality of anchor points defined on the frame and around the support component, so that the first continuous line extends from the frame to the support component.

[0004] In addition, documents US2019 / 0307208A1 and US11,602,196B2 disclose footwear articles comprising one or more continuous threads wound around an anchor point. Winding one or more continuous threads forms a thread pattern that imparts desired properties to the components of the footwear article.

[0005] Document EP3780985B1 provides a different approach, in which a fiber bundle is attached to a substrate. The document discloses a sole structure, such as a footwear article, comprising: a component including a first fiber bundle fixed to a substrate, a ground engaging assembly, the ground engaging assembly including a first traction element, a second traction element, and a connecting member extending between and connecting the first traction element and the second traction element. In addition, a resin is disclosed for consolidating the first fiber bundle and capturing the connecting member to fix the position of the first traction element, the second traction element and the connecting member relative to the substrate.

[0006] However, while the individual adaptability of footwear or its fit in general appears to have been the focus of improvements in uppers or footwear components based on wound wire, these footwear articles often require additional reinforcement components, such as metal or carbon plates, to provide the desired support or stiffness in various areas of the footwear. These additional components not only increase the complexity and cost of manufacturing such footwear, but also must be considered when considering the overall properties and wearing comfort of the footwear article. Therefore, there is a continuous need for innovation in footwear manufacturing and components used to manufacture footwear.

[0007] The problem underlying the present invention is therefore that of improving an article of footwear such that the above-mentioned disadvantages of the prior art are at least partially overcome. Summary of the invention

[0008] The above problems are solved by the embodiments of the present invention.

[0009] In one embodiment, the present invention provides a component for an article of footwear. The component may include a textile element. The textile element may include continuous threads arranged in a thread pattern. The thread pattern may include a plurality of rows of threads. The component may further include a polymer material, wherein the textile element may be at least partially embedded in the polymer material.

[0010] The line pattern used throughout the present invention can be manufactured by winding at least one continuous line around a plurality of anchoring points. The path of the line between the two anchoring points is referred to as a line row in this article, which can be a substantially straight line in particular. Therefore, the claimed line pattern of the claimed fabric element can be distinguished from a knitted or woven fabric. The term "substantially straight" should be understood to encompass deviations from a straight line-based on manufacturing uncertainty. The anchoring point can preferably be removed after completing the winding, and therefore may not be present in the finished footwear. Compared with not along the line row or even perpendicular to the direction of the line row, the line pattern can generally have a higher tensile resistance or tensile stiffness along the line row.

[0011] Thus, the claimed invention provides a component for a footwear article, wherein the directional stiffness can be easily adjusted based on the line pattern. In addition, by embedding the textile element at least partially in the polymer material, a second characteristic of the component can be provided in addition to the directional stiffness along the line row. Thus, the component can correspond to a hybrid component, combining the advantages provided by both the line pattern and the polymer material. For example, the polymer material can provide additional, in particular non-directional stiffness or reinforcement of the component. Alternatively, the polymer material can provide additional directional stiffness, for example based on the thickness or shape of the polymer material. Additionally or alternatively, the polymer material can increase the hardness of the line pattern. Thus, improved durability and / or wear resistance can be provided for the component. The polymer material can also provide a covering layer to protect the continuous line from being accidentally cut, for example when running or hiking in rough terrain or undergrowth or similar rough and uneven environments. The continuous line is also fixed and / or maintained in its intended arrangement at least partially based on the polymer material.

[0012] In some embodiments, the line pattern comprises only a single continuous line. Alternatively, a line pattern comprising two, three or more continuous lines is also applicable. The term "continuous line" as used in the present invention may be understood to be distinguished from a fabric in which each line path or at least the majority of line paths corresponds to an independent line that is attached to form a fabric. In some embodiments, the continuous line as used in the present invention may be wound around a plurality of anchor points, preferably around at least four anchor points.

[0013] The line pattern can be combined at least at the intersection of two lines. Thereby, the arrangement of continuous lines forming the line pattern can be ensured. Additionally or alternatively, entanglement of various lines that are not embedded in the polymer material in the non-tensioned state of the line pattern can be excluded.

[0014] In some embodiments, the footwear article may include a sole including components. The inventors of the present invention have discovered that by incorporating one or more of the components described herein into the sole of the footwear article, various desired properties of the sole may be improved, such as bending stiffness, propulsion, longitudinal stiffness, twisting of the sole, wear resistance, directional stiffness, non-directional stiffness, etc.

[0015] In some embodiments, the line pattern may include a first group of line rows, which are arranged in a direction substantially parallel to the longitudinal axis or walking direction of the footwear article. Thus, the first group of line rows can provide longitudinal bending stiffness. Therefore, at least partially based on the first group of line rows, the bending stiffness or bending resistance of the footwear article in the longitudinal direction can be higher than the bending stiffness or bending resistance transverse to or even perpendicular to the longitudinal direction. The term "substantially parallel" should be understood to encompass deviations of up to positive / negative 20 degrees from parallel arrangement. Throughout the present invention, the positive angle is defined as counterclockwise from the starting axis, and the negative angle is defined as clockwise from the starting axis. The level of longitudinal bending stiffness can be adjusted based on the number of line rows in the first group of line rows and / or based on the stiffness or tensile resistance of the continuous line itself (which can be adapted based on the material for the line row). For example, the number of line rows in the first group of line rows can be in the range of between 1 and 1000, preferably between 10 and 600. Advantageous line materials with high levels of stiffness or tensile resistance can include nylon or carbon fiber.

[0016] The line rows in the first group of line rows can extend from the heel area of ​​the footwear article to the toe area, in particular along at least 80%, preferably at least 90% and most preferably at least 95% of the length of the footwear article. The arrangement of the line rows along the longitudinal axis of the footwear article enables the level of longitudinal bending stiffness to be adjusted.

[0017] The rows of the first set of rows of wires can be arranged in the midfoot area of ​​the footwear. In this way, the longitudinal bending stiffness can be specially customized in the midfoot area. For example, the component can provide most of or more than 90% of the bending stiffness in the midfoot area of ​​the footwear. Therefore, additional rigid sole components, such as metal plates or carbon plates, can be omitted. In some embodiments, the first set of rows of wires can include multiple layers of rows of wires. As a result, the distribution of the rows of wires can be more uniform, thereby resulting in uniformly distributed bending stiffness.

[0018] The sole may include a midsole, and the component may be arranged on the midsole. Preferably, the component may be arranged on the side of the midsole opposite to the upper of the finished footwear article. The inventors have found that the rigid reinforcement material has a higher effect when arranged in the area of ​​the most deformable bendable component. Therefore, by arranging the component on the midsole instead of inside the midsole or between the layers of the midsole, a higher bending stiffness can be achieved. In addition, compared with the embodiment with the component inside the midsole or between the layers of the midsole, the manufacturing complexity and manufacturing cost of such an embodiment can be reduced.

[0019] In some embodiments, the component may be an outsole. For example, the fabric element of the component may provide a desired bending stiffness for a large portion of the assembled sole. Thus, additional rigid plates or rigid rods may be omitted in the sole. In addition, the polymer material of the component may be adapted to provide a high level of wear resistance and / or traction. In this way, the component may be able to manufacture the sole in a simplified and cost-effective process while providing the wearer with desired bending properties, high wear resistance, and thus a long service life of the footwear.

[0020] In some embodiments, the line pattern may include a second group of line rows, which are arranged at a first angle relative to a straight line along the longitudinal axis of the footwear article, and the first angle is in the range of 20 to 60 degrees, preferably 30 to 45 degrees. Thus, torsional motion can be provided in the footwear article. The line rows may not all have the same first angle. In some embodiments, each line row may have a different first angle. The second group of line rows may also include multiple sets of line rows with different first angles. For example, the second group of line rows may include: a first set of line rows with a positive or counterclockwise first angle, and a second set of line rows with a negative or clockwise first angle. Thus, the component can further improve the torsional characteristics of the footwear article. This may be particularly advantageous for the sole comprising the component. The first set of line rows and the second set of line rows may overlap at least partially in the heel area and / or in the midfoot area. In this way, a tapered stiffness can be achieved. The tapered gradual stiffness can be generated by the overlap of the first set and the second set of lines in a specific area, such as in the heel area and / or in the midfoot area, which can locally provide increased bending stiffness in this area. In addition, the bending stiffness can gradually decrease towards another area, such as the toe area or the outsole top gauge area, in which the first set of lines and the second set of lines may overlap less or even not overlap. This can provide adjustable local stiffness. Another advantage can be provided to the manufacturing process of the footwear, whereby a more flexible top gauge allows more flexibility and easier assembly of the sole to the upper.

[0021] The number of rows in the second set of rows may range from 1 to 1000, preferably from 10 to 600. Similar to the first set of rows, the level of bending stiffness may be adjusted based on the number of rows in the second set of rows and / or based on the stiffness of the material used to make the continuous wire. Advantageous wire materials with high levels of stiffness or stretch resistance may include nylon or carbon fiber.

[0022] In some embodiments, the line pattern may include a third group of line rows, which are arranged at a second angle relative to a straight line along the longitudinal axis of the footwear article, the second angle being in the range of 45 to 135 degrees, preferably 60 to 120 degrees. The line rows may not all have the same second angle. In some embodiments, each line row may have a different second angle. As described above, bending stiffness can generally be increased in the direction along the line rows. By arranging the third group of line rows transverse to the longitudinal axis of the footwear article, a desired bending axis can be introduced. The bending axis generally extends along the line rows. For example, the third group of line rows can be arranged in an area that is easy to bend in the sole of the footwear article, such as a ball of the foot area. The number of line rows in the third group of line rows can be between 1 and 160, preferably between 10 and 80. For the third group of line rows, a higher number of line rows will hinder the required bending. This may be based on the higher coverage of the line rows, resulting in a too wide bending axis. For the third set of wire rows, a more compliant wire material, such as thermoplastic polyurethane or polyether block amide, may be beneficial in reducing the bending stiffness along the bending axis.

[0023] In some embodiments, the line pattern may include a fourth group of line rows, which are arranged in a rod-like shape or a tubular shape. Based at least in part on the arrangement of the fourth group of line rows, a high level of bending stiffness of the line pattern with a rod-like shape or a tubular shape can be provided. The components including the fourth group of line rows may, for example, be arranged or embedded in a layer of a soft material (such as foam) or between layers. In this way, the increased bending stiffness of the rod-like shape or the tubular shape can provide customized stability for the soft material. In these embodiments, the polymer material of the components may be soft and / or foam material. In some embodiments, the rod-like shape or the tubular shape of the fourth group of line rows may be hollow. Thus, the weight of the components and the entire footwear article including such components may be reduced. In addition, the mechanical properties of the fourth group of line rows, such as the increased bending stiffness of the rod-like shape or the tubular shape, may be maintained or only slightly reduced at most compared to the non-hollow embodiment.

[0024] In some embodiments, the line pattern may include a fifth group of line rows, which extend from at least the sole of the footwear article to the upper of the footwear article. In this way, the fabric element comprising the fifth group of line rows can provide a component that is advantageously connected to the sole portion with the upper portion. For example, the fabric element can be partially embedded in a polymer material that forms a part of the sole, such as an injection molded or overmolded material. Thus, the fabric element can be firmly attached to the sole and / or can provide beneficial properties for the sole, as described above. Additionally or alternatively, the fabric element that is not embedded in the part of the sole and extends to the upper can provide at least one of the following: the improved fit of the footwear, the support to the increase of the wearer's foot, the stability of the increase, etc.

[0025] The invention may not be limited to thread patterns comprising only the first to fifth groups of thread rows described above. On the contrary, a combination of two or more groups of thread rows in one thread pattern of a single component is also applicable. For example, the sole portion of the fifth group of thread rows may correspond at least partially to a thread pattern according to one of the first to fourth groups of thread rows. Thus, for example, longitudinal bending stiffness in the sole may be combined with improved stability or fit of the upper.

[0026] In some embodiments, the article of footwear may include a heel counter, the heel counter comprising the component. Thus, improved stability of the heel region of the article of footwear may be provided. Since the heel counter including the component may provide tensile stiffness and / or bending stiffness in the heel region, the stability may be further improved. The level of tensile stiffness and / or bending stiffness of the heel counter may be adjusted based on the thread pattern of the textile element and / or the polymer material.

[0027] In some embodiments, the polymer material of the component of the heel counter can form at least a portion of the sole of the footwear article, wherein at least a portion of the textile element of the component of the heel counter can be embedded in the polymer material forming a portion of the sole. In this way, a strong chemical bond between the heel counter and the sole of the footwear article can be provided at least partially based on the component. Based on the bending stiffness of the textile element and / or the polymer material of the component of the heel counter, additional support elements in the heel area of ​​the upper of the footwear article can be omitted.

[0028] In some embodiments, in addition to a portion of the textile element of the heel counter being embedded in a polymer material forming part of the sole, at least an edge region of the textile element of the heel counter can be additionally embedded in a polymer material that is not part of the sole. Thus, due to the additional polymer material that is not part of the sole, additional stiffness of the heel counter can be provided.

[0029] In some embodiments, the line pattern can be arranged to form a substantially closed surface. The term "substantially closed surface" used throughout the present invention can be understood as a closed surface having only one or more openings with a diameter of less than 1 mm. In this way, the line pattern can provide protection from external factors, such as moisture. Additionally or alternatively, the substantially closed surface of the line pattern can provide a good surface for additional post-processing. For example, when overmolding a textile element with a polymer material to form a component according to an embodiment of the present invention, less polymer material can pass through the substantially closed surface of the line pattern compared to a more open line pattern.

[0030] In an alternative embodiment, the line pattern may be arranged to form a surface having at least one opening. Such a line pattern may be optimized to allow some materials of post-processing steps to penetrate the line pattern. For example, a line pattern having at least one opening may be beneficial for a textile element embedded in a polymer material by an injection molding process. In this way, a strong bond between the textile element and the polymer material may be achieved. The textile element may be protected by the surrounding polymer material, thereby providing improved wear resistance of the component.

[0031] In some embodiments, the textile element may be completely surrounded by the polymer material. Alternatively, at least 20%, preferably at least 35%, and most preferably at least 50% of the surface area of ​​the textile element may not be embedded in the polymer material.

[0032] The polymer material may include a polymer matrix material or a foam material. The polymer matrix material may include at least one of the following: thermosetting polyurethane, thermosetting rubber, polyamide, nylon, PA11, PA12, thermoplastic elastomers such as polyether block amide. In addition, the polymer matrix material may further include additional reinforcements, such as short fibers, carbon fibers or glass fibers. The foam material may include at least one of the following: polyamide, polyether block amide, expanded polyether block amide, thermoplastic polyurethane, expanded thermoplastic polyurethane or thermoplastic copolyester.

[0033] The continuous thread may comprise polyamide, thermoplastic polyurethane, nylon, rubber, silicone, carbon fibers, metal fibers, flax fibers, glass fibers, polyethylene block amide, polyester or a foamed polymer material.

[0034] In another aspect, the invention provides a footwear article comprising a component according to one of the embodiments described above. It may be noted that footwear articles comprising more than one component are also applicable. For example, the footwear article may comprise a sole comprising at least one component. One component of the sole may be an outsole. Furthermore, the footwear article may further comprise a heel counter comprising at least one further component.

[0035] In another aspect, the present invention provides a method of manufacturing a component of an article of footwear. The method may include the steps of defining a plurality of anchor points; winding a continuous thread around the plurality of anchor points to form a thread pattern. The thread pattern may include a plurality of thread rows, each thread row extending between two corresponding anchor points. The method may also include molding at least a portion of the thread pattern with a polymer material.

[0036] As discussed above with respect to embodiments of components for articles of footwear, various advantages of the present invention are similarly applicable to embodiments of methods of making components and are not repeated here for the sake of brevity.

[0037] In some embodiments, the method may further include applying heat and pressure to the wire pattern prior to molding to bond the rows of wires at least at intersections.

[0038] In some embodiments, an article of footwear may include a sole including components.

[0039] In some embodiments, the winding may further comprise: arranging the rows of threads in a direction substantially parallel to the longitudinal axis of the footwear article or parallel to the walking direction, thereby forming a first set of rows of threads in the thread pattern. In some embodiments, the rows of threads in the first set of rows of threads may extend from the heel region of the footwear article to the toe region, in particular along at least 80%, preferably at least 90% and most preferably at least 95% of the length of the footwear article. The method may further comprise: arranging the rows of threads in the first set of rows of threads in the midfoot region of the footwear article.

[0040] In some embodiments, the sole may include a midsole, and the method may further include arranging the component on the midsole, particularly on a side of the midsole opposite to an upper of the finished article of footwear.

[0041] In some embodiments, the winding may further include: arranging the lines at a first angle relative to a straight line along the longitudinal axis of the footwear article, the first angle being in the range of 20 to 60 degrees, preferably 30 to 45 degrees, to form a second set of lines in the line pattern. The arranging may also include: arranging the first set of lines of the second set of lines at a positive or counterclockwise first angle, and arranging the second set of lines of the second set of lines at a negative or clockwise first angle. In some embodiments, the arranging may further include: arranging the first set of lines and the second set of lines such that the first set of lines and the second set of lines overlap at least partially in the heel area and / or in the midfoot area.

[0042] In some embodiments, the number of lines in the first group of lines and / or the second group of lines may be in the range between 1 and 1000, preferably in the range between 10 and 600.

[0043] In some embodiments, the winding may further include: arranging the line rows at a second angle relative to a straight line along the longitudinal axis of the footwear article, the second angle being in the range of 45 to 135 degrees, preferably 60 to 120 degrees, thereby forming a third group of line rows in the line pattern. The number of line rows in the third group of line rows may be between 1 and 160, preferably between 10 and 80.

[0044] In some embodiments, the winding may further include: arranging the line rows into a rod-shaped shape or a tubular shape, thereby forming a fourth group of line rows in the line pattern. In these embodiments, the method may further include: arranging or embedding the fourth group of line rows in a soft material (such as foam). In this way, the increased bending stiffness of the rod-shaped shape or the tubular shape can provide customized stability for the soft material. In these embodiments, the polymer material of the component may be a soft and / or foam material. In some embodiments, the arrangement may further include: arranging the line rows into a hollow rod-shaped shape or a hollow tubular shape. For example, a hollow rod-shaped shape or a hollow tubular shape may be created in the following manner: winding a continuous line around an internal material, wherein the internal material is not bonded to the material of the continuous line. As an alternative to a material that is not bonded to the material of the continuous line, a hollow rod-shaped shape or a hollow tubular shape may also be created in the following manner: winding a continuous line around an internal material, which internal material may be dissolved after the line rows are wound into a rod-shaped shape or a tubular shape, for example, dissolved in water or another liquid. The method may further include: applying heat and pressure to the line pattern. Furthermore, the method may further comprise the step of removing the inner material. In embodiments comprising a soluble inner material, the method may further comprise: dissolving the inner material using water or another liquid. Thus, the weight of the component and the entire footwear article comprising such a component may be reduced. Furthermore, the mechanical properties of the fourth group of wire rows, such as the increased bending stiffness of the rod-like shape or the tubular shape, may be maintained or at most only slightly reduced compared to the non-hollow embodiment.

[0045] In some embodiments, winding may further include arranging the rows of threads such that the rows of threads extend from at least the sole of the article of footwear to the upper of the article of footwear, thereby forming a fifth set of rows of threads in the thread pattern.

[0046] In some embodiments, an article of footwear may include a heel counter that includes the component.

[0047] In some embodiments, wrapping may further include: arranging the thread pattern such that the textile element has a substantially closed surface. Alternatively, wrapping may further include: arranging the thread pattern such that the textile element has at least one opening in its surface.

[0048] In some embodiments, the component may have a higher tensile stiffness in a direction along the line row than in a direction perpendicular to the line row.

[0049] In some embodiments, molding may further comprise completely surrounding the textile element with the polymer material. Alternatively, molding may further comprise surrounding at most 80%, preferably at most 65%, more preferably at most 50% of the surface area of ​​the textile element with the polymer material.

[0050] In some embodiments, the polymer material may include a polymer matrix material or a foam material.

[0051] The polymer matrix material may include at least one of the following: thermosetting polyurethane, thermosetting rubber, polyamide, nylon, PA11, PA12, thermoplastic elastomers such as polyether block amide. In addition, the polymer matrix material may further include additional reinforcements, such as short fibers, carbon fibers or glass fibers.

[0052] The foam material may include at least one of a polyamide, a polyether block amide, an expanded polyether block amide, a thermoplastic polyurethane, an expanded thermoplastic polyurethane, or a thermoplastic copolyester.

[0053] The continuous thread may comprise polyamide, thermoplastic polyurethane, nylon, rubber, silicone, carbon fibers, metal fibers, flax fibers, glass fibers, polyethylene block amide, polyester or a foamed polymer material. BRIEF DESCRIPTION OF THE DRAWINGS

[0054] In the following detailed description, possible embodiments of the present invention will be further described with reference to the following drawings:

[0055] Figure 1 An embodiment of a thread pattern as part of a shoe sole is shown;

[0056] Figure 2 Another embodiment of a line pattern is shown as part of the heel to midfoot area of ​​the sole;

[0057] Figure 3 Another embodiment of a line pattern is shown as part of the forefoot area of ​​the sole;

[0058] Figure 4 Another embodiment of a line pattern is shown as part of the midfoot area of ​​the sole;

[0059] Figure 5 Another embodiment of a thread pattern is shown that acts as a heel stabilizer;

[0060] Fig. 6A An embodiment of a component is shown, the component being arranged as part of a heel counter;

[0061] Figure 6B Another embodiment of a component is shown, the component being arranged as part of a heel counter;

[0062] Figure 7 An embodiment of a line array is shown, which is arranged in a rod-like or tubular shape;

[0063] Figures 8A-8BAn embodiment of a die for applying heat and pressure to an array of wires arranged in a rod-like or tubular shape is shown in an open and closed state;

[0064] Figures 9A-9B An embodiment of a line pattern extending from the sole area to the vamp area is shown from two different views;

[0065] Fig. 9C An embodiment of a line pattern is shown - with an attached outsole, the line pattern extending from the sole area to the upper area;

[0066] Fig. 10A An embodiment of a component attached to a midsole is shown, the component having a substantially closed surface; and

[0067] Fig. 10B Another embodiment of a component attached to a midsole is shown, the component having a surface with openings. DETAILED DESCRIPTION

[0068] Below, exemplary embodiments of the present invention are described in more detail with reference to components for articles of footwear. Although specific feature combinations are described below with respect to exemplary embodiments of the present invention, it should be understood that the present disclosure is not limited to these embodiments. In particular, not all features must be present to implement the present invention, and embodiments may be modified by combining certain features of one embodiment with one or more features of another embodiment.

[0069] Figure 1 An embodiment of a component 110 as part of a sole 100 according to the present invention is depicted. Component 110 includes a textile element 120 including a continuous thread 150 wound around a plurality of anchor points (not shown) to produce a plurality of straight, extended rows of threads 140. The rows of threads 140 are arranged in a thread pattern 130. The rows of threads 140 may correspond to a first set of rows of threads. Figure 1 As shown, the line pattern 130 includes seventeen lines 140, which are arranged substantially parallel to a straight line 160 along the longitudinal axis of the sole 100. Therefore, the angle 170 between the longitudinal axis 160 and the line rows 140 has an absolute value of less than 20 degrees. Other numbers of line rows 140 ranging from 1 to 1000 lines are also suitable. For example, Figure 1Each line row 140 depicted in the figure can include multiple line rows (not shown) arranged in a zigzag pattern. Line row 140 is arranged on the entire length of sole 100, thereby providing longitudinal bending stiffness on the entire sole 100. In the embodiment of expected longitudinal bending stiffness, the line material can have high tensile stiffness. Preferred line material can be nylon, carbon fiber, etc. Component 110 can also include a polymer material (not shown) that at least partially covers fabric element 120. Component 110 can be manufactured by compression molding, which can provide additional mechanical properties for component 110. For example, by shaping component 110 into longitudinal ribs (not shown), the longitudinal bending stiffness provided by the line pattern 130 of component 110 can be further increased based on shape. Component 110 can be connected to the midsole. In certain embodiments, component 110 can be an outsole. In this case, a polymer material with high wear resistance and / or high traction friction can be selected.

[0070] Figure 2 An embodiment of a component 210 as part of a sole 200 according to the present invention is depicted. Component 210 includes a thread pattern 230 of a textile element 220, wherein a thread row 240 is arranged at a first angle 270 relative to a straight line 260 along the longitudinal axis of the sole 200. Figure 2 In the line pattern 230, the first angle 270 is in the range of 20 degrees to 80 degrees. The line rows 240 may correspond to the second group of line rows. In addition, the line pattern 230 is arranged to start from the heel area and extend to the midfoot area of ​​the sole 200. The line pattern 230 includes two sets of line rows 240, which are arranged at positive and negative first angles 270, respectively. The first set of line rows and the second set of line rows can be arranged in a basically symmetrical arrangement. An asymmetric arrangement of the first set and the second set of line rows is also applicable, which results in asymmetric bending characteristics. The first and second sets of line rows 240 overlap at least in the heel area to form a central rib, which improves the torsional behavior of the sole 200 around the central rib. In some embodiments, the first set and the second set of line rows 240 can be arranged alternately, thereby producing a three-dimensional line pattern 230, which further improves the torsional behavior of the sole 200. Figure 2 In FIG. 1 , each of the first and second sets of line rows 240 is shown by nine lines. Each of these lines may include a zigzag pattern of continuous lines (not shown). The zigzag pattern of adjacent lines may include the same continuous line. Thus, Figure 2 At least some of the lines depicting line row 240 may be made from the same continuous line and may thus be connected (not shown). Additionally or alternatively, Figure 2Some zigzag patterns depicted by single lines in the shoe sole 200 may not be connected to adjacent zigzag patterns. Therefore, these zigzag patterns may each include a single continuous line. In another embodiment (not shown), the first set and the second set of line rows may overlap in different areas of the sole 200, such as in the midfoot area.

[0071] Figure 3 An embodiment of a component 310 as part of a sole 300 according to the present invention is depicted. Component 310 includes a textile element 320, which includes a line pattern 330, wherein lines 340 are arranged at a second angle 370 relative to a straight line 360, which is along the longitudinal axis of the sole 300. The absolute value of the second angle 370 can be in the range of 45 degrees to 135 degrees. Line rows 340 can correspond to a third group of line rows. In a preferred embodiment, line rows 340 can be arranged substantially perpendicular to straight line 360. In addition, line pattern 330 is arranged in a forefoot region of the sole 300, which can be centered around a ball of the foot region. In this way, component 310 can provide improved bending compliance, wherein the lines 340 of line pattern 330 can define a bending axis. In Figure 3 In the embodiment of the present invention, the line pattern 330 includes twelve lines 340 composed of a single continuous line 350. Additionally or alternatively, as described above with respect to Figure 2 As described, each of the lines 340 may also include a zigzag pattern of a plurality of lines (not shown). The number of lines 340 may range between 10 and 80 lines 340. To improve bending flexibility, a compliant yarn comprising thermoplastic polyurethane or polyethylene block amide may be preferred.

[0072] Figure 4 An embodiment of a component 410 as part of a sole 400 according to the present invention is depicted. Component 410 includes a textile element 420 including a thread pattern 430, wherein a thread row 440 is arranged in a midfoot region of sole 400. Thread row 440 may correspond to a first set of thread rows. Figure 4 As shown, the row of lines 440 is arranged substantially parallel to a line 460 along the longitudinal axis of the sole 400, preferably extending under the arch area of ​​the wearer. In this way, the component 410 can provide increased longitudinal bending stiffness in the midfoot area. Figure 4 In the depicted embodiment, the line pattern 430 includes five line rows 440 shown as individual lines. Figure 2 As described in the embodiment of the present invention, each of these lines may include a zigzag pattern of continuous lines (not shown). The zigzag pattern of adjacent lines may include the same continuous line. Figure 4At least some of the lines depicting line row 440 may be made from the same continuous line and may thus be connected (not shown). Additionally or alternatively, Figure 4 Some zigzag patterns described by single lines in the diagram may not be connected to adjacent zigzag patterns. Therefore, these zigzag patterns may each include a single continuous line.

[0073] Figure 5 An embodiment of a component 510 as part of a heel counter 500 according to the invention is depicted. Component 510 comprises a textile element 520, which comprises a thread pattern 530, wherein rows of threads 540 are arranged in a mesh structure. In this way, component 510 can provide additional heel stability. Furthermore, due to the mesh structure of thread pattern 530, component 510 can be particularly suitable for providing tensile and bending stiffness in the heel region. Figure 5 In the depicted embodiment, the line pattern 530 includes lines 540 that are displayed as individual lines. Figure 2 As described in the embodiment of the present invention, each of these lines may include a zigzag pattern of continuous lines and may or may not be connected to adjacent rows of lines. Textile element 520 may be at least partially embedded in a polymer material to form component 510 (not shown).

[0074] Fig. 6A Another embodiment of a component 610 as part of a heel counter 600 according to the present invention is depicted. Component 610 includes a textile element 620 having a thread pattern 630. Thread pattern 630 includes a thread row 640 that can be arranged in a mesh structure to provide improved heel stability. Fig. 6A As depicted, in a bottom region 690 of heel counter 600, textile element 620 of component 610 partially overlaps sole 605. Bottom region 690 of textile element 620 is embedded with polymer material 680 for creating a strong chemical and / or mechanical bond between textile element 620 and sole 605. In a preferred embodiment, overlapping bottom region 690 of textile element 620 of heel counter 600 may have a width of at least 5 mm. In embodiments where the footwear includes an injection molded sole 605, bottom region 690 of textile element 620 may be embedded in polymer material 680 during the molding process of forming sole 605.

[0075] Figure 6B Another embodiment of a component 611 as part of a heel counter 601 according to the present invention is depicted. Component 611 includes a textile element 621 having a line pattern 631. Fig. 6A Heel counter 600 and Figure 6BThe difference between the heel counter 601 of FIG. 6 is that, in addition to the bottom area 691 of the textile element 621 of the heel counter 601, the edge area 698 which is not in contact with the sole 606 is also embedded in the polymer material 681. Thereby, the textile element 621 around the part 611 creates a frame of the polymer material 681. Therefore, in addition to the bending stiffness provided by the textile element 621, the additional frame of the polymer material 681 also increases the stiffness characteristics of the heel counter 601. In this way, a more resistant and more stable heel counter 601 can be provided compared to a heel counter without such a frame, for example, compared to Fig. 6A A heel counter 600 is shown (which in contrast may provide a higher degree of flexibility).

[0076] The type of thread material preferably used for fabric elements 620 and 621 may be polymer-based, such as nylon, particularly PA11 or PA12, or thermoplastic polyurethane. However, natural or petroleum-based fibers such as polyester may also be suitable.

[0077] In another embodiment of a component as part of a heel counter (not shown) according to the invention, the textile element and polymer material forming the component of the heel counter can be integrated into the upper of the footwear article. In this way, the component can be an integral part of the upper.

[0078] Figure 7 Describe the embodiment of the line pattern 730 according to the present invention, this line pattern has the line row 740 arranged on the frame 710 with a rod-like or tubular shape.Continuous line 740 can be wound around frame 710 many times to form a rod-like or tubular line pattern 730.After line pattern 730 has the expected thickness and / or form, it is removed from frame 710.Line row 740 can correspond to the fourth group of line rows.In a similar manner, a hollow rod-like shape or a hollow tubular shape can be produced.To this end, the material that is not combined with the material of the continuous line 740 can be wound around frame 710 to produce a core of a rod-like or tubular shape.Subsequently, the continuous line 740 can be wound around the same frame 710 and around the non-bonded material that has been wound.After consolidating it by applying heat and pressure to the continuous line 740, the internal non-bonded material can be removed, thereby producing the desired hollow rod-like or hollow tubular shape of the line pattern 730. In some embodiments, water soluble materials may also be applied, which may be washed out of the rod-shaped or tubular wire array 740 after consolidation. The rod-shaped or tubular wire pattern 730 may be encapsulated in a layer of polymer material (not shown). In these embodiments, the polymer material may preferably be foam.

[0079] Fig. 8A and 8BAn embodiment of a mold 800 is depicted for consolidating a wire pattern 830 including a rod-shaped or tubular wire array 840. The mold 800 can be used, for example, to consolidate a wire pattern 830 of a plurality of wires. Figure 7 Line pattern 830 is described. Fig. 8A The upper half 805 and the lower half 806 of the mold 800 are depicted in an open state. In addition, the arrows indicate the direction of closing the mold 800. Fig. 8A The upper half 805 and the lower half 806 of the mold 800 include shapes of wire arrays 840 in a rod-like or tubular shape for manufacturing the wire pattern 830 . Figure 8B An enlarged view of the left half of mold 800 is depicted in a closed state. Figure 8B Further shown are a plurality of wire rows 840 which, after application of heat and pressure by the die 800, can produce a wire pattern 830 in a rod-like or tube-like shape according to the present invention.

[0080] Fig. 9A and 9B An embodiment of a component 910 of an article of footwear 900 according to the present invention is depicted from two different views. Component 910 includes a textile element 920 connecting the sole and the upper of shoe 900. Textile element 920 has a plurality of different thread patterns 930a-c. Fig. 9A and 9B As depicted, thread pattern 930a may be used as a base layer upon which additional thread rows 940 are laid to increase specific stiffness in desired areas of shoe 900. In some embodiments, thread pattern 930a may be a conventional composite fabric, i.e., not wrapped around multiple anchor points. On top of thread pattern 930a, thread pattern 930b may be arranged in the forefoot and rearfoot areas of shoe 900. Fig. 9A and 9B As shown, line pattern 930b forms part of the sole and extends into the upper region as heel counter 905 and into the forefoot region at the first metatarsophalangeal joint. Line pattern 930b may correspond to the fifth set of line rows. Heel counter 905 may correspond to heel counter 500, 600, or 601 as described above. Based on the bending stiffness provided by line pattern 930b in the upper of shoe 900, favorable stability may be provided to the wearer of shoe 900. In addition, for example, as described above with reference to Figure 3 As described above with respect to thread pattern 330 of the first embodiment, the sole portion of thread pattern 930b can provide improved flexing characteristics in the ball area. Thus, the sole portion of thread pattern 930b can correspond to the third set of thread rows. Thread pattern 930c of textile element 920 is arranged in a direction substantially parallel to line 960, which is along the longitudinal axis of article of footwear 900. Thread pattern 930c forms a portion of the sole and provides improved longitudinal stiffness, for example, as described above with respect to the first set of thread rows and Figure 1As described above, the line pattern 930c can be at least partially embedded in the polymer material 980. For example, during the molding process, the line pattern 930c can be introduced into the injection molded outsole 981 (e.g., Fig. 9C depicted).

[0081] Fig. 9C Describes how Fig. 9A and 9B Component 910 of the shoe 900 described above and also includes a molded outsole 981. Outsole 981 can include a polymer material and / or can be manufactured by an injection molding process. In some embodiments, at least a portion of the line patterns 930a-c described above can be embedded in the polymer material 980 forming the outsole 981. In particular, at least a portion of the sole portion of the line patterns 930a-c can be embedded in the polymer material 980 of the outsole during the manufacturing process of the outsole 981.

[0082] Fig. 10A An embodiment of a component 1010 as a part of a sole 1000 according to the present invention is depicted. Component 1010 includes a fabric element 1020, which includes a plurality of continuous lines 1050 wound around a plurality of anchor points (not shown), thereby producing a plurality of straight extended lines 1040. Line lines 1040 are arranged in a line pattern 1030, which is attached to a side of a midsole 1080 opposite to the wearer's foot. Line pattern 1030 can be at least partially embedded in a polymer material facing the midsole 1080, forming component 1010. Line pattern 1030 can be additionally or alternatively embedded in a polymer material on a side opposite to the midsole 1080, thereby providing high wear resistance and / or high traction friction (not shown). Thus, component 1010 can form at least a portion of an outsole. Component 1010 is suitable for improving the bending properties of the midsole 1080, such as directional stiffness and / or bending flexibility, while having a minimal effect on the compression stiffness of the sole 1000. The line pattern 1030 itself may be flexible. However, after the component 1010 including the line pattern 1030 and the polymer material is attached to the midsole 1080, the bending stiffness of the entire sole 1000 is increased. In addition, compared to soles known in the art having similar compression and bending stiffness as the sole 1000, the present invention provides an advantageous solution by having a smaller weight and a more efficient manufacturing process. In addition, as Fig. 10A As depicted, line pattern 1030 includes a plurality of different continuous lines 1050 arranged in different patterns, which enables specific selection of directions having increased stiffness and / or adjustable stiffness levels. In the depicted embodiment, component 1010 can constrain expansion of the midsole surface to which component 1010 is attached. As a result, the flexion resistance of the wearer's toes moving toward the wearer's knees can be increased. To this end, as shown in FIG. Fig. 10AThe depicted row of substantially straight extension lines 1040 of line pattern 1030 is attached to each toe region of the wearer's foot, extending at least to the midfoot region of sole 1000 or even to the rearfoot region. Fig. 10A As depicted, line pattern 1030 has a substantially closed surface. This can provide, for example, a protective layer against external factors such as moisture or sharp objects. Furthermore, for embodiments where an additional overmolded outsole is contemplated, the closed surface provides a beneficial sealing layer that prevents mold material from passing through component 1010 into and / or onto midsole 1080.

[0083] Fig. 10B Another embodiment of a component 1011 as part of a sole 1001 according to the present invention is depicted. Component 1011 and Fig. 10A 1081 . The present invention is similar to component 1011, but with two differences. First, textile element 1021 includes a different arrangement of line pattern 1031 compared to line pattern 1030. Second, line pattern 1031 has an open surface structure, that is, the surface of line pattern 1031 includes eight substantially oval openings 1060. These openings 1060 allow additional post-processing, such as injection molding of materials through openings 1060. For example, textile element 1021 can be inserted into a mold, and polymer material can be injected onto the side of textile element 1021 facing midsole 1081. The polymer material can be further injected through openings 1060, encapsulating line pattern 1031, for excellent bonding and / or for providing improved wear resistance to component 1011. As a result, a plurality of spike tips (not shown) can be attached to component 1011 through openings 1060.

Claims

1. A component (110, 210, 310, 410, 510, 610, 611, 910, 1010, 1011) for an article of footwear (900), the component comprising: a textile element (120, 220, 320, 420, 520, 620, 621, 920, 1020, 1021), wherein the textile element comprises continuous threads (150, 350, 750, 1050) arranged in a thread pattern (130, 230, 330, 430, 530, 630, 631, 730, 830, 930a-c, 1030, 1031), the thread pattern comprising a plurality of rows of threads (140, 240, 340, 440, 540, 640, 740, 840, 940, 1040); and Polymer materials (680, 681, 980); Wherein the textile element is at least partially embedded in the polymer material.

2. The component according to claim 1, wherein The line patterns are joined at least at the intersection of two lines.

3. A component according to claim 1 or 2, wherein: The article of footwear comprises a sole (100, 200, 300, 400, 1000, 1001) comprising the component.

4. A component according to any one of claims 1 to 3, wherein The thread pattern includes a first set of rows of threads arranged in a direction (160, 260, 360, 460, 960) substantially parallel to a longitudinal axis or walking direction of the article of footwear.

5. The component according to claim 4, wherein The rows of the first set of rows extend from a heel region to a toe region of the footwear article, in particular along at least 80%, preferably at least 90% and most preferably at least 95% of the length of the footwear article.

6. A component according to claim 4 or 5, wherein: The rows of threads of the first set of rows of threads are arranged in a midfoot region of the article of footwear.

7. A component according to any one of claims 3 to 6, wherein The sole comprises a midsole (1080, 1081), and wherein the component is arranged on the midsole, in particular on a side of the midsole opposite to an upper of the finished article of footwear.

8. A component according to any one of claims 1 to 7, wherein The line pattern includes a second set of line rows arranged at a first angle (270) relative to a straight line (160, 260, 360, 460, 960) along the longitudinal axis of the footwear article, the first angle ranging from 20 degrees to 90 degrees, preferably from 30 degrees to 80 degrees.

9. The component according to claim 8, wherein The second group of wire arrays includes: a first set of wire arrays having a positive or counterclockwise first angle, and a second set of wire arrays having a negative or clockwise first angle.

10. The component according to claim 9, wherein The first set of thread rows and the second set of thread rows at least partially overlap in the heel area and / or in the midfoot area.

11. A component according to any one of claims 4 to 10, wherein The number of the lines in the first group of lines and / or the second group of lines is in the range between 1 and 1000, preferably in the range between 10 and 600.

12. A component according to any one of claims 1 to 11, wherein The line pattern includes a third group of line rows, which are arranged at a second angle (370) relative to a straight line (160, 260, 360, 460, 960) along the longitudinal axis of the footwear article, and the second angle is in the range of 45 degrees to 135 degrees, preferably in the range of 60 degrees to 120 degrees.

13. The component according to claim 12, wherein The number of the line rows in the third group of line rows is in the range between 1 and 160, preferably in the range between 10 and 80.

14. A component according to any one of claims 1 to 13, wherein The line pattern includes a fourth group of line rows arranged in a rod-like shape or a tube-like shape.

15. A component according to any one of claims 1 to 14, wherein The thread pattern includes a fifth set of thread rows extending from at least the sole of the article of footwear to the upper of the article of footwear.

16. A component according to claim 1, 2 or 15, wherein: The article of footwear comprises a heel counter (500, 600, 601, 905) comprising the component.

17. A component according to any one of claims 1 to 16, wherein The line pattern is arranged to form a substantially closed surface.

18. A component according to any one of claims 1 to 16, wherein The line pattern is arranged to form a surface having at least one opening (1060).

19. A component according to any one of claims 1 to 18, wherein The component has a higher tensile stiffness in a direction along the row of lines than in a direction perpendicular to the row of lines.

20. The component of any one of claims 1 to 19, wherein the textile element is completely surrounded by the polymer material.

21. A component according to any one of claims 1 to 19, wherein at least 20%, preferably at least 35% and most preferably at least 50% of the surface area of ​​the textile element is not embedded in the polymer material.

22. A component according to any one of claims 1 to 21, wherein the polymer material comprises a polymer matrix material or a foam material.

23. The component according to claim 22, wherein The polymer matrix material includes at least one of the following: thermosetting polyurethane, thermosetting rubber, polyamide, nylon, PA11, PA12, thermoplastic elastomer such as polyether block amide.

24. The component according to claim 22, wherein The foam material includes at least one of the following: polyamide, polyether block amide, expanded polyether block amide, thermoplastic polyurethane, expanded thermoplastic polyurethane or thermoplastic copolyester.

25. A component according to any one of claims 1 to 24, wherein The continuous thread comprises polyamide, thermoplastic polyurethane, nylon, rubber, silicone, carbon fiber, metal fiber, flax fiber, glass fiber, polyethylene block amide, polyester or foamed polymer material.

26. An article of footwear (900) comprising a component (110, 210, 310, 410, 510, 610, 611, 910, 1010, 1011) according to any one of claims 1 to 25.

27. A method of manufacturing a component for an article of footwear, the method comprising: Define multiple anchor points; winding a continuous wire around the plurality of anchor points to form a wire pattern, the wire pattern comprising a plurality of wire rows, wherein each wire row extends between two respective anchor points; as well as At least a portion of the line pattern is molded with a polymer material.

28. The method of claim 27, further comprising: Prior to molding, heat and pressure are applied to the wire pattern to bond the rows of wires at least at the intersections.

29. The method according to claim 27 or 28, wherein: The article of footwear comprises a sole including the component.

30. The method according to any one of claims 27 to 29, wherein: The winding further comprises arranging the rows of threads in a direction substantially parallel to a longitudinal axis of the article of footwear or parallel to a walking direction, thereby forming a first set of rows of threads in the thread pattern.

31. The method according to claim 30, wherein: The rows of the first set of rows extend from a heel region to a toe region of the footwear article, in particular along at least 80%, preferably at least 90% and most preferably at least 95% of the length of the footwear article.

32. The method according to claim 30 or 31, further comprising: Arranging rows of the first plurality of rows of threads in a midfoot region of the article of footwear.

33. The method according to any one of claims 29 to 32, wherein: The sole comprises a midsole, and wherein the method further comprises arranging the component on the midsole, in particular on a side of the midsole opposite to an upper of the finished article of footwear.

34. A method according to any one of claims 27 to 33, wherein: The winding further comprises arranging the rows of threads at a first angle in the range of 20 to 60 degrees, preferably 30 to 45 degrees, relative to a line along the longitudinal axis of the article of footwear, thereby forming a second set of rows of threads in the thread pattern.

35. The method of claim 34, wherein: The arranging further comprises arranging a first set of line rows in the second group of line rows at a positive or counterclockwise first angle, and arranging a second set of line rows in the second group of line rows at a negative or clockwise first angle.

36. The method of claim 35, wherein the arranging further comprises: The first set of thread rows and the second set of thread rows are arranged such that the first set of thread rows and the second set of thread rows at least partially overlap in the heel area and / or in the midfoot area.

37. A method according to any one of claims 30 to 36, wherein: The number of the lines in the first group of lines and / or the second group of lines is in the range between 1 and 1000, preferably in the range between 10 and 600.

38. The method according to any one of claims 27 to 37, wherein: The winding further comprises arranging the rows of threads at a second angle in the range of 45 to 135 degrees, preferably 60 to 120 degrees, relative to a line along the longitudinal axis of the article of footwear, thereby forming a third set of rows of threads in the thread pattern.

39. The method of claim 38, wherein: The number of the line rows in the third group of line rows is in the range between 1 and 160, preferably in the range between 10 and 80.

40. The method according to any one of claims 27 to 39, wherein: The winding further includes arranging the wire rows in a rod-like shape or a tube-like shape to form a fourth group of wire rows in the wire pattern.

41. A method according to any one of claims 27 to 40, wherein: The winding further includes arranging the rows of threads so that the rows of threads extend at least from the sole of the article of footwear to the upper of the article of footwear, thereby forming a fifth group of rows of threads in the thread pattern.

42. The method according to claim 27 or 28, wherein: The article of footwear comprises a heel counter comprising the component.

43. A method according to any one of claims 27 to 42, wherein: The wrapping further includes arranging the thread pattern such that the textile element has a substantially closed surface.

44. The method of any one of claims 27 to 42, wherein the winding further comprises: The thread pattern is arranged such that the textile element has at least one opening on a surface thereof.

45. A method according to any one of claims 27 to 44, wherein: The component has a higher tensile stiffness in a direction along the row of lines than in a direction perpendicular to the row of lines.

46. ​​The method of any one of claims 27 to 45, wherein the molding further comprises: The textile element is completely surrounded by the polymer material.

47. The method of any one of claims 27 to 45, wherein the molding further comprises: At most 80%, preferably at most 65% and more preferably at most 50% of the surface area of ​​the textile element is surrounded by the polymer material.

48. A method according to any one of claims 27 to 47, wherein the polymer material comprises a polymer matrix material or a foam material.

49. The method of claim 48, wherein the polymer matrix material comprises at least one of the following: thermosetting polyurethane, thermosetting rubber, polyamide, nylon, PA11, PA12, thermoplastic elastomer such as polyether block amide.

50. The method of claim 48, wherein the foam material comprises at least one of a polyamide, a polyether block amide, an expanded polyether block amide, a thermoplastic polyurethane, an expanded thermoplastic polyurethane, or a thermoplastic copolyester.

51. A method according to any one of claims 27 to 50, wherein: The continuous thread comprises polyamide, thermoplastic polyurethane, nylon, carbon fibers, metal fibers, flax fibers, glass fibers, polyethylene block amide, polyester or a foamed polymer material.

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