Method of manufacturing footwear by direct injection production and footwear manufactured

Abstract

A method of manufacturing footwear by direct injection production (DIP) and footwear manufactured by direct injection production, the method comprising:-providing (50) a direct injection mold (2) attachable to an injection molding apparatus and configured for at least partially guiding injection material to a mold cavity (40),-providing (52) at least one prefabricated sole part (80) of a sole structure, -positioning (54) the prefabricated sole part with respect to the direct injection mold (2),-positioning (56) an upper (30) with respect to the direct injection mold (2),-injecting (60) an injection material into the mold cavity (40), the mold cavity being at least partially formed by the direct injection mold (2),-injecting (60) the injection material into the mold cavity (40), and an injection material configured for attaching the upper (30) to the at least one prefabricated sole component (80), the injection material providing an attached sole component (90) of the sole structure upon curing, where the at least one prefabricated sole component (80) is a sole component manufactured by a supercritical foaming process.

Description

Technical Field

[0001] The present invention relates to a method of manufacturing footwear by direct injection production (DIP).

[0002] Furthermore, the present invention relates to footwear manufactured by direct injection production (DIP). Background Art

[0003] It is known in the art to manufacture footwear by injecting the sole directly into the upper, whereby the injected material, when cured, serves as the sole or a portion of the sole and is used to connect the upper to the sole structure.

[0004] Direct Injection Process (DIP) or Direct Injection Production (DIP), which may also be referred to below, is advantageous in many respects because the footwear produced can be made to have both flexibility and strength.

[0005] Various methods have been used in the prior art to improve the direct injection process and footwear produced by such methods, for example, to increase production efficiency, reduce costs, increase user comfort, etc.

[0006] US2004 / 0143995 A1 discloses a direct-attachment footwear construction in which a boot is constructed of an outsole that is directly attached to a midsole that is directly attached to an upper. The outsole is made of relatively hard rubber or other sufficiently wear-resistant material and is pre-manufactured (e.g., injection molded) before the outsole is directly attached to the footwear.

[0007] As an example of another footwear construction, a foam article that can be used as a cushioning element for an article of footwear is disclosed in WO 2021 / 183475 A1, wherein the cushioning element can be a midsole. The cushioning element can be foamed by using a foaming agent such as a supercritical fluid containing supercritical nitrogen or supercritical carbon dioxide. However, this requires further production steps, thereby increasing costs, because the midsole disclosed in this document is bonded to the upper by an adhesive, and the midsole is also bonded to the outsole by an adhesive.

[0008] It is therefore apparent that such a cushioning element is not suitable for direct injection production of footwear in which the sole structure is attached to the upper by a direct injection process. Summary of the invention

[0009] It has been recognized that improvements in methods of manufacturing footwear by a direct injection process, and improvements in footwear manufactured by such direct injection processes, are desirable to reduce costs and improve user comfort.

[0010] In a first aspect, the present invention relates to a method of manufacturing footwear by direct injection production (DIP), the method comprising:

[0011] - providing a direct injection mold attachable to an injection molding apparatus and configured for at least partially directing injection material to the mold cavity,

[0012] - providing at least one prefabricated sole element of a sole structure,

[0013] - positioning the prefabricated sole component relative to the direct injection mould,

[0014] - positioning the upper relative to said direct injection mould,

[0015] - injecting an injection material into the mold cavity, the mold cavity being at least partially formed by the direct injection mold, the injection material being configured for attaching the upper to the at least one prefabricated sole component, the injection material providing, after curing, an attached sole component of the sole structure of the footwear,

[0016] Wherein, the at least one prefabricated sole component is a sole component manufactured by a supercritical foaming process.

[0017] Thus, footwear can be manufactured by direct injection production (DIP), wherein the sole component manufactured by the supercritical foaming process and thus having the desired properties can be easily applied as a part of the sole structure. Such desirable properties of the sole component manufactured by the supercritical foaming process can be, for example, a softer sole that is lighter than the sole component made of, for example, foamed PU (polyurethane), such as PU injected in the DIP process and expanded / cured in the DIP mold. In addition, when using the sole component manufactured by the supercritical foaming process in the DIP process, less energy can be used in the manufacturing process.

[0018] Thus, by means of the present invention it is achieved that the direct injection production process (DIP) can be applied to footwear construction, including sole components manufactured by means of a supercritical foaming process, and a separate bonding process can thereby be avoided.

[0019] According to one embodiment, the attachment sole component for attaching the upper to the at least one prefabricated sole component may be used as at least a part of another sole component of the sole structure of the footwear.

[0020] Thus, it will be appreciated that the attached sole component may consist of a relatively thin layer of injection material that expands and solidifies. Furthermore, it will be appreciated that such a relatively thin layer of injection material may not have a uniform thickness, but may include one or more regions of increased thickness, for example, taking into account the configuration of, for example, the bottom surface of the upper and the corresponding surface of the prefabricated sole component, and taking into account the mutual positioning of the bottom surface of the upper and the prefabricated sole. Thus, footwear may be manufactured by direct injection production (DIP), wherein the attached sole component itself may also be used as a sole component, for example as a midsole, a part of a midsole, an additional midsole or other sole component, which may, for example, attach the upper to a lower portion of the sole structure, such as an outsole or a midsole.

[0021] According to one embodiment, the at least one prefabricated sole component may be configured for forming an outsole.

[0022] Hereby it is achieved that footwear can be manufactured by direct injection production (DIP), wherein the outsole is provided as a prefabricated component, which has increased softness and is in a lightweight form, i.e. low density, which therefore means that the outsole can have a desired thickness without adversely affecting the weight of the finished footwear. Thus, footwear can be manufactured by the DIP process which has an outsole of increased thickness compared to the thickness of footwear manufactured hitherto by DIP, wherein the outsole is made of, for example, PU, ​​and which has a still lighter overall weight compared to conventionally manufactured footwear.

[0023] According to one embodiment, the at least one prefabricated sole component may be configured for forming a midsole.

[0024] Hereby it is achieved that footwear can be manufactured by direct injection production (DIP), wherein the midsole is provided as a prefabricated part, which has increased softness and is in a lightweight form, i.e. low density, thus meaning that the midsole can have a desired thickness without adversely affecting the weight of the finished footwear. Thus, footwear can be manufactured by the DIP process which has a midsole of increased thickness compared to the thickness of footwear manufactured to date by DIP, wherein the midsole is made of, for example, PU, ​​and which still has a lighter overall weight compared to conventionally manufactured footwear.

[0025] It should be noted that in such a case, the outsole may have been pre-attached to the prefabricated midsole, for example by adhesive or any other suitable means.

[0026] According to one embodiment, the attached sole component provided at least in part by the injected material upon curing may form at least a portion of a midsole.

[0027] Hereby, it is achieved that footwear can be manufactured by direct injection production (DIP), wherein the at least one prefabricated and supercritically foamed sole component can be directly attached to an upper of the footwear or another part of the footwear via the midsole, ie via the injected material.

[0028] Therefore, the advantages of the DIP manufacturing process can be fully utilized.

[0029] According to one embodiment, the at least one prefabricated sole component may be prefabricated by subjecting a base component to a supercritical foaming agent, thereby expanding the base component into a preform.

[0030] Thus, a base component made of, for example, a granular thermoplastic material that has been injected into an initial "baby size" form is subjected to the supercritical foaming agent treatment and expanded into a preform, the shape, size, etc. of which corresponds to the actual size of the actual footwear, but allows the prefabricated sole component to be placed in a direct injection mold. During the direct injection process, in which the heated injection material is injected and the component in the mold is thereby subjected to heat and pressure, the prefabricated sole component will be formed into its final shape in accordance with the constraints of the direct injection mold.

[0031] According to one embodiment, the supercritical blowing agent may be a gas, such as carbon dioxide (CO 2 ) and / or nitrogen.

[0032] Thus, supercritical foaming can be carried out in such a way that the prefabricated (e.g. foamed) sole components can be manufactured using natural constituent gases in the atmosphere and thus without any disadvantages in terms of toxic and / or other environmentally unfavorable properties. In addition, such gases can be recovered in a gas recovery facility.

[0033] According to one embodiment, the at least one prefabricated sole component may include TPU (thermoplastic polyurethane), TPE (thermoplastic elastomer), (polyether block amide), natural rubber, synthetic rubber, ethylene vinyl acetate (EVA) and / or polyvinyl chloride (PVC).

[0034] Other materials may be used instead or in addition.

[0035] According to one embodiment, the injection material may include PU (polyurethane), latex, polyvinyl chloride (PVC) and / or thermoplastic rubber (TR).

[0036] Other materials may be used instead or in addition.

[0037] According to one embodiment, the at least one prefabricated sole component may be configured with a ground facing surface and a foot facing surface, wherein the foot facing surface comprises at least one indentation for receiving the injected material.

[0038] Hereby, it can be achieved that a soft and low density material of a prefabricated and supercritically foamed sole component (e.g. an outsole) can be influenced by a harder material of an injected material (e.g. PU), wherein said injected material in connection with the injection and / or expansion will enter at least one recess. After curing, when said injected material of e.g. a midsole has been attached to e.g. an outsole, said cured material in said at least one recess will have a reinforcing effect on the softer material of e.g. an outsole, depending on the size and shape of said at least one recess.

[0039] It is obvious that the recesses may have any shape and size and, as provided, there may be at least one, for example one, two, three, etc., recesses.

[0040] According to one embodiment, the at least one depression comprised in the foot facing surface for receiving the injected material may form a groove along the foot facing surface.

[0041] Thereby, it can be achieved that a soft and low density material of a prefabricated and supercritically foamed sole component (e.g. an outsole) can be influenced by the harder material of the injected material (e.g. PU) so that an increased rigidity can be achieved in a direction along the at least one recess direction. Thus, for example, the softness and flexibility of the outsole can be designed by the layout of the at least one recess / groove and / or the depth of the at least one recess / groove.

[0042] According to one embodiment, the at least one recess forming a groove along the foot-facing surface for receiving the injected material may extend in the longitudinal and / or transverse direction of the footwear.

[0043] Thereby, it can be achieved that an increased rigidity is achieved in a direction along the longitudinal direction of the footwear and / or in a direction transverse to the longitudinal direction of the footwear. Thus, for example, the softness and flexibility of the outsole can be designed by the layout (e.g. direction) of the at least one depression / groove and / or by the depth of the at least one depression / groove.

[0044] According to one embodiment, said at least one recess forming a groove along said foot-facing surface for receiving injected material may extend in a direction substantially forming an angle different from 0° with respect to a longitudinal direction of said footwear.

[0045] Thereby, further options of configuring the footwear to obtain a desired softness and flexibility of, for example, the outsole, are achieved, for example by designing the layout, such as the direction / angle of at least one depression / groove and / or the depth of at least one groove / groove.

[0046] According to one embodiment, said at least one recess forming a groove along said foot-facing surface for receiving the injected material may extend substantially straight, in an angled form and / or in a curved form.

[0047] Thereby, further options of configuring the footwear to obtain a desired softness and flexibility of the outsole, for example, can be achieved, for example by designing the layout, for example the direction / angle and / or form of the at least one recess / groove and / or the depth of the at least one recess / groove.

[0048] According to one embodiment, the at least one recess for receiving injected material may extend through the at least one prefabricated sole component.

[0049] Thereby, further options of configuring the footwear to obtain a desired softness and flexibility of the outsole, for example, may be achieved by allowing one or more portions of the injected material to extend through a prefabricated sole component, thereby possibly forming a portion of the ground-facing surface of the outsole, which thereby also affects the properties of the ground-facing surface of the outsole, such as, for example, friction of the outsole against the ground, rigidity, wear resistance, etc.

[0050] According to one embodiment, said at least one recess for receiving injected material may be arranged asymmetrically in / on said foot-facing surface.

[0051] Thus, the support of the sole, such as hardness, comfort, etc., can be adjusted according to the needs of the user, for example, when filled with a relatively hard cured injection material composition compared to the softer SCF foam material of the prefabricated sole component, the recessed area can provide a load-bearing area, such as at the heel and the ball of the foot, while the softer SCF foam material can provide a greater degree of comfort in other areas. In addition, it can be understood that such "fine tuning" of hardness / comfort, such as achieving variable hardness, can be used to adapt footwear to a specific user, such as to provide greater support on the medial or lateral side, etc.

[0052] According to one embodiment, the at least one recess for receiving injected material may be configured for providing a variable hardness and / or support of the sole structure.

[0053] According to one embodiment, said at least one prefabricated sole component may comprise an adhesive layer on at least a portion of the surface subjected to said injected material.

[0054] Thereby, once cured, adhesion to the injected material and thereby to the attached sole component may be promoted, eg, increased and enhanced.

[0055] According to one embodiment, the adhesive layer may include materials such as glue, fabric, woven or non-woven material, scrim, or the like.

[0056] According to one embodiment, at least a portion of the surface subjected to the injected material, such as the bottom and / or sides of a recess, etc., may be free of the adhesive layer.

[0057] Thereby, adhesion to the depressions may be reduced, which may be taken into account when configuring, for example, the variable hardness and comfort of the sole structure.

[0058] In a second aspect, the invention relates to a footwear manufactured by direct injection production (DIP), said footwear comprising

[0059] -vamp

[0060] - at least one prefabricated sole element,

[0061] - at least one further sole component of said footwear,

[0062] - wherein the at least one prefabricated sole component is a sole component manufactured by a supercritical foaming process, and

[0063] - wherein said at least one further sole component of said footwear is at least partially manufactured by injecting an injection material into a mould cavity at least partially formed by a direct injection mould, and wherein said injected material attaches said upper to said at least one prefabricated sole component.

[0064] Thus, a footwear manufactured by direct injection production (DIP) can be provided, wherein the sole component manufactured by supercritical foaming process and therefore having desired properties can be easily applied as a part of the described sole structure of the footwear. This desirable property of the sole component manufactured by supercritical foaming process can be a softer sole whose weight ratio is, for example, lighter than the sole component made of foamed PU (polyurethane). In addition, when using the sole component manufactured by supercritical foaming process in the DIP process, less energy can be used in the manufacturing process. Therefore, compared with the footwear manufactured by prior art DIP, footwear according to the present invention can be provided in a lightweight form and have a softer sole structure.

[0065] By the present invention, a footwear is provided which can be easily manufactured by direct injection production (DIP) and includes a sole component manufactured by supercritical foaming process, thereby avoiding a separate bonding process of the sole component and the upper, thereby achieving cost-effective production.

[0066] According to one embodiment, the at least one prefabricated sole component may be configured for forming an outsole.

[0067] Hereby it is achieved that footwear can be manufactured by direct injection production (DIP), wherein the outsole is provided as a prefabricated component, which has increased softness and is in a lightweight form, i.e. low density, which therefore means that the outsole can have a desired thickness without adversely affecting the weight of the finished footwear. Thus, footwear can be manufactured by the DIP process, which has an outsole of increased thickness compared to footwear manufactured by DIP to date, wherein an outsole made of, for example, PU is used, and which has a lower overall weight compared to conventionally manufactured footwear.

[0068] According to one embodiment, said further sole component of said footwear provided at least partly by said injected material may be a midsole.

[0069] Hereby it is achieved that footwear can be manufactured by direct injection production (DIP), wherein at least one prefabricated and supercritically foamed sole component can be directly attached to an upper or another part of the footwear through the midsole, ie by injecting material.

[0070] According to one embodiment, the at least one prefabricated sole component may be prefabricated by subjecting a base component to a supercritical foaming agent, whereby the base component expands into a preform.

[0071] Thus, a base component made of, for example, a granular thermoplastic material that has been injected into an initial "baby size" form is subjected to a supercritical foaming agent treatment and expanded into a preform, the shape, size, etc. of which corresponds to the actual size of the actual footwear, but the prefabricated sole component can be placed in a direct injection mold. During the direct injection process, in which the heated injection material is injected and the component in the mold is thereby subjected to heat and pressure, the prefabricated sole component will be formed into a final shape according to the constraints of the direct injection mold.

[0072] According to one embodiment, the supercritical blowing agent may be a gas, such as carbon dioxide (CO 2 ) and / or nitrogen.

[0073] Thus, supercritical foaming can be performed in such a way that prefabricated (e.g. foamed) sole components can be manufactured using gases of natural composition in the atmosphere and thus without any disadvantages in terms of toxic and / or other environmentally unfavorable properties. Furthermore, such gases can be recovered in gas recovery facilities. Thus, footwear can be produced in an environmentally friendly manner.

[0074] According to one embodiment, the at least one prefabricated sole component may include TPU (thermoplastic polyurethane), TPE (thermoplastic elastomer), (polyether block amide), natural rubber, synthetic rubber, ethylene vinyl acetate (EVA) and / or polyvinyl chloride (PVC).

[0075] According to one embodiment, the injection material may include PU (polyurethane), latex, polyvinyl chloride (PVC) and / or thermoplastic rubber (TR).

[0076] According to one embodiment, the at least one prefabricated sole component may be configured with a ground facing surface and a foot facing surface, wherein the foot facing surface may include at least one recess for receiving the injected material.

[0077] Thus, it can be achieved that the soft and low-density material of the prefabricated and supercritically foamed sole component (e.g., outsole) can be influenced by the harder material of the injected material (e.g., PU), wherein the injected material associated with the injection and / or expansion will enter the at least one recess. After solidification, when the injected material of, e.g., the midsole is attached to, e.g., the outsole, the solidified material in the at least one recess will have a reinforcing effect on the softer material of, e.g., the outsole, depending on the size and shape of the at least one recess.

[0078] It will be apparent that the recesses may be of any shape and size and as described there may be at least one, such as one, two, three, etc., recess.

[0079] Thus, according to this embodiment, footwear may be designed to have desired properties with respect to softness, flexibility, and / or rigidity of the sole structure.

[0080] According to one embodiment, the at least one depression comprised in the foot facing surface for receiving the injected material may form a groove along the foot facing surface.

[0081] Thus, it can be achieved that the soft and low-density material of the prefabricated and supercritically foamed sole component (e.g. the outsole) can be influenced by the harder material of the injected material (e.g. PU), so that an increased rigidity can be achieved in the direction along the at least one recess direction. Thus, for example, the softness and flexibility of the outsole can be designed by the layout of the at least one recess / groove and / or the depth of the at least one recess / groove.

[0082] According to one embodiment, the at least one depression forming a groove along the surface facing the foot for receiving the injected material may extend in the longitudinal and / or transverse direction of the footwear.

[0083] Thereby, an increased rigidity in a direction along the longitudinal direction of the footwear and / or in a direction perpendicular to the longitudinal direction of the footwear can be achieved. Thereby, for example, the softness and flexibility of the outsole can be designed by the layout (e.g. direction) of the at least one depression / groove and / or the depth of the at least one groove / groove.

[0084] According to one embodiment, said at least one recess forming a groove along said foot-facing surface for receiving injected material may extend in a direction substantially forming an angle different from 0° with respect to a longitudinal direction of said footwear.

[0085] Thereby, further options of configuring the footwear to obtain a desired e.g. softness and flexibility of the outsole, e.g. by designing the layout, e.g. the direction / angle of at least one recess / groove and / or the depth of at least one groove / groove, are achieved.

[0086] According to one embodiment, said at least one recess forming a groove along said foot-facing surface for receiving the injected material may extend substantially straight, in an angled form and / or in a curved form.

[0087] Thereby, further options of configuring the footwear to obtain a desired e.g. softness and flexibility of the outsole can be achieved, e.g. by designing the layout, e.g. the direction / angle and / or shape of at least one recess / groove and / or the depth of at least one recess / groove.

[0088] According to one embodiment, the at least one recess for receiving injected material may extend through the at least one prefabricated sole component.

[0089] Thus, even further options for configuring the footwear to obtain desired properties, such as softness and flexibility of the outsole, can be achieved, for example by allowing one or more portions of the injected material to extend through the prefabricated sole component, thereby possibly forming a portion of the ground-facing surface of the outsole, which thereby also affects the properties of the ground-facing surface of the outsole, such as friction, rigidity, wear resistance, etc. of the outsole against the ground.

[0090] According to one embodiment, said at least one recess for receiving injected material may be configured asymmetrically in / on said foot-facing surface.

[0091] Thus, the support of the sole, such as hardness, comfort, etc., can be adjusted according to the needs of the user, for example, when filled with a relatively hard cured injection material composition compared to the softer SCF foam material of the prefabricated sole component, the recessed area can provide a load-bearing area, such as at the heel and the ball of the foot, while the softer SCF foam material can provide a greater degree of comfort in other areas. In addition, it can be understood that such "fine tuning" of hardness / comfort to achieve, for example, variable hardness can be used to adapt the shoe to a specific user, such as to provide greater support on the medial or lateral side, etc.

[0092] According to one embodiment, the at least one recess for receiving injected material may be configured for providing a variable hardness and / or support of the sole structure.

[0093] According to one embodiment, said at least one prefabricated sole component may comprise an adhesive layer on at least a portion of the surface subjected to said injected material.

[0094] Thereby, adhesion to the injected material, and thereby adhesion to attached sole components, may be facilitated once cured, such as increased and enhanced adhesion.

[0095] According to one embodiment, the adhesive layer may include materials such as glue, fabric, woven or non-woven material, scrim, or the like.

[0096] According to one embodiment, at least a portion of the surface subjected to the injected material, such as the bottom and / or the sides of the recess, may be free of the adhesive layer.

[0097] Thereby, adhesion to depressions can be reduced, which can be taken into account when configuring, for example, the variable hardness and comfort of the sole structure.

[0098] According to one embodiment, the footwear may be manufactured by a direct injection production (DIP) method according to any one of claims 1 to 20. BRIEF DESCRIPTION OF THE DRAWINGS

[0099] The present invention will be explained in more detail below with reference to the accompanying drawings, in which

[0100] Figure 1 A shoe last and a direct injection mold for direct injection molding of footwear according to the prior art are shown schematically in a cross-sectional view,

[0101] Figure 2 Shows Figure 1 The schematic diagram of the shoe last and the direct injection mold shown in FIG. 1 is shown in FIG. 2 , but in a closed position, with the injection material injected into the mold cavity.

[0102] Figure 3 In a similar manner, Figure 1 The schematic diagram of the shoe last and the direct injection mold is shown, but in a closed position after the injection material is injected and expanded in the mold cavity.

[0103] Figure 4 shows a flow chart illustrating the steps involved in an embodiment of a method according to the present invention,

[0104] Figure 5 is another flow chart showing further steps involved in providing a prefabricated sole component manufactured by a supercritical foaming process,

[0105] Figure 6 A DIP mold for manufacturing footwear according to one embodiment of the present invention is shown, wherein a prefabricated sole component is used.

[0106] Figure 6a Corresponds to Figure 6 , but wherein the adhesive layer is shown on the prefabricated sole component,

[0107] Figure 7 Shows the Figure 6 A DIP mould for making footwear in a corresponding manner, but wherein the recess is included in the prefabricated sole component,

[0108] Figure 7a Corresponds to Figure 7 , but wherein the adhesive layer is shown on the components of the prefabricated sole component,

[0109] Figure 8a -f shows an example of footwear made from an example of the present invention,

[0110] Figure 9a -f shows an embodiment of footwear made from an embodiment of the present invention, wherein the prefabricated sole component includes one or more recesses,

[0111] Fig.10a -f shows an embodiment of footwear made from an embodiment of the present invention and wherein the prefabricated sole component includes depressions,

[0112] Fig.11a -f shows an embodiment of footwear made from an embodiment of the present invention, wherein the prefabricated sole component includes various depressions,

[0113] Fig.12a -f shows an embodiment of footwear made by an embodiment of the present invention, wherein the prefabricated sole component includes a plurality of recesses,

[0114] Fig.13a -f shows an embodiment of footwear made from an embodiment of the present invention, wherein the prefabricated sole component includes a depression extending through the sole,

[0115] Fig.14a -f shows an embodiment of footwear made from an embodiment of the present invention, wherein the prefabricated sole component includes depressions located at the periphery of the sole,

[0116] Fig.15a -f shows an embodiment of footwear made by an embodiment of the present invention, showing another example of a prefabricated sole component including depressions located at the periphery of the sole,

[0117] Fig.16a -f shows an embodiment of footwear made from an embodiment of the present invention, wherein the prefabricated sole component includes depressions primarily located around the heel portion of the sole,

[0118] Fig.17a-f shows an embodiment of footwear made from an embodiment of the present invention, wherein the prefabricated sole component includes a depression at the perimeter of one side of the sole,

[0119] Fig.18a -f shows an embodiment of footwear made from an embodiment of the present invention, wherein the prefabricated sole component includes relatively large depressions, one in the heel area and another in the forefoot area,

[0120] Fig.19a -f shows an embodiment of a footwear manufactured by an embodiment of the present invention, wherein the prefabricated sole component comprises depressions substantially located in a lateral direction along the sole, and

[0121] Fig.20a -f shows an embodiment of footwear made by an embodiment of the present invention, wherein the prefabricated sole component includes depressions formed on and distributed over the foot-facing surface to adapt the support and comfort functions of the sole to the user. DETAILED DESCRIPTION

[0122] Reference Figure 1 , the DIP molding method and system of the prior art will be explained. The figure schematically shows a direct injection mold 2 and a shoe last 20, both of which are seen in a cross-sectional view taken vertically, for example, in the ankle area of ​​a shoe, which can be used for direct injection molding of footwear according to the prior art. The direct injection mold 2 can be made of metal, such as aluminum made by CNC machinery, such as Figure 1 As shown in , it may include a first side mold 4, a second side mold 6 and a bottom mold 8, which are arranged in such a way that the mold 2 can be opened and closed, for example, by the first side mold 4 and the second side mold 6 being able to move in the horizontal directions indicated by arrows A and B respectively, and by the bottom mold 8 being arranged to move in the vertical direction as indicated by arrow C. Figure 1 As shown in the figure, the first side mold 4 and the second side mold 6 can be provided with a first side surface 5 and a second side surface 7, respectively, which are made during, for example, CNC milling and generally define the desired shape of the side portion of the sole of the shoe to be molded. In addition, the bottom mold 8 can be correspondingly provided with a bottom inner surface 9, which is made during, for example, CNC milling and generally has a shape corresponding to the desired shape of the underside of the sole to be molded.

[0123] also, Figure 1, the upper 30 can be placed on the shoe last 20, and the shoe last 20 with the upper 30 can be moved in various directions, including downward relative to the mold 2 as shown by arrow D. It is understood that when performing such steps, the mold 2 needs to be in an open state to allow the shoe last 20 to move downward toward the mold and enter the mold 2 a suitable distance so that the circumference of the closed mold coincides with the upper 30 carried by the shoe last 20. When the shoe last 20 moves downward, the mold 2 can be closed to form a mold cavity 40 between the upper 30, the first side mold 4, the second side mold 6 and the bottom mold 8. The mold 2 is attached to the injection molding device ( Figure 1 The injection molding device (not shown) injects the injection material into the mold cavity, wherein the injected material contacts the first side surface 5, the second side surface 7, the bottom inner surface 9 and the bottom member of the upper 30. When the injected material forms the shape of the mold cavity, it is cured.

[0124] More details of the direct injection mold and molding process will be understood from the following, wherein Figure 2 and Figure 3 Used to further illustrate the direct injection process.

[0125] Figure 2 The bottom mold 8 is shown moving upward in the vertical direction C to close the mold cavity 40. When the direct injection mold 2 for footwear is closed, the mold cavity 40 is closed to the surrounding environment, which ensures Figure 2 The injection material 42 just injected as shown in FIG. 4 will take on the shape of the mold cavity 40 .

[0126] Figure 3 The scene in which the injection material 42 has expanded to fill the entire volume of the mold cavity 40 is shown, wherein the injection material 42 is in contact with the first side surface 5, the second side surface 7 and the bottom inner surface 9 ( Figure 1 ) and the bottom part of the upper 30, resulting in the outer surface of the injected material 42 taking the shape of the mold cavity and the respective inner and lower surfaces of the upper 30 to form the sole 44. It should be noted that, for example, when expanded, the injected material 42 adheres to the bottom part of the upper 30. The inner surfaces of the direct injection mold 2, such as the first side surface 5, the second side surface 7 and the bottom inner surface 9, can be prepared to not adhere to the injected material, for example, by applying a sliding / anti-sticking means.

[0127] After the injection material 42 is solidified, the first side mold 4 and the second side mold 6 can be respectively Figure 3 The double arrows A and B in FIG. 8 are shown to move outward horizontally, and the bottom mold 8 can be as shown in FIG. Figure 3 The double arrow C shown in the figure moves downward to open the direct injection mold 2 of footwear. The movement of the first side mold 4, the second side mold 6 and the bottom mold 8 removes the inner surface of the mold from the injection material 42, and the shoe last 20 and the upper 30 with the sole 44 attached can be removed from the mold 2.

[0128] It should be noted that, for example, a separate outer sole ( Figure 2 and Figure 3 44) so ​​that the outsole can be attached to the bottom portion of the cured sole 44 after curing.

[0129] In order to illustrate an embodiment of the method according to the present invention, reference will be made to Figure 4 , which shows a flow chart showing the steps involved in such an embodiment. Here, a direct injection (DIP) mold is provided at step 50, and a prefabricated sole component is provided at step 52, which is manufactured by a supercritical foaming process including subjecting it to a supercritical fluid (SCF), and can be referred to as an SCF sole component. At step 54, the SCF sole component is positioned in the DIP mold, and at step 56, the upper, for example, carried by a shoe last, is positioned relative to the DIP mold. Next, the DIP mold is closed at 58, and an amount of injection material is injected at 60, which is suitable for filling the mold cavity between the upper and the prefabricated sole component when the injection material expands. Subsequently, as shown in 62, the injection material is cured under certain temperature and pressure conditions, which further promotes the expansion of the prefabricated sole component to form a shape determined by the DIP mold, for example. After curing, the DIP mold is opened at 64, and the manufactured footwear is removed at 66, after which possible further processing steps can be performed, such as removing excess injection material.

[0130] Figure 5 Corresponds to Figure 4 , but in Figure 5 , the steps involved in providing a SCF sole component are shown, including the step of providing a base component at 68, the base component being made using, for example, granular thermoplastic material, "virgin" and / or recycled material, which is injected into a base shape to produce a base component of a sole component, such as a "baby size" component. As shown in step 70, the base component is subjected to a supercritical form of an SCF reagent, such as carbon dioxide (CO2) and / or nitrogen, and at step 72, the base component is expanded into a preform, the shape and size of which substantially corresponds to the final shape and size of the finished sole component, which may be after being pressed into the final shape and in order to allow it to enter the DIP mold.

[0131] It should be noted that, according to various embodiments, the steps involved in providing the SCF sole components (e.g., 68, 70, and 72) are performed separately from the DIP process itself, and the SCF sole components that may be provided in the DIP process in step 52 may be pre-manufactured and provided in a corresponding shape, size, etc., and readily introduced into the DIP process. However, it is possible that the production of the SCF sole components and the DIP process for manufacturing footwear including one or more such SCF sole components may be performed side by side on a production line.

[0132] Figure 6 A direct injection mold 2 and a shoe last 20 are shown schematically, both in a cross-sectional view taken vertically through the ankle region of a footwear, and can be used for direct injection molding of footwear according to a method according to an embodiment of the present invention.

[0133] exist Figure 6 , the following scene is shown, in which, for example, a prefabricated sole component 80 manufactured by a supercritical foaming process has been positioned in a direct injection mold 2 when the mold is in an open state. After this, the shoe last 20 carrying the upper 30 has moved downward toward the mold and entered the mold 2 by an appropriate distance so that the periphery of the closed mold will coincide with the upper 30 carried by the shoe last 20. After the shoe last 20 moves downward, the mold 2 is closed, thereby forming a mold cavity 40 as shown in the figure between the upper 30, the first side mold 4, the second side mold 6 and the prefabricated sole component 80.

[0134] It should be noted that, as described above, the prefabricated sole component 80 manufactured by the supercritical foaming (SCF) process fills a majority of the volume defined by the upper 30, the first side mold 4, the second side mold 6 and the bottom mold 8, and is formed to substantially conform to the shape defined by the first side surface 5 and the second side surface 7 along the periphery of the prefabricated sole component 80.

[0135] However, if Figure 6 As shown in FIG. 1 , a space is left between the bottom of the upper 30, the first side surface 5, the second side surface 7 and the prefabricated sole component 80, which provides a mold cavity 40 according to an embodiment of the present invention. Figure 6 When an appropriate amount of injection material is injected into the mold cavity 40 (not shown), as the injection material expands and then solidifies, the injection material will eventually contact the first side surface 5, the second side surface 7, the bottom part of the upper 30 and the prefabricated sole part 80.

[0136] Thus, the injected material will be used to attach the prefabricated sole component 80 to the upper 30 and, after curing, the DIP mold can be opened and the manufactured footwear removed, after which possible further processing steps can be performed, such as removing excess injected material, etc.

[0137] As mentioned above, according to the present embodiment, prefabricated sole components 80 are manufactured by supercritical foaming process, and therefore have some ideal characteristics, such as for example provide than the softer sole of the sole components weight being made by for example foaming PU (polyurethane).In addition, when using the sole components manufactured by supercritical foaming process in DIP process, less energy can be used in manufacturing process.Even further, it should be noted that prefabricated sole components are lightweight forms, promptly have low density due to supercritical foaming process, so the outer sole of the footwear manufactured which means this can have required thickness, for example large thickness, and can not have adverse effect on the weight of finished footwear.Therefore, can manufacture footwear by DIP process, it has the outer sole of the thickness of increase compared with the footwear manufactured by prior art DIP of the outer sole made by for example PU wherein used, and still has lighter gross weight compared with the footwear of traditional manufacturing.

[0138] In such Figure 6 In the example of an embodiment of the invention shown in , the prefabricated sole component 80 is shown as an outsole, ie, the lower surface of which is the surface of the sole that contacts the ground during normal use.

[0139] However, it should be noted that the prefabricated sole component 80 may be used as a midsole, in which case the outsole ( Figure 6 The remaining steps of the process will be substantially the same as in the case of the combination of the prefabricated sole component 80 and the ground-facing surface of the prefabricated sole component 80. Figure 6 As described, for example, this means that a space is left between the bottom of the upper 30, the first side surface 5, the second side surface 7, and the prefabricated sole component 80 (the outer sole is attached to its lower side), and the space provides a mold cavity 40 according to an embodiment of the present invention. Therefore, when an appropriate amount of injection material is injected into the mold cavity 40 by the injection molding device, the injection material will eventually contact the first side surface 5, the second side surface 7, the bottom component of the upper 30, and the prefabricated sole component 80 assembled with the outer sole as the injection material expands and subsequently solidifies.

[0140] Other variations of footwear manufacturing processes are possible in which prefabricated sole components are used, and in which a direct injection process (DIP) provides for attachment of the prefabricated sole component to the footwear configuration.

[0141] Figure 6a The scenario shown in corresponds to Figure 6 , but in Figure 6a , it is shown that an adhesive layer 86 may be applied, such as a thin layer placed on the surface of the preformed sole component 80 to promote the injection material to adhere firmly to the preformed sole component 80 when it is cured. Such an adhesive layer may include materials such as glue, adhesive, fabric, woven or non-woven material, scrim, etc.

[0142] In the case of applying glue as the adhesive layer, various glues can be used, such as, for example, glue Loctite Bondace 2520-2, hardener Loctite Bondace RFE-TH (TPFE), hardener Loctite Bondace ARF-12, glue Loctite Bondace 223-2, curing agent Loctite Bondace ARF-1000, etc. However, it is obvious to those skilled in the art that other types and variations can be used.

[0143] As above combined Figure 6 As described, due to the use of the supercritical foaming process, the prefabricated sole component 80 has certain desirable properties, such as, for example, a softer sole that is lighter in weight than, for example, a sole component made of foamed PU (polyurethane). It should be noted that the prefabricated sole component is of a lightweight form, i.e., has a low density due to the supercritical foaming process, which means that the outer sole of the manufactured footwear can have a desired thickness, such as a large thickness, without adversely affecting the weight of the finished footwear.

[0144] However, for example, in the event that a relatively thick outsole with a relatively soft structure is found to be inconvenient, for example due to being too flexible or for other reasons, it may be desirable to adjust the properties of the assembled sole structure. This may be accomplished by utilizing the properties of an injected material (e.g., PU) that may be harder than the material of the prefabricated and supercritically foamed sole component, as described below.

[0145] exist Figure 7 In the figure, the DIP mold 2 is shown with Figure 6 A corresponding approach is used to manufacture footwear, but in which the depression(s) 82 are included in the preformed sole component 80. Since the preformed sole component 80 manufactured by the supercritical foaming process has increased softness, low density, and therefore low weight, the thickness can be increased without negatively affecting the weight, and therefore the softness and flexibility of the sole may need to be adjusted to achieve the desired stiffness and / or stability. Figure 7As shown in , this can be achieved by providing one or more depressions 82 on the prefabricated sole component 80. When the prefabricated sole component 80 is provided with a depression 82 facing the upper surface (the surface facing the foot) of the prefabricated sole component 80, it is understood that when the injection material 42 is injected into the mold cavity 40, it will fill and expand into the depression 82. When the injection material solidifies, it will adhere to the bottom of the upper and the upper surface of the prefabricated sole component 80, including the depression 82 and the surface of these. Therefore, compared with the material of the SCF sole component, the solidified injection material 42, such as PU, can have an increased hardness and stiffness, and can provide an increased stiffness in the direction along the direction of one or more depressions. Thus, the softness and flexibility of, for example, the outsole, including the prefabricated sole component 80, can be designed by the layout of at least one depression 82 and / or the depth of at least one depression.

[0146] Figure 7a The scene shown in corresponds to Figure 7 , but in Figure 7a In the figure, it is shown that Figure 6a As mentioned above, an adhesive layer 86 may be applied, such as a thin layer placed on the surface of the prefabricated sole component 80, to promote the injection material to adhere firmly to the prefabricated sole component 80 when it is cured. Figure 7a , it is shown that the adhesive layer 86 may not be applied to portions of the depression 82, such as the bottom and / or sides of the depression. Therefore, adhesion to the depression may be reduced, which may be taken into account when configuring, for example, the variable hardness and comfort of the sole structure, as will be described later.

[0147] As discussed above, the bonding layer 86 may include materials such as glue, adhesive, fabric, woven or nonwoven material, scrim, and the like.

[0148] In the case of applying glue as the adhesive layer, various glues can be used, such as, for example, glue Loctite Bondace 2520-2, hardener Loctite Bondace RFE-TH (TPFE), hardener Loctite Bondace ARF-12, glue Loctite Bondace 223-2, curing agent Loctite Bondace ARF-1000, etc. However, it is obvious to those skilled in the art that other types and variations can be used.

[0149] It should be understood that one or more depressions 82 may have a variety of forms, shapes, depths, vertical angles, etc. In addition, it is understood that one or more depressions 82 may extend partially through or completely through the prefabricated sole component 80, and one or more depressions 82 may be positioned within the prefabricated sole component 80 or at the periphery of the prefabricated sole component 80, such as on the peripheral side surrounding the prefabricated sole component 80. In addition, it is understood that one or more depressions 82 may be in the form of grooves, and such grooves may extend in the longitudinal direction of the footwear, the transverse direction of the footwear, or in a direction that forms an angle relative to the longitudinal or transverse direction of the footwear. Further, it is understood that one or more depressions 82 may extend as grooves, and the grooves may take the form of a variety of geometric shapes, such as, for example, straight lines, circles, curves, ellipses, spirals, etc.

[0150] The following will refer to Figures 8a to 20f Various embodiments of footwear made from embodiments of the present invention are illustrated.

[0151] Figure 8a A prefabricated sole component 80 manufactured by a supercritical foaming process is shown viewed from above, i.e., wherein a foot-facing surface 98 is also shown, and Figure 8b Shows along Figure 8a The prefabricated sole component 80 is visible in the cross-sectional view along line MM in FIG. Figure 8c A cross-sectional view of the footwear along the longitudinal direction is shown, wherein Figure 8a and 8b The prefabricated sole component 80 shown is used as an outsole. Figure 8d-8f Shows Figure 8c A corresponding cross-sectional view of the footwear shown in Figure 8d is a transverse cross-section of the heel region (along line DD), Figure 8e is a transverse cross-section of the arch area (along line EE), Figure 8f is a transverse cross-sectional view of the forefoot region (along line FF). As described above, the attachment sole component 90 is used to attach the sole component 90 to the forefoot region, possibly via the adhesive layer 86 ( Figure 8a-20f Attach the upper 30 to the prefabricated sole component 80 ).

[0152] It should be noted that Figures 9a-9f , Figures 10a-10f Wait until Figures 20a-20f , these include Figures 8a-8f The drawings are arranged in a corresponding order and manner. Therefore, no further information about the views and the order in which these drawings are arranged will be provided, and only comments on the subject matter of these drawings will be explained below.

[0153] Figure 9a-f shows an embodiment of footwear made by an embodiment of the present invention, wherein a prefabricated sole component 80 includes one or more depressions 82, including depressions 82 forming grooves 84, which extend along a majority of the heel portion and extend on each side of the footwear and connect to a curved portion at the heel. Figure 9d and 9e As shown, this provides a Figure 7 Basically corresponding configuration.

[0154] Fig.10a -f shows another embodiment in which a prefabricated sole component 80 comprises a depression 82 which is also shaped as a groove 84, since three grooves are positioned substantially along one another at the rear of the footwear.

[0155] Fig.11a -f shows another example of footwear made by an embodiment of the present invention, wherein a prefabricated sole component includes various depressions 82, including groove-shaped depressions 84 and depressions 82 having larger areas (eg, semicircular) in the heel and toe areas.

[0156] Fig.12a -f shows another example of footwear made by an embodiment of the present invention, where Fig.12a As shown in FIG. 8 , the depressions 82 are in the shape of small circular holes distributed over the foot-facing surface 98 of the prefabricated sole component 80 .

[0157] Fig.13a -f shows another embodiment of footwear manufactured by an embodiment of the present invention, wherein Figure 13c-13f As shown in , the preformed sole component 80 includes a depression that extends through the sole, whereby the attached sole component 90 also serves as a ground contacting medium with the preformed sole portion 80 by the ground facing surface 96 .

[0158] Fig.14a -f shows an embodiment of footwear made according to an embodiment of the present invention, wherein a prefabricated sole component 80 includes depressions 82 placed around the perimeter of the sole, such as Fig.14a The perimeter shown is, for example, recessed on the medial and lateral sides of the preformed sole component 80. Fig.14d and 14e As shown in , this may have the effect of causing a majority of the outboard side of the sole to be comprised of the cured injected material, which may be preferred where this material is harder or stronger than the SCF foam material of the preformed sole component 80.

[0159] Fig.15a-f shows an embodiment of footwear made according to an embodiment of the present invention, showing another example of a prefabricated sole component 80, which includes depressions 82 placed around the perimeter of the sole. Here, depressions 82 are shown, as well as depressions 82 located on the medial and lateral sides of the sole, and can also be located in the heel portion, for example, except for the forefoot portion, where depressions 82 are continuous depressions along most of the perimeter of the footwear.

[0160] Fig.16a -f shows an embodiment of footwear made by an embodiment of the present invention, wherein a prefabricated sole component 80 includes depressions 82 primarily located around the heel portion of the sole.

[0161] Fig.17a -f shows an embodiment of footwear manufactured according to an embodiment of the present invention, wherein a prefabricated sole component 80 includes a recess 82 which is provided on only one side of the sole, e.g. Fig.17a , although it can also be placed on the outside.

[0162] Fig.18a -f shows an embodiment of footwear made by an embodiment of the present invention, wherein a prefabricated sole component 80 includes a relatively large recess 82, which has a relatively large area, for example when viewed from above, see Fig.18a , one located in the heel area and one located in the forefoot area. Fig.18d and 18f As shown in , the injected material of the attached sole component 90 can be seen from the side through the recesses 82 of the preformed sole component 80 in certain portions of the sole.

[0163] Fig.19a -f shows an embodiment of footwear manufactured according to an embodiment of the present invention, wherein a prefabricated sole component 80 comprises a recess 82, which is substantially located in the transverse direction of the sole and is in the form of a transverse groove 84, such as Fig.19a In addition, Fig.19a As shown in FIG. 1 , depressions 82, such as holes, apertures, etc., may be arranged on the side of the prefabricated sole component 80 so that the material of the attached sole component 90, whose pattern is defined by these holes, apertures, or the like, can be seen from the side, such as Fig.19e as shown in .

[0164] It should be noted that the depressions 82 in the form of grooves may be arranged at an angle relative to the longitudinal or transverse direction of the footwear.

[0165] Fig.20a -f shows another embodiment of footwear made according to an embodiment of the present invention, wherein a prefabricated sole component 80 includes depressions 82 formed in and distributed over a foot-facing surface 98 to adapt the support and comfort features of the sole to the user. Fig.20aAs shown in the figure, the prefabricated sole component 80 may include two relatively large depressions 82, both of which may be asymmetric relative to line MM or relative to the approximate center line (not shown) of the footwear. One of these depressions may be a smaller kidney-shaped depression 82 located in the arch area and the inner side, and the other may include a larger portion of the heel and forefoot area as shown in the figure, connected by a depression of a smaller length in the arch area. Other forms and variations are also possible. It is understood that, by such a configuration, the support of the sole, such as hardness, comfort, etc., may be adapted to the user, such as when filled with a relatively hard solidified injection material component compared to the softer SCF foaming material of the prefabricated sole component 80, the depressed area may, for example, provide a load-bearing area at the heel and the sole, and the softer SCF foaming material may provide a greater degree of comfort in other areas. In addition, it is understood that such a "fine adjustment" of the hardness / comfort for realizing variable hardness may be used to adapt the shoes according to a specific user, such as providing greater support in the inner side or the outer side, etc.

[0166] It should be noted that the above Figures 8a to 19f Other embodiments of the illustrated footwear may be configured with asymmetrical support / comfort configurations.

[0167] Through the above examples, it is shown that the prefabricated sole components 80 and attached sole components 90 can be arranged in a variety of ways to achieve desired characteristics, such as overall sole and footwear stiffness, flexibility, weight, etc. In addition, it should be noted that variations can be made to achieve a desired design, appearance, etc.

[0168] Furthermore, it should be noted that the above examples can be combined with each other in various ways, which will be obvious to a person skilled in the art.

[0169] Reference numerals

[0170] 2Direct injection mold

[0171] 4First side mold

[0172] 5First side surface

[0173] 6 Second side mold

[0174] 7 Second side surface

[0175] 8 bottom mold

[0176] 9 Bottom inner surface

[0177] 20 shoe lasts

[0178] 30 Upper

[0179] 40 cavities

[0180] 42 Injection material

[0181] 44 soles

[0182] 50DIP molds available

[0183] 52 Provide SCF sole components

[0184] 54 Positioning SCF sole components

[0185] 56 Positioning upper

[0186] 58 closed DIP mold

[0187] 60 injection injection material

[0188] 62 Curing injection material

[0189] 64 Open the mold

[0190] 66 Remove Footwear

[0191] 68 Provide basic components

[0192] 70 SCF agent

[0193] 72 Expanded into preform

[0194] 80 Prefabricated sole components

[0195] 82 Depression

[0196] 84 grooves

[0197] 86 Adhesive layer

[0198] 90 Attaching the sole components

[0199] 92 sole pattern

[0200] 94 Ground

[0201] 96Surface facing the ground

[0202] 98 facing the surface of the foot

Claims

1. A method of manufacturing footwear by direct injection production (DIP), the method comprising: - providing a direct injection mold (2) which is attachable to an injection molding apparatus and is configured for at least partially directing the injection material to the mold cavity (40), - providing at least one prefabricated sole component (80) of a sole structure, - positioning the prefabricated sole component (80) relative to the direct injection mould (2), - positioning the upper (30) relative to the direct injection mould (2), - injecting an injection material into the mold cavity (40), the mold cavity being at least partially formed by the direct injection mold (2), the injection material being configured for attaching the upper (30) to the at least one prefabricated sole component (80), the injection material providing, after curing, an attached sole component (90) of the sole structure of the footwear, Wherein, the at least one prefabricated sole component (80) is a sole component manufactured by a supercritical foaming process.

2. The method according to claim 1, wherein: The attachment sole component (90) for attaching the upper (30) to the at least one prefabricated sole component (80) may be used as at least a portion of another sole component of the sole structure of the footwear.

3. The method according to claim 1 or 2, wherein: The at least one prefabricated sole component (80) is configured to form an outsole.

4. The method according to any one of claims 1 to 3, wherein: The at least one prefabricated sole component (80) is configured to form a midsole.

5. The method according to any one of claims 1 to 4, wherein: The attached sole component (90) provided at least in part by the injected material when cured forms at least a portion of a midsole.

6. The method according to any one of claims 1 to 5, wherein: The at least one prefabricated sole component is prefabricated by subjecting a base component to a supercritical foaming agent, whereby the base component expands into a preform.

7. The method according to claim 6, wherein: The supercritical blowing agent is a gas, such as carbon dioxide (CO2) and / or nitrogen.

8. The method according to any one of claims 1 to 7, wherein: The at least one prefabricated sole component comprises TPU (thermoplastic polyurethane), TPE (thermoplastic elastomer), (polyether block amide), natural rubber, synthetic rubber, ethylene vinyl acetate (EVA) and / or polyvinyl chloride (PVC).

9. The method according to any one of claims 1 to 8, wherein: The injection material includes PU (polyurethane), latex, polyvinyl chloride (PVC) and / or thermoplastic rubber (TR).

10. The method according to any one of claims 1 to 9, wherein: The at least one prefabricated sole component (80) is configured with a ground-facing surface (96) and a foot-facing surface (98), wherein the foot-facing surface includes at least one depression (82) for receiving injected material.

11. The method according to claim 10, wherein: The at least one depression included in the foot facing surface for receiving injected material forms a groove (84) along the foot facing surface (98).

12. The method according to claim 11, wherein: The at least one depression (82) for receiving injected material forming a groove (84) along the foot-facing surface may extend in the longitudinal and / or transverse direction of the footwear.

13. The method according to claim 11 or 12, wherein: The at least one depression (82) for receiving injected material forming a groove (84) along the foot-facing surface (98) may extend in a direction substantially forming an angle different from 0° relative to the longitudinal direction of the footwear.

14. The method according to claim 11, 12 or 13, wherein: The at least one recess forming a groove along the foot-facing surface for receiving the injected material may extend substantially straight, in an angled form and / or in a curved form.

15. The method according to any one of claims 10 to 14, wherein: The at least one recess for receiving injected material may extend through the at least one prefabricated sole component (80).

16. The method according to any one of claims 10 to 15, wherein: The at least one depression (82) for receiving injected material is asymmetrically arranged in / on the foot-facing surface (98).

17. The method according to any one of claims 10 to 16, wherein: The at least one depression (82) for receiving injected material is configured to provide variable stiffness and / or support to the sole structure.

18. The method according to any one of claims 1 to 17, wherein: The at least one prefabricated sole component (80) includes an adhesive layer (86) on at least a portion of the surface subjected to the injected material.

19. The method according to claim 18, wherein: The adhesive layer (86) includes materials such as glue, fabric, woven or non-woven material, scrim, and the like.

20. The method according to claim 18 or 19, wherein: At least a portion of the surface subjected to the injected material, such as the bottom and / or sides of the recess, is free of the adhesive layer (86).

21. Footwear manufactured by direct injection production (DIP), the footwear comprising -Upper(30) - at least one prefabricated sole component (80), - at least one further sole component of said footwear, - wherein the at least one prefabricated sole component (80) is a sole component manufactured by a supercritical foaming process, and - wherein the at least one further sole component of the footwear is manufactured at least in part by injecting an injection material into a mould cavity (40) at least in part formed by a direct injection mould (2), and wherein the injection material has attached the upper to the at least one prefabricated sole component.

22. The footwear according to claim 21, wherein: The at least one prefabricated sole component (80) is configured to form an outsole.

23. Footwear according to claim 21 or 22, wherein: The further sole component of the footwear provided at least in part by the injected material is a midsole.

24. Footwear according to any one of claims 21 to 23, wherein The at least one prefabricated sole component (80) is prefabricated by subjecting a base component to a supercritical foaming agent, whereby the base component expands into a preform.

25. The footwear according to claim 24, wherein: The supercritical blowing agent is a gas, such as carbon dioxide (CO2) and / or nitrogen.

26. Footwear according to any one of claims 21 to 25, wherein: The at least one prefabricated sole component comprises TPU (thermoplastic polyurethane), TPE (thermoplastic elastomer), (polyether block amide), natural rubber, synthetic rubber, ethylene vinyl acetate (EVA) and / or polyvinyl chloride (PVC).

27. Footwear according to any one of claims 21 to 26, wherein: The injection material includes PU (polyurethane), latex, polyvinyl chloride (PVC) and / or thermoplastic rubber (TR).

28. Footwear according to any one of claims 21 to 26, wherein The at least one prefabricated sole component (80) is configured with a ground-facing surface (96) and a foot-facing surface (98), wherein the foot-facing surface includes at least one depression (82) for receiving injected material.

29. The footwear according to claim 28, wherein: The at least one depression (82) for receiving injected material contained in the foot facing surface forms a groove (84) along the foot facing surface (98).

30. The footwear according to claim 29, wherein: The at least one recess forming a groove along the foot-facing surface for receiving injected material may extend in a longitudinal and / or transverse direction of the footwear.

31. Footwear according to claim 29 or 30, wherein: The at least one recess forming a groove along the foot-facing surface for receiving the injected material may extend in a direction substantially forming an angle different from 0° with respect to the longitudinal direction of the footwear.

32. Footwear according to any one of claims 29 to 31, wherein The at least one recess forming a groove along the foot-facing surface for receiving the injected material may extend substantially straight, in an angled form and / or in a curved form.

33. Footwear according to any one of claims 28 to 32, wherein: The at least one recess for receiving injected material may extend through the at least one prefabricated sole component.

34. Footwear according to any one of claims 28 to 33, wherein: The at least one depression (82) for receiving injected material is asymmetrically arranged in / on the foot-facing surface (98).

35. Footwear according to any one of claims 28 to 34, wherein: The at least one depression (82) for receiving injected material is configured to provide variable stiffness and / or support to the sole structure.

36. Footwear according to any one of claims 21-35, wherein: The at least one prefabricated sole component (80) includes an adhesive layer (86) on at least a portion of the surface subjected to the injected material.

37. The footwear according to claim 36, wherein: The adhesive layer (86) includes materials such as glue, fabric, woven or non-woven material, scrim, and the like.

38. Footwear according to claim 36 or 37, wherein: At least a portion of the surface subjected to the injected material, such as the bottom and / or sides of the recess, is free of the adhesive layer (86).

39. Footwear according to any one of claims 21 to 38, wherein: The footwear is manufactured by a direct injection production (DIP) method according to any one of claims 1 to 20.

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