Method for producing a sole element and sole element

Abstract

Disclosed herein is a sole element (1) comprising one or more tubular channel structures (3, 4) wherein a cured fibrous component comprising fibers and a resin is introduced into the one or more tubular channel structures (3, 4). Further, a method for producing a sole element is provided.

Description

Technical Field

[0001] The invention belongs to the technical field of shoes, in particular running shoes, and relates to a method for producing a sole element and a sole element. Background Art

[0002] In recent years, energy recovery systems have become an important aspect of running shoes. The most prominent system is a rigid plate, which is typically elastic and therefore often incompressible. For example, a continuous carbon fiber composite plate can be incorporated into the sole structure of a running shoe. Such a plate typically extends at least over the metatarsal joint area and is therefore preferably located at least in the forefoot and midfoot areas of the sole structure. During the foot's push-off and subsequent roll-off motion, the rigid plate bends and temporarily stores energy due to its elastic behavior. During push-off, the bent elastic plate then returns to its original, relatively flat shape, thereby supporting the runner's push-off motion. Ultimately, this improves the runner's performance (e.g., in terms of running speed and fatigue reduction).

[0003] Most commonly, a single rigid plate is provided, essentially extending over the entire forefoot and midfoot area, and in some cases also over the heel area. This plate is usually a single piece made of a suitable material (e.g., a fiber composite material). A disadvantage of such continuous plates is that they increase the overall weight of the sole, and therefore the overall weight of the running shoe. However, especially in high-performance fields and professional competitions, even a slight increase in weight can have serious consequences for running performance and competitiveness.

[0004] Some known energy recovery systems use plates with cutouts to minimize system weight, or utilize only one or more separate rigid rod elements extending through the midfoot and forefoot regions. However, common issues with these latter systems are the securing of the individual rods to other elements of the sole structure and their relatively cumbersome production. Furthermore, these separate rods often exhibit reduced force transmission.

[0005] Another common problem with known energy recovery systems is the limited design freedom due to manufacturing limitations. For example, if it is desired to tailor a particular energy recovery system to an individual's gait and / or foot anatomy, manufacturing difficulties arise because most systems are traditionally injection molded, and the molds must therefore be adjusted for each individual. Furthermore, many known energy recovery systems are manufactured in a manner that does not allow the system to be easily and quickly adapted to the specific requirements of an individual. Summary of the Invention

[0006] Therefore, the overall purpose of the present invention is to improve the current state of the art in the field of shoe technology, in particular in energy recovery systems for shoes, and preferably to overcome the problems of the prior art in whole or in part. In an advantageous embodiment, a method for producing a sole element is provided that can easily and efficiently adapt to the specific requirements of a runner. In another advantageous embodiment, a method for producing a sole element is provided that allows for more efficient production and / or greater freedom of design of the produced sole element. In another advantageous embodiment, a sole element is provided that allows for energy to be fed back to the runner and preferably has a lower weight than known systems. In another advantageous embodiment, a sole element is provided that generally has a better energy return effect than known systems.

[0007] This general object is achieved by the subject matter of the independent claims. Further advantageous embodiments result from the dependent claims and the overall disclosure.

[0008] In a first aspect, the present invention relates to a method for producing a sole element, in particular a reinforced sole element. The method comprises the following steps: a. A blank sole element is provided, the blank sole element comprising one or more, in particular a plurality of, tubular channel structures.

[0009] b. Introducing, preferably injecting, a fiber component comprising or consisting of fibers and a resin (particularly a flowable resin) into one or more tubular channel structures (i.e., into channels formed by the tubular channel structures).

[0010] c. Curing the introduced, preferably injected, fiber component to provide a sole element, in particular a reinforced sole element.

[0011] The method according to the present invention allows a fast and efficient method to produce sole elements. The sole elements produced by this method can be regarded as reinforced sole elements. Compared with sole elements with a tubular channel structure that does not define channels filled with fiber components, the reinforced sole elements are reinforced. The tubular channel structure can be easily arranged in a desired manner and can be reinforced by inserting fiber components. By arranging the tubular channel structure in a desired manner, it is easy to predefine which areas of the sole element have been reinforced by the cured fiber components. In contrast to continuous plate-like elements, reinforcement only occurs in predefined areas, thereby reducing the total weight of the sole and therefore the total weight of the shoe. In addition, the tubular channel structure ensures that the reinforcement carried out by the cured fiber components stays at the predefined positions and will not move even during long-term use.

[0012] The term "blank sole element" refers to a sole element whose tubular channel structure contains only air (eg at an ambient pressure of 1 atm) and into which fiber components have not yet been introduced.

[0013] In some embodiments, the blank sole element provided in step a. further comprises a base body, and the one or more tubular channel structures extend along the base body.

[0014] The term "extending along the base body" encompasses a tubular channel structure that may be arranged within the base body, adjacent to the base body, on and / or below the base body. Typically, however, the tubular channel structure is in direct contact with the base body.

[0015] In some embodiments, the blank sole element provided in step a. further comprises a blank base body, and one or more tubular channel structures extend along the blank base body. The blank base body is transformed into a base body before or after step b. It will be understood that such transformation requires physical and / or chemical modification of the blank base body. For example, the blank base body may be foamed to transform into a base body, which is then foamed. The term "extending along the blank base body" encompasses tubular channel structures that may be arranged within the blank base body, adjacent to the blank base body, on and / or below the blank base body. However, typically, the tubular channel structures are in direct contact with the blank base body.

[0016] Should be understood that one or more tubular channel structures define corresponding channels individually or together with the base body. Each channel can have a channel volume. If the tubular channel structure defines the channel individually, the channel wall is formed only by the tubular channel structure. In such embodiments, except any channel opening, the tubular channel structure circumferentially defines the channel. As used herein, the channel opening generally refers to the distal channel opening, which preferably defines the starting point and / or end point of the channel.

[0017] If the tubular channel structure defines a channel together with the base body, the channel is defined by the channel structure and the base body, and therefore the channel wall is formed by the tubular channel structure and the base body. Similarly, in such embodiments, except for any channel openings, the tubular channel structure circumferentially defines the channel together with the base body. For example, the tubular channel structure can then have a U-shaped or V-shaped cross section, which together with the base body then produces a substantially rectangular or triangular channel cross section. Therefore, one or more tubular channel structures each individually or together with the base body define a cavity, and fiber components can be introduced into this cavity.

[0018] Typically, each tubular channel structure, alone or in combination with the base body, defines two channel openings, namely, a channel inlet and a channel outlet for introducing the fiber component. Each tubular channel structure typically includes at least one, at least two, at least three, or at least four channel walls, alone or in combination with the base body, to define the corresponding channel. The channel walls of the tubular channel structure typically have a wall thickness t.

[0019] As used herein, a flowable resin is a resin having a viscosity selected so that the resin can be injected into one or more tubular channel structures. This can be, for example, a resin that is in an uncured state in liquid form and can be brought into a solid form, for example, by heating and subsequent cooling, by a chemical reaction, and / or by irradiation. In particular, the flowable resin can be a molten resin.

[0020] The solidification of the fiber component may, for example, include the solidification of the resin. In particular, the resin may solidify and / or harden during solidification. In some embodiments, solidification may include the cooling of the resin.

[0021] In some embodiments, curing may include heating the introduced fiber component to a temperature at or above the resin curing temperature of the resin. In certain embodiments, curing may then include cooling the heated resin. The resin curing temperature is the minimum temperature required to achieve curing. In some embodiments, curing may include irradiating the introduced fiber component with light of a suitable wavelength.

[0022] In some embodiments, providing the blank sole element in step a. comprises the sub-step a1. of producing one or more tubular channel structures by additive manufacturing, blow molding or extrusion.

[0023] In some embodiments, the base body or blank base body is also produced by additive manufacturing, blow molding, or extrusion. In certain embodiments, the one or more tubular channel structures and the base body or blank base body are integrally formed, that is, they are produced as a single piece. In alternative embodiments, the one or more tubular channel structures and the base body or blank base body are produced separately and then connected by a suitable connection method, such as welding, gluing, etc. It is also possible that the base body or blank base body defines a recess into which the tubular channel structure can be arranged, particularly in a form-locking and / or force-locking engagement. Although the tubular channel structure is produced before step b. (i.e., before injecting the fiber component), it is also possible that the base body or blank base body can also be produced either before step b. or after step b. However, typically, during step b., the fiber component is preferably injected into a channel that is circumferentially bounded by channel walls, except for at least two channel openings. Therefore, the channel is preferably not a groove along its extension direction to the environment.

[0024] In a preferred embodiment, one or more tubular channel structures and optionally also the base body or blank base body are produced by additive manufacturing. Additive manufacturing may include any suitable 3D printing technology, such as SLS, FDM, etc. The use of additive manufacturing allows the sole elements produced to be easily personalized according to the requirements of a specific individual. For example, the arrangement, number, size, shape and other characteristics of the tubular channel structures can be easily adjusted by additive manufacturing. Considered together with the injection and curing of fiber components, the design freedom is significantly increased while maintaining an efficient production process. Combining additive manufacturing with steps a. to c. of the method according to the invention allows to quickly provide elements in the sole element that are strengthened and rigidified in terms of shape and arrangement, which would otherwise be impossible or almost impossible to achieve.

[0025] In some embodiments, the one or more tubular channel structures are provided such that they extend at least partially along the longitudinal direction of the blank sole element and the produced sole element and / or such that they extend from the midfoot region of the blank sole element and the produced sole element to the forefoot region. In a preferred embodiment, the one or more tubular channel structures may be arranged such that they extend from the heel region to the forefoot region via the midfoot region of the blank sole element and the produced sole element.

[0026] As used in this disclosure, directional designations are to be understood as follows: the longitudinal direction L of a sole element is described by the axis from the heel region (respectively, from the heel edge) to the forefoot region (respectively, to the toe of the sole element), and thus extends along the longitudinal axis of the sole element. The transverse direction T of the sole element extends transversely to the longitudinal axis and is substantially parallel to the ground in the operating state. Thus, the transverse direction extends along the transverse axis of the sole element. In the context of the present invention, the vertical direction V is arranged in the direction of the wearer's foot in the operating state and thus extends along the vertical axis of the sole element. The longitudinal direction, the vertical direction, and the transverse direction may all be perpendicular to each other. The lateral side of the sole element is the outer perimeter of the sole element between the heel edge and the toe of the sole element, which, when worn, rests against the outer instep of the wearer's foot. The medial side of the sole element is the inner perimeter of the sole element between the heel edge and the toe of the sole element, which is positioned opposite the lateral side. Thus, in a worn pair of shoes, the medial sides of the two shoes face each other and the lateral sides face away from each other. Furthermore, the sole element can typically be divided in the longitudinal direction into a forefoot region, a midfoot region, and optionally also a heel region. If the heel region is present, the midfoot region is arranged between the forefoot region and the heel region.

[0027] In some embodiments, providing the blank sole element includes performing a gait analysis and / or a foot analysis on an individual and producing the blank sole element based on the performed gait analysis and / or foot analysis. The blank sole element can then be provided (or correspondingly produced) based on the gait analysis and / or foot analysis. The foot analysis can, for example, include a 3D scan of the individual's foot. The gait analysis can, for example, include monitoring the individual's gait using a high-speed camera or using a pressure plate with a force sensor. Such embodiments can preferably be combined with embodiments in which step a. includes sub-step a1. Therefore, it may be possible to perform a gait and / or foot analysis on an individual and then, for example, produce the blank sole element based on the gait and / or foot analysis by additive manufacturing, blow molding, or extrusion.

[0028] In some embodiments, the fibers of the fibrous component may be selected from one or more of the following: carbon fibers, basalt fibers, aramid fibers, glass fibers, flax fibers, and hemp fibers.

[0029] In some embodiments, the fibers may be endless fibers and / or fiber bundles, preferably fiber bundles of endless fibers.

[0030] In some embodiments, the blank sole element provided in step a. includes a plurality of tubular channel structures forming a channel structure network. The channel structure network includes at least two openings that provide fluid communication between the interior of the plurality of tubular channel structures and the external environment of the blank sole element. Typically, for each set of fluidically connected tubular channel structures, two openings per set are sufficient to introduce the fiber component. In some embodiments, most or even all of the tubular channel structures in the channel structure network are in fluid communication with each other.

[0031] In some embodiments, the blank sole element provided in step a. comprises a plurality of tubular channel structures, wherein the plurality of tubular channel structures comprises a plurality of main channel structures and one or more connecting channel structures, wherein the one or more connecting channel structures fluidically connect two or more main channel structures to each other.

[0032] In some embodiments, the fibers and the resin are introduced, in particular injected, simultaneously in step b. This has the advantage that the fibers are efficiently transported into the channel by the resin.

[0033] In some embodiments, at least one of the one or more tubular channel structures includes a branch, at which the at least one tubular channel structure branches into two or more sub-channel structures. The branch may be, for example, a fork.

[0034] In some embodiments, the fiber component is injected so that the tubular channel structure is filled to greater than 90%, particularly greater than 95%, more particularly greater than 98%, and more particularly 100% of its channel volume. It should be understood that the channel volume refers to the volume of the channel before any fiber component is introduced. The channel volume is generally defined (respectively, defined) by the channel walls. The tubular channel structure is then filled with the fiber component, particularly within these ranges.

[0035] In some embodiments, one or more tubular channel structures may have an angular (such as a rectangular, trapezoidal, or triangular) or circular (particularly an elliptical or circular) cross section. Unless otherwise noted, the term "cross section" of a tubular channel structure preferably refers to a plane perpendicular to the channel extension direction (i.e., the direction along which the tubular channel structure extends).

[0036] In some embodiments, the channel or channels formed by the tubular channel structure alone or together with the base body have an angular (such as rectangular, trapezoidal or triangular) or circular (particularly elliptical or circular) cross section. Unless otherwise noted, the term "cross section" of the channel preferably refers to a plane perpendicular to the direction of extension of the channel (i.e., the direction along which the channel extends).

[0037] In some embodiments, it may be possible for at least one of the tubular channel structures and / or at least one channel defined by the tubular channel structure, alone or in combination with the base body, to have a cross-section that varies along the channel (i.e., along a particular channel). For example, it may be possible for the corresponding channel to have a rectangular cross-section in the midfoot region and a circular cross-section in the forefoot region, or vice versa.

[0038] In some embodiments, each channel defined by the tubular channel structure alone or in combination with the base body may define a channel having a diameter between 2.5 mm and 1.5 mm. 2 Up to 15.0 mm 2 between, especially between 4.0 mm 2 Up to 10.0 mm 2 The term "open area" refers to the surface area defined by the tubular channel structure and optionally the base body (ie, by the channel walls), and does not include any fiber components within the tubular channel structure (respectively, the channel).

[0039] In certain embodiments, the cross-sectional open area defined by one of the at least one tubular channel structure and optionally the base body may vary along the channel.

[0040] In some embodiments, the height of the channel defined by the one or more tubular channel structures, optionally the base body, is between 1.2 mm and 10.0 mm, in particular between 1.7 mm and 7.5 mm. The height of the channel may be the extension of the channel in the vertical direction.

[0041] In some embodiments, the ratio of the channel height to the height of the base body (ie the extension of the base body in the vertical direction) is between 5:1 and 1:1, in particular between 21:5 and 9:8.

[0042] In some embodiments, the width of the channel defined by the one or more tubular channel structures is between 1.2 mm and 20.0 mm, in particular between 1.7 mm and 7.5 mm. The width is perpendicular to the direction along which the tubular channel extends and may be the extension of the channel in the transverse direction.

[0043] In some embodiments, the ratio of the channel width to the total width of the sole element (ie the extension of the sole element along the transverse direction) is between 1:1 and 85:1, in particular between 3:1 and 21:1.

[0044] The height and width of the channels are typically in a cross-sectional plane perpendicular to the extension direction of the corresponding channel and / or tubular channel structure.

[0045] In some embodiments, the height and / or width of the channel defined by one of the at least one tubular channel structures and optionally the base body may vary along the channel.

[0046] In some embodiments, the raw sole element and the produced sole element include one, two, three, four, five, or six separate tubular channel structures. The separate tubular channel structures are not fluidically connected to each other. In certain embodiments, the raw sole element and the produced sole element include only one, only two, only three, only four, only five, or only six separate tubular channel structures.

[0047] In some embodiments, the base body includes (and accordingly defines) a plurality of through-holes, i.e., holes extending through the base body. The total open area defined by the sum of the open areas defined by each hole is between 0% and 90%, particularly between >0% and 90%, and more particularly between 10% and 75%, of the total surface area of ​​the base body.

[0048] The one or more tubular channel structures and the base body may be made of one or more selected from the group consisting of thermoplastic polyurethane (TPU), thermoplastic elastomer, polyamide, polyether block amide, ethylene vinyl acetate, polyvinylidene fluoride, polyolefin, and polyester.

[0049] The one or more tubular channel structures and the base body may be made of the same material or different materials.

[0050] In some embodiments, the sole element can be a sole plate. In certain embodiments, the sole plate can be a rigid sole plate. For example, the sole plate can be an elastic and incompressible sole plate.

[0051] In some embodiments, the sole plate extends at least from the midfoot region to the forefoot region and has a toe portion. This toe portion typically coincides with the toe portion of the shoe for which the sole plate is intended. Thus, when worn, the toe portion is positioned longitudinally in front of the wearer's toes. In certain embodiments, the sole plate extends from the heel region through the midfoot region to the forefoot region. In such embodiments, the sole plate has a heel edge. The heel edge is the portion with the greatest distance to the toe portion in the longitudinal direction. In embodiments in which the sole plate extends only from the midsole region to the forefoot region (and therefore not in the heel region), the sole plate accordingly has a midfoot edge. In this case, the midfoot edge is the portion with the greatest distance to the toe portion in the longitudinal direction.

[0052] In some embodiments, the obtained sole element, in particular the sole plate, has the following flexural modulus as determined by Test Method 1: at least 12000 N / mm 2 , in particular at least 15000 N / mm 2 , more particularly at least 20000 N / mm 2 In some embodiments, the sole element, in particular the sole plate, has the following flexural modulus as determined by Test Method 1: at most 70,000 N / mm 2 , in particular up to 60000 N / mm 2 , more particularly up to 55000 N / mm 2 This flex modulus provides a stable stance and efficient push-off.

[0053] According to Test Method 1, a 3-point flexural test is performed (for details on the 3-point flexural test, see https: / / en.wikipedia.org / wiki / Three-point_flexural_test and DIN EN ISO 178:2019). To this end, the sole element, in particular the sole plate, is positioned with its base layer on two support pins that extend over the entire transverse direction of the sole element, in particular the sole plate. The sole element, in particular the sole plate used, can typically be a US size 10 sole plate and have a length of 262 mm. The two support pins are spaced 160 mm apart from one another. Each support pin has a width of 70 mm (extending in the transverse direction of the sole plate during the measurement) and a rounded edge with a curve radius of 25 mm, which supports the sole element, in particular the sole plate. A loading pin is then placed on the top layer at 70% of the total length of the sole element, in particular the sole plate, measured from the heel edge to the toe. The loading pin has a width of 70 mm (extended in the transverse direction of the sole element, in particular the sole plate, during measurement) and a rounded semi-cylindrical edge with a 25 mm radius of curvature extending along the sole element, in particular the sole plate. The loading pin is arranged longitudinally between the two support pins. The front support pin (i.e., the support pin closer to the tip of the sole element, in particular the sole plate) is spaced 80 mm from the loading pin in the longitudinal direction (measured from the pin's extreme point); and the rear support pin (i.e., the support pin arranged closer to the heel edge (and, accordingly, the midfoot edge) of the sole element, in particular the sole plate) is spaced 80 mm from the loading pin in the longitudinal direction (measured from the pin's extreme point). All three pins arranged on the longitudinal centerline of the sole element, in particular the sole plate, are essentially identical (i.e., the extent of each pin in the transverse direction towards the lateral peripheral edge and towards the medial peripheral edge). Then, if a sole element, in particular a sole plate, is tested, the loading pin is preloaded with a preload force (F0) of 10 N, or if a complete shoe with an upper is tested, the loading pin is preloaded with a preload force (F0) of 25 N, and then loaded stepwise (5 times) with a force that bends the sole element, in particular the sole plate, and the force (F1) required to deflect the sole element, in particular the sole plate, by 15 mm in the vertical direction in order to measure the corresponding force (test speed: 300 mm / min) is measured. According to the formula E = l 3 v ΔF / (4D L ba 3 ), the flexural modulus can be determined, where ΔF is the difference in Newtons between the end of the measurement (F1) and the beginning of the measurement (F0); v D is the width of the support span in mm; Lis the bending distance between F1 and F0 in mm; b is the width of the sample at the loading pin location in mm, and a is the thickness of the sample at the loading pin location in mm.

[0054] In embodiments where the sole element, in particular the sole plate, includes more than one tubular channel structure, the tubular channel structures may generally be preferably spaced apart from one another. Preferably, at least two tubular channel structures are spaced apart from one another in the transverse direction. In certain embodiments, at least a portion of the base body may be arranged between the spaced-apart tubular channel structures. In certain embodiments, it may be possible that one or more tubular channel structures are each arranged between two portions of the base body.

[0055] In some embodiments of the sole plate, the base body and the one or more tubular channel structures are made of the same material. Alternatively, it may be possible that they are made of different materials.

[0056] In an alternative embodiment, the sole element may be a midsole. It may be possible that the tubular channel structure and the base body are integrally formed. In some embodiments where the sole element is a midsole, the base body and / or the tubular channel structure may be made of polymer foam.

[0057] In an alternative embodiment in which the sole element is a midsole, the one or more tubular channel structures are separated from the base body. For example, the base body can be made of polymer foam. The tubular channel structure can be made of the same material or another material (particularly a polymer material, but preferably non-foamed). Therefore, the polymer foam structure and the one or more tubular channel structures are not formed integrally. In some embodiments, the polymer foam structure at least partially or completely surrounds the one or more tubular channel structures. However, it should be understood that this does not include openings in the tubular channel structures. Perhaps, for example, it is possible that the base body, as a polymer foam element, defines a groove or recess into which the (multiple) tubular channel structures can be arranged, particularly in a force-locking and / or form-locking engagement.

[0058] In certain embodiments where the sole element is a midsole, step a. may include forming the tubular channel structure and a blank base body. Then, in a subsequent sub-step, the blank base body is transformed into a base body, i.e., a finished base body. This base body and the entire blank sole element are then used in step b. For example, it may be possible to manufacture the blank base body and the one or more tubular channel structures together or separately. The blank base body may be manufactured so that it is foamable. For example, it may be possible to include a foaming agent in, preferably only in, the blank base body. In a subsequent step, the blank base body may be foamed to provide a polymer foam structure. For example, and as further outlined above, the blank base body and the one or more tubular channel structures may be formed by additive manufacturing. In an alternative embodiment, step a. includes only forming the tubular channel structure, in particular, forming the tubular channel structure from a foamed polymer material. Then, step b. is performed, i.e., injecting a fiber component into the tubular channel structure to fill the channels defined by the tubular channel structure. Thereafter, the tubular channel structure is connected to a base body (such as a polymer foam element), for example before or after curing.

[0059] In a second aspect, the invention relates to a sole element, and in particular a sole element obtained by a method as described in any of the embodiments herein, in particular with respect to the first aspect of the invention.

[0060] It should generally be understood that the embodiments and features described herein with respect to the method according to any of the embodiments of the first aspect of the invention are preferably also applicable to the embodiments of the second aspect of the invention. Vice versa, the embodiments and features described herein with respect to the sole element according to any of the embodiments of the second aspect of the invention are preferably also applicable to the embodiments of the method according to any of the embodiments of the first aspect of the invention.

[0061] The sole element comprises one or more tubular channel structures. Furthermore, a cured fiber component comprising, or consisting of, fibers and resin is introduced, preferably injected, into the one or more tubular channel structures (respectively, into the channels formed by the one or more tubular channel structures). Thus, the cured fiber component is arranged within the one or more tubular channel structures (respectively, the channels). The sole element is preferably a reinforced sole element.

[0062] In some embodiments, the sole element further includes a base body, and the one or more tubular channel structures extend along the base body.

[0063] In some embodiments, the one or more tubular channel structures protrude from the base body. Preferably, the one or more tubular channel structures protrude from the base body in a vertical direction.

[0064] In some embodiments, the one or more tubular channel structures have at least one, at least two, at least three, or at least four channel walls, each having a wall thickness t. The channel walls, alone or in combination with the base body, define a channel having a maximum channel width w. The maximum channel width is perpendicular to the direction along which the channel extends and defines the maximum distance between opposing channel wall segments. For a circular cross-section, the maximum channel width is, for example, given by the channel diameter.

[0065] In certain embodiments, the ratio of t:w is between 1:150 and 1:3, particularly between 1:75 and 2:7, and more particularly between 1:50 and 1:4.

[0066] In some embodiments, the tubular channel structure (respectively, the channel) is filled with the cured fiber component to more than 90%, particularly more than 95%, more particularly more than 98%, more particularly 100% of its channel volume.

[0067] In some embodiments, the cured fiber component's resin is directly materially bonded to the one or more tubular channel structures and, optionally, the base body. Direct material bonding means that no additional adhesive is used. For example, the uncured fiber component can be inserted into the one or more tubular channel structures (and, accordingly, the channels defined thereby), as explained with respect to the first aspect of the present invention. Curing then also involves forming a direct material bond between the resin and the one or more tubular channel structures and, optionally, the base body. This securely connects the fiber components and maintains their position even during extended and extensive use in the shoe. It should be understood that even if a material bond exists, the tubular channel structures and the cured fiber components are not integral to one another; that is, they are preferably distinguishable from one another. For example, it may be possible that the one or more tubular channel structures and the cured fiber components (particularly, the fiber component's resin) are different materials and / or have different physical properties (such as hardness or density). Preferably, the resin is directly materially bonded to the one or more tubular channel structures and, optionally, the base body, over at least 90%, particularly at least 95%, more particularly at least 99%, or even 100% of the length of each tubular channel structure.

[0068] In some embodiments, the sole element includes a plurality of tubular channel structures. In certain embodiments, the plurality of tubular channel structures may include a main channel structure and one or more connecting channel structures, wherein the one or more connecting channel structures connect two or more of the main channel structures to each other. The main channel structure and the connecting channel structure may, for example, define a channel structure network. It should be understood that a connected channel is a channel in which the cured fiber component arranged in the channel extends continuously through the connected channel.

[0069] In some embodiments, the sole element comprises a plurality of tubular channel structures forming a channel structure network.At least some or even all of the tubular channel structures of the tubular channel network are connected to each other.

[0070] As outlined above with respect to the first aspect of the invention, the sole element may be a sole plate, in particular a rigidified sole plate, ie a sole plate configured to rigidify the sole of a shoe.Alternatively, the sole element may be a midsole.

[0071] In embodiments where the sole element is a sole plate, the weight of the plate element may preferably be between 10 g and 40 g, in particular between 15 g and 35 g. In some embodiments, the average density of the sole plate may be 0.8 g / cm 3 Up to 3g / cm 3 , especially 0.9 g / cm 3 Up to 2.5 g / cm 3 .

[0072] In some embodiments, the surface area of ​​the base body along which the one or more tubular channel structures extend is between 3% and 85%, in particular between 5% and 60%, of the total surface area of ​​the sole element. The total surface area is defined as the surface area of ​​one of the side portions of the sole element. The sole element has a top side and a bottom side in a vertical direction. When worn or in operation, the bottom side faces the ground, and the bottom side faces the wearer's foot. Therefore, the total surface area refers to the surface area of ​​one of these side portions, typically the side along which the one or more tubular channel structures extend.

[0073] In some embodiments, the sole element and in particular the sole plate comprises a curvature in the forefoot region or in the midfoot region in a vertical direction. In other words, the forefoot region may be inclined relative to the midfoot region and optionally the heel region.

[0074] According to a third aspect, the present invention relates to a shoe having a sole element according to any of the embodiments described herein, particularly with respect to the second aspect. In some embodiments, the shoe comprises: a sole structure comprising such a sole element; and an upper connected to the sole structure. The upper and the sole structure generally define a foot-receiving compartment. BRIEF DESCRIPTION OF THE DRAWINGS

[0075] The invention described herein will be more fully understood from the detailed description and accompanying drawings given below, which should not be considered as limiting the invention described in the appended claims. The accompanying drawings show: Figure 1 is a perspective view of a sole element 1 according to an embodiment of the invention; Figure 2is a cross-sectional view of a sole element according to another embodiment of the invention, perpendicular to the longitudinal direction L and in a plane defined by the transverse direction T and the vertical direction V; Figure 3 is a top view of a sole element according to another embodiment of the present invention; Figure 4 is a schematic diagram of a sole element according to another embodiment of the present invention; Figure 5 is a schematic diagram of a sole element according to another embodiment of the present invention; Figure 6 is a schematic diagram of a sole element that is a midsole according to another embodiment of the present invention; Figure 7 is a cross-sectional view of a sole element according to another embodiment of the invention, perpendicular to the longitudinal direction L and in a plane defined by the transverse direction T and the vertical direction V; Figure 8 is a schematic diagram of a sole element that is a midsole according to another embodiment of the present invention; Figure 9 is a schematic diagram of a sole element that is a midsole according to another embodiment of the present invention; Figure 10 1 is a test result of the flexural modulus of the sole plate according to the present invention and a comparison with a standard sole plate. DETAILED DESCRIPTION

[0076] Figure 1 Shown is a blank sole element 1' from which a sole element 1 as a sole plate can be produced. The blank sole element 1' comprises a base body 2 and two tubular channel structures 3 and 4, which extend essentially parallel to the base body 2 on the bottom side of the sole element 1. The tubular channel structures 3 and 4 extend along a longitudinal direction L and have a rectangular shape in a cross-section perpendicular to the longitudinal direction L (i.e., in the V and T planes). The tubular channel structures 3 and 4 each have two openings 31, 32, and 42 (the second opening of the tubular channel 4 is not visible in this perspective view) arranged at the opposite ends of the corresponding tubular channel structure. During manufacturing, a fiber component is introduced into the corresponding tubular channel structure from one of the openings of each tubular channel structure (e.g., opening 31) and is transported from there to the second opening 32. The fiber component comprises resin and fibers. If the resin is in a flowable or liquid state, the resin transports the fibers into the channel defined by the tubular channel structure 3 and evenly distributes the components therein. The shown blank sole element 1 ' extends from the heel region through the midfoot region into the forefoot region.

[0077] Figure 2A cross-sectional view of a sole element 1 according to another embodiment is shown. The cross-section is perpendicular to the direction of extension of the corresponding channel, which in this embodiment is the longitudinal direction L. Furthermore, the cross-section lies in a plane defined by the vertical direction V and the transverse direction T. The sole element 1 comprises a base body 2 and again two tubular channel structures 3 and 4. As can be seen, a cured fiber component 5 is introduced into the tubular channel structures 3 and 4, and the corresponding channels are completely filled with the cured fiber component 5. Each channel structure has a channel wall with a wall thickness t and defines a corresponding channel with a maximum channel width w.

[0078] Figure 3 Another embodiment of a sole element 1 is shown, in which the base body 2 includes (and accordingly defines) a plurality of through-openings, which reduce the overall weight of the sole element. Since the desired stiffening effect is primarily achieved by the cured fiber component inserted into the tubular channel structures 3 and 4, it is possible to achieve a relatively large open area defined by the through-openings without sacrificing any stiffening effect.

[0079] Figure 4 Another embodiment of a sole element 1 is shown, wherein the base body 2 comprises (respectively, defines) a plurality of through-openings. Furthermore, the sole element comprises two tubular channel structures 3 and 4, which extend in the longitudinal direction of the sole element from the heel region of the sole element to the toe region of the sole element.

[0080] Figure 5 A different embodiment of a sole element 1 according to the present invention is shown. In this embodiment, the sole element essentially consists of a single tubular channel structure. It should be noted that the channel opening is arranged on the back side and is not visible in this view. In this or any other embodiment described herein, the tubular channel structure can peripherally delimit the sole element 1.

[0081] Figure 6 Another embodiment of a sole element 1 is shown. Figure 2 、 Figure 3 or Figure 4 In contrast to the embodiment shown in , the sole element 1 is not a sole plate but a midsole. This sole element comprises a base body 2, which may be made of polymer foam. The base body 2 defines two recesses, within which tubular channel structures 3 and 4 are arranged. As can be seen, both channels defined by the tubular channel structures 3 and 4 are filled with a fiber component.

[0082] Figure 7 Another sole element 1 according to the invention is shown. In this embodiment, a cross-section is shown and it can be seen that the sole element 1 comprises two tubular channel structures. Figure 9, each of the tubular channel structures branches into two sub-channel structures, namely sub-channel structures 33 and 34 and sub-channel structures 43 and 44. Such an embodiment may be made, for example, from a midsole having one or more tubular channel structures defining void channels into which a fiber component is infused.

[0083] Figure 8 Another embodiment of a sole element 1 is shown as a cross-section in the transverse and longitudinal directions. In this embodiment, the sole element 1 includes only a single tubular channel structure 3 extending along the base body 2. Both openings 31 and 32 of the tubular channel structure 3 are arranged at the heel edge of the sole element 1 in the heel region. In this or any other embodiment described herein, in the forefoot region, at least one of the tubular channel structures (in this embodiment, the tubular channel structure 3) may form a serpentine structure.

[0084] Figure 9 An alternative embodiment is shown having two tubular channel structures 3 and 4. Both tubular channel structures include a branch, such as branch 42, at which the corresponding tubular channel branches into a plurality of sub-channel structures, such as sub-channel structures 43 and 44 (for purposes of clarity, only two sub-channel structures are referenced).

[0085] Figure 10 Shown is a sole plate (such as, Figure 3 The results of the measurements of the flexural modulus and energy return of a sole plate shown in FIG1 and a continuous plate element according to the prior art, which is essentially a continuous plate extending completely over the entire forefoot, midfoot and heel areas. Measurements a) and b) were carried out in the forefoot / midfoot area as described herein with respect to Test Method 1. Measurements c) and d) are comparative measurements in the heel area. As can be seen, although the flexural modulus of the continuous plate in the forefoot / midfoot area [24.4 N / mm 2 , see b)] is higher than the flexural modulus of the sole element according to the invention [16.7 N / mm 2 , see a)], but the energy feedback W of the sole element according to the invention Frem / W Fapply [72%, see a)] is much higher than the energy return of the continuous sole element [54%, see b)]. Since this energy return is most important in the forefoot / midfoot area (where the sole plate bends during running), Figure 6 It has been shown that a better energy return can be achieved by the method and sole element according to the invention. Furthermore, the energy return can be easily adjusted by changing the size, dimensions, shape, position and / or number of the tubular channel structures.

[0086] Reference Signs List 1 Sole element 1' billet sole element 2 Basic ontology 2' blank base body 3 Tubular channel structure 31 Opening 32 Opening 33 Subchannel Structure 34 Subchannel Structure 4 Tubular channel structure 41 Opening 42 branches 43 Subchannel Structure 44 Subchannel Structure 5 Fiber Content L Longitudinal direction T Horizontal direction V vertical direction

Claims

1. A method for producing a sole element (1) for a shoe, said method comprising the following steps: a. Providing a blank sole element (1 '), the blank sole element comprising one or more tubular channel structures (3, 4); b. introducing, preferably injecting, a fiber component (5) into the one or more tubular channel structures (3, 4), the fiber component (5) comprising fibers and resin; c. Solidification of the introduced fiber components (5).

2. The method according to claim 1, wherein The blank sole element (1 ') provided in step a. further comprises a base body (2), and wherein the one or more tubular channel structures (3, 4) extend along the base body (2).

3. The method according to claim 1, wherein The blank sole element (1') provided in step a. further comprises a blank base body, and wherein the one or more tubular channel structures (3, 4) extend along the blank base body, wherein the blank base body is transformed into a base body (2) before or after step b., in particular by foaming.

4. A method according to any one of the preceding claims, wherein Step a. comprises the sub-step a1. of producing the one or more tubular channel structures (3, 4) and optionally the base body (2) by additive manufacturing, blow molding or extrusion.

5. A method according to any one of the preceding claims, wherein The one or more tubular channel structures (3, 4) are provided such that they extend at least partially along a longitudinal direction (L) of the sole element (1).

6. A method according to any one of the preceding claims, wherein Step a. comprises performing a gait analysis and / or a foot analysis on an individual and producing the sole element (1) based on the gait analysis and / or foot analysis.

7. A method according to any one of the preceding claims, wherein The fibers are endless fibers, and / or wherein, The fibers are selected from one or more of the following: carbon fibers, basalt fibers, aramid fibers, glass fibers, flax fibers, and hemp fiber.

8. A method according to any one of the preceding claims, wherein The blank sole element (1') provided in step a. comprises a plurality of tubular channel structures (3, 4) forming a channel structure network, wherein the channel structure network comprises at least two openings (31, 32, 41) providing fluid communication between the interior of the plurality of tubular channel structures (3, 4) and the external environment of the sole element (1).

9. A method according to any one of the preceding claims, wherein The blank sole element (1') provided in step a. comprises a plurality of tubular channel structures (3, 4), and wherein the plurality of tubular channel structures (3, 4) comprises a plurality of main channel structures and one or more connecting channel structures, wherein the one or more connecting channel structures fluidically connect two or more main channel structures to each other.

10. A method according to any one of the preceding claims, wherein In step b., the fibers and the resin are introduced simultaneously.

11. A method according to any one of the preceding claims, wherein At least one of the one or more tubular channel structures (3, 4) includes a branch (42), and the at least one tubular channel structure (3, 4) branches into two or more sub-channel structures (43, 44) at the branch.

12. A method according to any one of the preceding claims, wherein The fiber component (5) is injected so that the tubular channel structure (3, 4) is filled to more than 90%, in particular more than 95%, more particularly more than 98%, more particularly 100% of its channel volume.

13. A sole element (1), in particular obtained by a method according to any one of the preceding claims, comprising one or more tubular channel structures (3, 4), wherein A cured fiber composition (5) comprising fibers and resin is introduced, preferably injected, into the one or more tubular channel structures (3, 4).

14. The sole element (1) according to claim 13, further comprising a base body (2), wherein The one or more tubular channel structures (3, 4) extend along the base body (2).

15. Sole element (1) according to claim 14, wherein The one or more tubular channel structures (3, 4) protrude from the base body (2).

16. Sole element (1) according to any one of claims 13 to 15, wherein The one or more tubular channel structures (3, 4) have channel walls with a wall thickness t, wherein the channel walls define a channel with a maximum channel width w, wherein, preferably, the ratio t:w is between 1:150 and 1:3, in particular between 1:75 and 2:7, more in particular between 1:50 and 1:

4.

17. Sole element (1) according to any one of claims 13 to 16, wherein The resin of the cured fiber component (5) is directly materially bonded to the one or more tubular channel structures (3, 4).

18. Sole element (1) according to any one of claims 13 to 17, wherein The sole element (1) comprises a plurality of tubular channel structures (3, 4), wherein the plurality of tubular channel structures (3, 4) comprises a main channel structure and one or more connecting channel structures, wherein the one or more connecting channel structures connect two or more main channel structures to each other.

19. Sole element (1) according to any one of claims 13 to 18, wherein The sole element (1) comprises a plurality of tubular channel structures (3, 4) forming a channel structure network, wherein at least some, in particular all, of the tubular channel structures (3, 4) of the channel structure network are connected to one another.

20. Sole element (1) according to any one of claims 13 to 19, wherein The sole element (1) is a sole plate or a midsole.

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