Liquid thermoplastic polymer application patterns for high adhesion friction applications

Abstract

The present invention relates to a sole structure, preferably for a sports shoe, comprising a base layer and a polymer layer arranged in a pattern on a ground-facing side of the base layer wherein the pattern comprises one or more first regions and one or more second regions, the one or more second regions have a smaller thickness than the one or more first regions, and wherein the pattern comprises an alternating arrangement of the first regions and the second regions such that a longitudinal extension of the first regions and the second regions is substantially perpendicular to a longitudinal axis of the sole structure, and / or wherein the surface area of the first region is at least twice the surface area of the second region for providing grip when contacting a surface, preferably a wet surface. Furthermore, the invention relates to a shoe comprising such a sole structure and to a method of manufacturing such a sole structure.

Description

Technical Field

[0001] This invention relates to the field of footwear, and more particularly to a sole structure, preferably used in athletic shoes. Furthermore, this invention relates to a shoe including the sole structure and a method for manufacturing the sole structure. Background Technology

[0002] Sufficient traction is essential for improving performance and safety during exercise, especially in athletic shoes. Reducing the slipperiness of athletic shoe soles on smooth surfaces is necessary and desirable for improving athletic performance and preventing injuries. To this end, advanced materials, surface designs, and coatings are used in the manufacture of athletic shoe soles. Special rubber compounds are used because they provide high friction on smooth surfaces. Modern athletic shoe soles use blends of synthetic and natural rubbers to enhance grip. One approach, for example, is to design compounds that soften at higher temperatures, resulting in increased traction as the sole heats up during activity.

[0003] One different approach to enhancing the adhesion and traction of shoe soles is to incorporate nanoparticles, such as silica or carbon black, into the rubber matrix. This improves durability and grip. These materials enhance the microstructure of the rubber, providing better interaction with surfaces. Furthermore, advanced designs include microtexturing on the sole, which increases the contact area, improving grip on smooth surfaces. Another method to prevent slippage includes—depending on the application—water-repellent or water-absorbing—sole coatings. This method is primarily used to maintain adhesion and traction in wet conditions.

[0004] EP 1 784 095 B1 relates to an athletic shoe with an upper and a sole, the athletic shoe providing an adhesion friction pattern on the sole to help grip the surface of a grass or hard court, wherein the running sole is directly molded inside the upper and only the adhesion friction aids extend through the upper to reduce weight while maintaining mechanical strength and flexibility.

[0005] Furthermore, US 8,800,174 B2 relates to soles—with and without removable / replaceable traction pods—used in athletic or sport shoes—for enhanced grip friction. The sole portion or traction pod may be supplied with a material that exhibits adhesiveness—for enhancing friction between the sole and a hard floor.

[0006] US 10 279 581 B2 relates to footwear articles having a sole structure, and systems and methods for manufacturing such footwear articles. An example shoe includes an upper and a sole plate, the sole plate including a lower surface adapted for ground contact, having a first sole portion including a first sole structure and a second sole portion including a second sole structure, the first sole structure having a distal end and sidewalls, the sidewalls having extensions extending from a central core, and the second sole structure having at least one geometric feature that differs from a corresponding geometric feature of the first sole structure in one or more aspects.

[0007] However, a common drawback of these soles is that while they provide high traction in dry conditions, they struggle to maintain a high level of grip on smooth surfaces. This is even more detrimental when the soles are wet, particularly on wet surfaces during outdoor activities. Summary of the Invention

[0008] Therefore, the object of the present invention is to provide an improved sole structure and a method for manufacturing the same, as well as a sports shoe including the sole structure, so as to at least partially overcome the above-mentioned defects of the prior art.

[0009] The present invention addresses the aforementioned problems in various aspects.

[0010] In a first aspect, the present invention relates to a sole structure, preferably used in athletic shoes, the sole structure comprising: a. basal layer; and b. A polymer layer, patterned on the ground-facing side of a substrate layer; wherein the pattern includes one or more first regions and one or more second regions; wherein the one or more second regions have a smaller thickness than the one or more first regions; and The pattern includes an alternating arrangement of a first region and a second region, such that the longitudinal extension of the first region and the second region is substantially perpendicular to the longitudinal axis of the sole structure, and / or The surface area of ​​the first region is at least twice the surface area of ​​the second region.

[0011] The sole structure of this invention has been shown to enhance adhesion friction on smooth and wet surfaces while reducing the likelihood of slippage. When using the sole structure according to the invention, the running performance of the wearer (e.g., an athlete) is significantly improved. Due to the reduced risk of slippage—for example, on wet and smooth surfaces—the sole structure provides an improved overall workout experience and results. In particular, the sole structure of this invention exhibits a significant improvement in friction compared to conventional sole structures. Furthermore, the sole structure has the advantage of being individually designed based on the frictional forces acting on it. Specifically, individual gait patterns and dominant force vectors can be used to tailor the sole structure for specific applications, such as adapting to an athlete's individual running style. Moreover, due to the materials and manufacturing method of this invention, the sole structure is significantly lighter and thinner, resulting in a more ideal overall sole structure.

[0012] According to this disclosure, "sole structure" is, but is not limited to, the bottom portion of a shoe or footwear that provides cushioning, support and adhesive friction for the wearer.

[0013] According to this disclosure, a "polymer layer" is, but is not limited to, a layer comprising one or more polymers. The polymer layer is preferably made of a durable and long-lasting material. In particular, the polymer material provides contact areas that come into contact with the ground during, for example, gait. Furthermore, the polymer layer provides flexibility, durability, cushioning, and support within the sole structure.

[0014] According to this disclosure, the "base layer" is, but is not limited to, a fundamental part of the sole structure and helps maintain the structural integrity of the sole structure. The base layer may contain materials that absorb shock and reduce impact on the joints. The base layer is made of durable materials to withstand wear and tear from normal use. The base layer works in conjunction with the sole structure and other layers of the athletic shoe, particularly with polymer layers.

[0015] In some embodiments, the thickness of the polymer layer in one or more first regions may be 0.1 mm-0.9 mm, preferably 0.2 mm-0.8 mm, more preferably 0.3 mm-0.7 mm, even more preferably 0.4 mm-0.6 mm, and most preferably 0.5 mm.

[0016] This specific thickness of the polymer layer provides an overall thin sole structure. The advantage of this is that it allows for a more natural movement of the foot, enabling better flexion and, for example, toe spread. In this way, it promotes a more natural gait, which reduces strain on certain parts of the foot and leg. Furthermore, by using a polymer layer of specific thickness, the wearer's proprioception on the ground is enhanced. This is particularly important in sports such as running, barefoot training, and agility exercises, where precise foot placement and balance are crucial. Additionally, by using the polymer layer of this invention, less material is provided between the foot and the ground compared to conventional soles, resulting in a faster response time for the wearer. This is advantageous in sports requiring rapid changes of direction, acceleration, or deceleration. Moreover, the specific thickness of the polymer layer keeps the foot closer to the ground, reducing, for example, the "stack height" of athletic shoes. This improves stability and balance when using the polymer layer of this invention.

[0017] In some embodiments, the polymer layer in one or more second regions may have a thickness of 0 mm. In this way, the second region contains no polymer and consists only of a base layer. This results in an increased surface area of ​​the sole structure, which enhances grip on the ground and the adhesion friction of the sole structure.

[0018] In some embodiments, the pattern may be a grid, lattice, line, spiral, honeycomb, dot, wave, sine wave pattern, or any combination thereof. Alternatively or additionally, the pattern may be an outlined and / or filled pattern. In some embodiments, the polymer layer in one or more second regions may have the same thickness as the polymer layer in one or more first regions.

[0019] These specific patterns improve the adhesion friction of the sole structure, which helps the wearer maintain a firm foothold on a variety of surfaces. Due to this improved adhesion friction, the wearer experiences greater stability, reducing the chance of slipping or losing balance. This is especially important in sports requiring sudden stops, lateral movements, and rapid turns, such as running, soccer, basketball, and tennis. In particular, the patterns used in this invention allow for faster turning, cutting, and lateral movement.

[0020] In some embodiments, each of one or more first regions may contain a higher amount of polymer than each of one or more second regions.

[0021] This difference in polymer content between the first and second zones provides varying height, which offers better grip on a variety of surface types, such as wet, dry, muddy, or uneven terrain. The first zone can dig into softer surfaces, such as grass or soil, while the second zone remains in contact with harder surfaces. In this way, the grip of the sole structure is improved.

[0022] In some embodiments, the surface area of ​​one or more first regions may be at least 2.5 times, preferably at least 3 times, the surface area of ​​one or more second regions.

[0023] These specific ratios in the first and second zones allow for enhanced grip and adhesion friction in the sole structure.

[0024] In some embodiments, the pattern may include an alternating arrangement of a first region and a second region, such that the longitudinal extensions of the first and second regions are substantially perpendicular to the longitudinal axis of the outsole, wherein the first region may have the following length, depth, and / or width in a direction substantially perpendicular to the longitudinal extension: at least 1.0 mm, preferably at least 2.0 mm, more preferably at least 2.5 mm, most preferably at least 3.0 mm; and / or at most 9.0 mm, preferably at most 7.0 mm, more preferably at most 5.0 mm, most preferably at most 3.5 mm, and / or The second region may have the following length, depth and / or width in a direction substantially perpendicular to the longitudinal extension: at least 0.2 mm, preferably at least 0.3 mm, more preferably at least 0.4 mm, most preferably at least 0.5 mm; and / or at most 3.0 mm, preferably at most 2.5 mm, more preferably at most 2.0 mm, and most preferably at most 1.5 mm.

[0025] This specific length, depth, and / or width has demonstrated improved adhesion and friction characteristics. In particular, the substantially vertical first and second zones provide excellent grip on wet and / or smooth surfaces.

[0026] In some embodiments, the polymer in the polymer layer may be selected from the group consisting of polyurethane (PU), thermoplastic polyamide (TPE-A or TPA), thermoplastic polyester (TPE-E or TPE), thermoplastic styrene block copolymer (TPE-S or TPS), thermoplastic polyurethane (TPE-U or TPU), thermoplastic vulcanized rubber (TPE-V or TPV), rubber or ethylene-vinyl acetate copolymer (EVA), preferably thermoplastic polyurethane (TPE-U or TPU), and / or combinations thereof.

[0027] These polymers allow for enhanced adhesion friction while reducing the likelihood of slippage. Furthermore, the use of these specific polymers has been shown to enable a time-efficient and sustainable process in the production of sole structures, while providing a more durable and long-lasting sole structure. Suitable polymer materials can be elastic foam materials, such as thermoplastic elastomers and / or elastomers. Preferred materials used in this disclosure are thermoplastic elastomers. More preferred materials used in this disclosure are urethane-based thermoplastic elastomers (TPU), polyester-based thermoplastic elastomers (TPE), and / or polyamide-based thermoplastic elastomers (TPA).

[0028] The polymer is characterized by a Shore A value and / or a Shore D value, wherein the Shore A value is in the range of 20 to 120, preferably 40 to 100, more preferably 60 to 80; and the Shore D value is in the range of 2 to 80, preferably 5 to 75, more preferably 8 to 70. Using a polymer containing these Shore A and / or Shore D values ​​provides durable properties for the polymer layer and the entire sole structure.

[0029] In some embodiments, one or more first regions and one or more second regions may have an undulating shape.

[0030] The undulating shape allows for an increased surface area of ​​the sole structure, while the longitudinal extension of the first and second regions is substantially perpendicular to the longitudinal axis of the sole structure. In this way, the sole structure provides enhanced adhesion friction and grip.

[0031] In some embodiments, the undulating shape may have the following amplitude: at least 1 mm, preferably at least 2 mm, more preferably at least 3 mm, most preferably at least 3.5 mm; and / or at most 9 mm, preferably at most 8 mm, more preferably at most 7 mm, even more preferably at most 6 mm, even more preferably at most 5 mm, most preferably at most 4.5 mm.

[0032] It has been shown that these specific amplitude values ​​of the undulating shape enhance the adhesion and friction properties of the sole structure.

[0033] In some embodiments, the undulation shape may substantially correspond to a sine wave. In some embodiments, the undulation shape may have a wavelength of at least 2 mm, preferably at least 4 mm, more preferably at least 6 mm, and most preferably at least 7 mm; and / or at most 14 mm, preferably at most 12 mm, more preferably at most 10 mm, and most preferably at most 9 mm.

[0034] It has been shown that specific wavelengths exhibit excellent adhesion and friction characteristics for shoe sole structures on wet surfaces.

[0035] In some embodiments, the ratio between amplitude and wavelength can be: at least 0.1:4, preferably at least 0.2:3, more preferably at least 0.3:2, most preferably at least 0.8:3.5, and / or at most 3:0.5; preferably at most 2:1, more preferably at most 1:1, and most preferably at most 1:2.

[0036] These specific ratios between wavelength and amplitude provide beneficial grip characteristics to the sole structure.

[0037] In some embodiments, the pattern may be a linear pattern, and the width of the first region in one or more first regions may be at least 1 mm, preferably at least 1.5 mm, more preferably at least 2 mm, most preferably at least 3 mm, and / or the second region in one or more second regions may have a width of at least 0.3 mm, preferably at least 0.7 mm, most preferably at least 1 mm.

[0038] In some embodiments, the shoe may be a running shoe. By using the sole structure of the present invention, an improved athletic shoe is provided that exhibits excellent adhesion and friction on wet and smooth surfaces.

[0039] In some embodiments, the base layer may be the midsole of the athletic shoe or a portion thereof.

[0040] In this way, the sole structure of the present invention is directly integrated into the midsole. This reduces the overall weight of the athletic shoe, making it more desirable and more material-efficient. It is conceivable that the base layer may include cushioning elements.

[0041] In some embodiments, the polymer layer may be disposed in one or more segments corresponding to a segment of the athletic shoe, including a toe segment, a forefoot segment, a heel segment, a midfoot segment, a sidewall segment, and / or an upper segment.

[0042] In doing so, the sole structure can be designed based on the wearer's individual needs. For example, polymer layers can be placed in the sidewall sections to provide greater grip during quick turns and cuts, such as when playing basketball.

[0043] In a second aspect, the present invention relates to an athletic shoe including a sole structure according to the invention. The athletic shoe of the present invention exhibits improved adhesion friction and grip characteristics, particularly on wet and / or smooth surfaces. Furthermore, grip and adhesion friction are improved during exercise when using the athletic shoe of the present invention. In some embodiments, the athletic shoe may be a running shoe. The running shoe of the present invention—when used during running—exhibits improved adhesion friction. In particular, when using the running shoe of the present invention (e.g., during wet weather conditions), the sole structure provides a reduced risk of slippage for the wearer.

[0044] In a third aspect, the present invention relates to a method for manufacturing a sole structure, preferably for athletic shoes, the method comprising the following steps: a. Provide polymers, b. Provide solvents, c. Mix the polymer with a solvent to form a liquefied polymer. d. Arrange the liquefied polymer from step c) onto the substrate layer. e. The liquefied polymer arranged on the cured substrate, and f. Thus providing a patterned sole structure, wherein the pattern includes one or more first areas and one or more second areas, In step d), the liquefied polymer is patterned on the base layer, and / or the pattern is obtained by post-processing the cured polymer after step e), and the arrangement of the liquefied polymer provides an alternating arrangement of a first region and a second region such that the longitudinal extension of the first region and the second region is substantially perpendicular to the longitudinal axis of the sole structure, and / or the surface area of ​​the first region is at least twice the surface area of ​​the second region.

[0045] According to this disclosure, "solvent" is, but is not limited to, a compound capable of dissolving, dispersing or extracting polymers.

[0046] According to this disclosure, "curing" should be understood as, but not limited to, the chemical and / or physical processes of hardening, setting, and / or solidifying a polymer. Curing may be performed using radiation.

[0047] According to this disclosure, “mixing” should be understood as, but not limited to, the process of combining two or more substances to produce a mixture of the substances (preferably in liquid form).

[0048] According to this disclosure, “arrangement” should be understood as, but not limited to, the process of applying and depositing, for example, a liquefied polymer, onto a substrate layer.

[0049] "Liquefied polymer" should be understood as, but not limited to, polymers with semi-solid or liquid physical properties.

[0050] The terms "post-processing," "texturing," or "post-treatment" as used in this disclosure should be understood as, but not limited to, processes that manipulate the physical properties of the sole structure to enhance its adhesive friction. In particular, this can be achieved through external influences—such as mechanical forces, lasers, and / or the addition of additives. By doing so, a texture is provided by the sole structure, which can significantly improve the adhesive friction characteristics of the sole structure.

[0051] The advantage of methods used to manufacture sole structures is that they avoid deposition, such as that based on glue and injection molding, while providing sole structures with enhanced adhesion and friction properties. While sole structures can be specifically used to create lighter and thinner outsoles, for example, sole structures can also be used to enhance the grip of athletic shoes for specific exercises, such as when liquefied polymers are placed in specific areas of the athletic shoe.

[0052] Conventional shoe sole structures, such as the outsoles of athletic shoes, are typically manufactured, for example, by injection molding. The method according to the invention is based on a different approach: preparing a liquefied polymer by mixing a polymer and a solvent, and then applying and curing it onto a base layer. In this way, the sole structure is manufactured more efficiently, and the liquefied polymer can be arranged more precisely and effectively. By doing so, for example by cutting off excess material, no material waste is generated. Thus, the method according to the invention provides an improved method for manufacturing—for example, the sole structure of athletic shoes—by consuming only the required material and avoiding any waste generation.

[0053] It has been shown that using liquefied polymers is advantageous for the entire manufacturing process because the properties of liquefied polymers can be fine-tuned based on specific process requirements. Specifically, by increasing or decreasing the amount of solvent, liquefied polymers can exhibit different dynamic viscosities. In this way, polymer deposition can be significantly affected, meaning the polymer can be deposited onto the substrate in a more efficient manner.

[0054] Furthermore, manual assembly is not required, and glue-free application is possible, providing an efficient process—with reduced material consumption and thus lower overall costs—suitable for automated processes. Gluing may require complex pretreatment of parts, and the adhesives used for gluing plastic parts are often hazardous or environmentally harmful.

[0055] The liquefied polymer can be deposited on predetermined sections of the athletic shoe. For example, the liquefied polymer can be applied only to the heel section or the toe section. Furthermore, the liquefied polymer can include different physical properties on each predetermined section. In this way, the athletic shoe can be conceptually adapted to individual needs while allowing for a lighter overall weight and enhanced durability and grip.

[0056] In some embodiments, the method may further include a texturing step, which may be performed prior to the curing of the liquefied polymer. The texturing step may include the addition of additives. For example, rubber particles may be added to the liquefied polymer. The particle size of the rubber particles may be 0.3-0.4 mm. After curing the liquefied polymer, the sole structure acquires a grainy design with an uneven surface structure. Another example of texturing includes adding, for example, silica, preferably 2 wt% (e.g., Evonik Acematt TS100 or Evonik Acematt 790) to the polymer before mixing with a solvent. In this way, the produced sole structure has a non-smooth appearance. It has been shown that the post-processing steps according to the invention provide a sole structure that exhibits 30% better adhesion and friction compared to conventional sole structures.

[0057] The polymer is textured before the curing step. Alternatively, it can be textured after the polymer has cured. In this way, a pattern is obtained by post-processing, such as mechanically roughening the polymer.

[0058] In some embodiments, the method may further include mechanically post-treating the cured polymer.

[0059] For example, the sole structure can be treated—by using a rotating brush—in a grinding manner. In this way, a texture is added to the sole structure. By doing so, the surface area of ​​the sole structure is increased, resulting in better adhesion and friction. Furthermore, the surface of the sole structure is manipulated in this way, providing—for example, an individual design that the wearer might desire. The choice of post-treatment device depends on the desired pattern and / or the physical properties of the cured polymer.

[0060] In some embodiments, post-processing of the cured polymer may include laser treatment.

[0061] Laser processing can be performed by manipulating the thickness of the polymer layer, i.e., cutting out specific areas in the polymer layer to provide a second area of ​​the sole structure. For example, the surface of the sole structure can be etched via laser energy. In this way, the top surface is processed by laser and, for example, burned away. Preferably, this will affect the thickness of the cured polymer by about 0.3 mm. By doing so, an improved appearance of the sole structure is created while providing a second area.

[0062] In some embodiments, the solvent may be a mixture selected from the group consisting of solvent-based and / or water-based solvents, preferably selected from the group consisting of solvent-based solvents, more preferably selected from the group consisting of C1-C6 ethers, ... 10 Esters, C1-C8 ketones, C1-C8 alkanes, and / or combinations thereof.

[0063] The solvent can be one or a mixture of the following: tetrahydrofuran (THF), methyl ethyl ketone (MEK), cyclohexane (CYC), ethyl acetate, butyl acetate, preferably THF and / or CYC. The advantage of these solvents is that they provide a homogeneous mixture when mixed with the polymer. Furthermore, the solvents have the advantage of being able to be removed in a time-efficient manner during the curing process and allowing for production processes that can accommodate a wide range of physical properties of the liquid polymer.

[0064] In some embodiments, in step e), curing can be carried out at a temperature of 20°C to 150°C, preferably 30°C to 100°C, more preferably 40°C to 50°C, and the curing time can be 2 minutes to 750 minutes, preferably 5 minutes to 390 minutes, more preferably 10 minutes to 30 minutes.

[0065] These specific curing temperatures offer the advantage of providing rapid curing times.

[0066] In some embodiments, during step c), the ratio of polymer to solvent in the mixture may be in the range of 10 wt% to 90 wt%, preferably 20 wt% to 80 wt%, more preferably 30 wt% to 70 wt%.

[0067] It has been shown that a specific ratio provides the desired viscosity of the liquefied polymer.

[0068] In some embodiments, the liquefied polymer of step c) can be disposed on the substrate at a dynamic viscosity of 10,000-50,000 mPa⋅s, preferably 20,000-40,000 mPa⋅s.

[0069] These specific viscosities provide a rapid method for deploying liquefied polymers onto a substrate. In this way, the entire process is performed in a time- and energy-efficient manner.

[0070] Dynamic viscosity is measured using rotational viscosity determination. Viscosity is determined by applying rotational shear stress and observing the rotational resistance. Specifically, viscosity is determined by rotating a probe in a sample of liquefied polymer and measuring the torque required to rotate the probe, thereby measuring the fluid resistance of the liquid polymer.

[0071] In some embodiments, the outsole may be a sole structure according to the first aspect of the invention. Additionally or alternatively, the sole structure may be a sole. Using the sole structure of the present invention as the outsole and / or sole has been shown to improve the adhesion and friction of athletic shoes.

[0072] In a fourth aspect, the present invention relates to an outsole obtained by a method according to a third aspect of the invention.

[0073] Many of the advantages discussed in the context of other aspects of the invention also apply to the outsole obtained by the method according to the third aspect, namely the method of the invention.

[0074] We emphasize that all aspects, features, and options discussed and disclosed above in the context of the first aspect are applicable to, or in combination with, the discussion and disclosure of the second aspect, and vice versa, unless physically or technically excluded, even if not every possible combination or sub-combination of features is explicitly described in detail below. Therefore, the technical advantages of these options and features already discussed above will not be repeated, at least not to the same degree, but for the sake of brevity, refer to the corresponding explanations above. Attached Figure Description

[0075] Possible embodiments of the invention are further described in the following detailed description with reference to the accompanying drawings.

[0076] Figure 1 An embodiment of a sole structure including a linear pattern is shown.

[0077] Figure 2 An embodiment of a shoe sole structure including an undulating pattern is shown.

[0078] Figure 3 An embodiment of a sole structure including a grid pattern that has been post-processed is shown.

[0079] Figure 4 An embodiment of a shoe sole structure including a wave pattern that has been post-processed is shown.

[0080] Figure 5 Three embodiments of textured and post-processed sole structures are shown.

[0081] Figure 6 This is a schematic diagram illustrating, in a comparative manner, the frictional characteristics of the sole structure according to the present invention.

[0082] Figures 7a-7c A preferred embodiment of an athletic shoe including a sole structure according to the present invention is shown.

[0083] Figure 8 The flowchart illustrates a method for manufacturing shoe sole structures. Detailed Implementation

[0084] The following describes possible embodiments of the invention and different aspects thereof primarily with regard to athletic shoes. However, it is emphasized again that different aspects may also be implemented in different types of soles and shoes, and are not limited to the specific embodiments described below.

[0085] Referring further to the fact that only specific embodiments may be described in more detail below, those skilled in the art will understand that the features and possible modifications described with reference to these specific embodiments may be further modified and / or combined with each other in different ways or in different sub-combinations without departing from the scope of the invention and disclosure. If an individual feature or sub-feature is not necessary to obtain the desired result, then that individual feature or sub-feature may be omitted. To avoid repetition, the explanations in the preceding sections also apply to the detailed description below.

[0086] Figure 1 An embodiment of the sole structure 10 is shown. The sole structure 10 includes a base layer 40 on which polymer layers 30 are arranged in a linear pattern 50.

[0087] Pattern 50 includes a first region 35 and a second region 45. The first and second regions 35 and 45 are arranged alternately in pattern 50. Figure 1 As can be seen, the first and second regions 35 and 45 are substantially perpendicular to the longitudinal axis of the sole structure 10 (as shown by the dashed line).

[0088] However, pattern 50 can also be a grid, lattice, line, spiral, honeycomb, dot, wave, sine wave pattern or any combination thereof.

[0089] The first region 35 contains a higher amount of polymer than the second region 45. As can be seen, the second region 45 has no polymer layer 30. In other words, the polymer layer 30 is 0 mm thick in these second regions 45. The polymer layer 30 is 0.5 mm thick in the first region 35. However, the thickness of the polymer layer in the first region 35 can vary depending on the individual requirements of the application. The sole structure 10 can therefore have a thickness between 0.1 and 0.9 mm. The surface area of ​​the first region 35 is significantly larger than that of the second region 45. Preferably, the surface area of ​​the first region 35 is at least three times larger.

[0090] Figure 1The first region 35 has a depth in a direction substantially perpendicular to the longitudinal extension. The depth of the first region 35 is at least 1.0 mm, preferably at least 2.0 mm, more preferably at least 2.5 mm, and most preferably at least 3.0 mm. The width of the second region 45 is at most 9.0 mm, preferably at most 7.0 mm, more preferably at most 5.0 mm, and most preferably at most 3.5 mm. The second region 45 also has a depth in a direction substantially perpendicular to the longitudinal extension of the sole structure. The depth of the second region 45 is: at least 0.2 mm, preferably at least 0.3 mm, more preferably at least 0.4 mm, and most preferably at least 0.5 mm; and / or, at most 3.0 mm, preferably at most 2.5 mm, more preferably at most 2.0 mm, and most preferably at most 1.5 mm.

[0091] Specifically, the first region 35 has a width of at least 1 mm. The width of the first region 35 is preferably at least 1.5 mm, more preferably at least 2 mm, and most preferably at least 3 mm. The second region 45 has a width of at least 0.3 mm. Preferably, the width of the second region 45 is at least 0.7 mm, and most preferably at least 1 mm.

[0092] The polymer layer 30 contains a TPU-based polymer. However, the polymer in the polymer layer 30 may also be derived from polyurethane (PU), thermoplastic polyamide (TPE-A or TPA), thermoplastic polyester (TPE-E or TPE), thermoplastic styrene block copolymer (TPE-S or TPS), thermoplastic polyurethane (TPE-U or TPU), thermoplastic vulcanizate (TPE-V or TPV), rubber, or ethylene-vinyl acetate copolymer (EVA).

[0093] It is conceivable that the base layer 40 is partially or completely integrated into the midsole of the athletic shoe. Preferably, the polymer layer 30 is the outsole of the athletic shoe. Athletic shoes including the sole structure 10 are especially running shoes. In this case, the running shoe has excellent adhesion and traction properties due to the sole structure 10. This is particularly advantageous when running on wet and / or slippery surfaces—for example, outdoors during wet weather conditions.

[0094] To avoid repetition, the following is about Figure 2 In the embodiments shown in Figure 7, only additional features and / or differences are described.

[0095] like Figure 2As can be seen, the first and second regions 35 and 45 of the sole structure 10 have an undulating shape—corresponding to a sine wave. In particular, the second region 45 has a smaller thickness and width than the first region 35. This increases the surface area of ​​the first region 35. Specifically, the surface area of ​​the first region 35 is at least 2.5 times that of the second region 45. Preferably, the surface area ratio between the first and second regions 35 and 45 can be at least 3 times.

[0096] The undulating shapes of the first and second regions 35, 45 have a wavelength of at least 2 mm. It is conceivable that the wavelength can be at least 4 mm, more preferably at least 6 mm, and most preferably at least 7 mm. Furthermore, the wavelength of the undulating shapes of the first and second regions 35, 45 is at most 14 mm. Preferably, this wavelength can be at most 12 mm, more preferably at most 10 mm, and most preferably at most 9 mm.

[0097] Specifically, the undulating shapes of the first and second regions 35 and 45 have an amplitude of at least 1 mm and at most 9 mm. It is conceivable that the amplitude can be at least 2 mm, more preferably at least 3 mm, and most preferably at least 3.5 mm. Furthermore, such amplitude of the undulating shape can be at most 8 mm, more preferably at most 7 mm, even more preferably at most 6 mm, even more preferably at most 5 mm, and most preferably at most 4.5 mm.

[0098] When the wavelength and amplitude of the undulating shape are correlated with each other, the ratio between the amplitude and wavelength is at least 0.1:4. However, this ratio may preferably be at least 0.2:3, more preferably at least 0.3:2, and most preferably at least 0.8:3.5.

[0099] Furthermore, the ratio between wavelength and amplitude is at most 3:0.5. Preferably, the ratio can be at most 2:1, more preferably at most 1:1, and most preferably at most 1:2.

[0100] exist Figure 3 In the design, pattern 50 has a grid-like pattern. The sole structure 10 includes an alternating arrangement of a first region and second regions 35, 45. This arrangement extends longitudinally along the longitudinal axis of the sole structure (shown as dashed lines). The surface area of ​​the first region 35 is twice the surface area of ​​the second region 45.

[0101] The second region 45 has a smaller thickness than the first region 35. For example... Figure 3 As can be seen, the second region 45 is not devoid of the polymer layer 30, but rather includes a polymer layer 30 with a specific thickness. This thickness is preferably 0.2 mm. The second region is carefully fabricated using a laser process. In this way, the polymer layer 30 in the second region 45 is cut away using a laser to a depth of 0.3 mm.

[0102] also, Figure 3 The sole structure 10 includes a texture. This texture is provided by using additives—particularly silica-based or rubber-based additives. In this way, the surface of the sole structure 10 is further expanded, resulting in improved adhesion and grip while maintaining a glossy and shiny appearance. It is conceivable that the textured sole structure could be further post-processed using a brush or roller device.

[0103] See now Figure 4 The first and second regions 35 and 45 have undulating shapes and both include a polymer layer 30. The polymer layer 30 in the first region 35 has a different thickness and width compared to the polymer layer 30 in the second region 45.

[0104] like Figure 4 As shown, the width of the second region 45 is smaller than the width of the first region 35. Specifically, the surface area of ​​the first region 35 is three times the surface area of ​​the second region 45. As in... Figure 3 Explained in the context of the illustrated embodiments, Figure 4 The sole structure 10 shown also has a texture. The texture is provided by adding a silica-based or rubber-based material before the polymer is cured. Furthermore, the surface of the polymer layer 30 has been mechanically roughened—using a device such as a pattern brush. Figure 4 As can be seen, the sole structure 10 maintains a shiny appearance and glossy design.

[0105] exist Figure 5 The image shows detailed views of three different sole structures 10, each with different textures. Each sole structure 10 includes additives, resulting in an uneven surface. Additionally, the sole structures 10 have been mechanically roughened, resulting in a matte and rough appearance.

[0106] The resulting appearance of the sole structure 10 depends on the mechanical treatments applied. For example, mechanical treatments—including the application of pattern brushes or rollers—can be used during post-processing.

[0107] exist Figure 6 Various embodiments of the sole structure 10 according to the present invention have been tested—compared with simple sole structures based on TPU and rubber materials.

[0108] As from Figure 6 It can be concluded that the sole structure according to the invention exhibits a higher friction value than a simple TPU sole, wherein the friction value is expressed as “CoF” (coefficient of friction).

[0109] The relationship between normal force and friction is defined as the coefficient of friction (CoF). To determine the CoF of a shoe sole structure, a sample of the shoe sole structure according to the invention is placed on a test surface, and a given load corresponding to the normal force is applied. Subsequently, the surface is moved relative to the sample by a lateral force, which is measured as friction. This measurement is performed using a footwear / shoe slip resistance tester.

[0110] Specifically, the sole structure including the polymer layer 30 in the second region 45 achieves the highest CoF value and a 30% improvement in friction compared to conventional TPU soles. This indicates that the sole structure of the present invention provides a considerable enhancement in adhesive friction compared to conventional TPU soles.

[0111] See now Figures 7a to 7c It shows an embodiment of an athletic shoe 20 or a portion thereof, including a sole structure 10 according to the invention.

[0112] exist Figure 7a In this shoe, athletic shoe 20 has a sole structure 10, wherein a base layer 40 is a midsole 65. The athletic shoe 20 can be a running shoe 26. First and second regions 35, 45, arranged in an undulating manner, provide a sinusoidal shape. A polymer layer 30 of the athletic shoe 20 is disposed in the toe section 21, forefoot section 22, heel section 23, and midfoot section 24. It is also conceivable that the polymer layer 30 is disposed in the sidewall section 27 and upper section 28 of the athletic shoe 20. Figure 7a (Not shown in the text)

[0113] As can be seen, the basic vertical arrangement of the first and second regions 35 and 45 in the heel section 23 differs from the arrangement of the first and second regions 35 and 45 in the toe, forefoot, and midfoot sections 21, 22, and 24, and is inclined at approximately 10° relative to the longitudinal axis of the sole structure 10.

[0114] The first and second regions 35 and 45 may have different arrangements and are inclined at up to 35°, preferably 25°, more preferably 20°, and most preferably 15° relative to the longitudinal axis of the sole structure 10.

[0115] like Figure 7b As can be seen, the pattern 50 of the sole structure 10 has a linear pattern. Specifically, the first and second regions 35 and 45 are arranged as lines perpendicular to the longitudinal axis of the shoe 20. The arrangement of the first and second regions 35 and 45 in the heel section differs from their arrangement in the toe, forefoot, and midfoot sections 21, 22, and 24. In particular, the first and second regions 35 and 45 include a contour design. In other words, the pattern 50 of the sole structure is outlined. This contour includes polymer layers 30 in the heel section and in the midfoot to toe sections 24-21.

[0116] exist Figure 7c In this embodiment, the athletic shoe 20 includes an outsole based on a sole structure 10, which comprises additives. Furthermore, the sole structure 10 has been mechanically post-processed. The addition of silica-based and rubber-based materials, together with the mechanical post-processing, results in an uneven surface of the sole structure 10, which has a matte and rough design. Additionally, a second region 45 obtained by post-processing the sole structure 10 includes a polymer layer 30 in substantially the same amount as the first region 35. In this embodiment, the surface area of ​​the first region 35 is at least twice the surface area of ​​the second region 45.

[0117] Go to Figure 8 It depicts a flowchart of the method 1000 according to the present invention.

[0118] Method 1000 for manufacturing a sole structure 10 (preferably for athletic shoes 20) includes a first step 1010 of providing a polymer. The polymer is TPU. The polymer may also be derived from polyurethane (PU), thermoplastic polyamide (TPE-A or TPA), thermoplastic polyester (TPE-E or TPE), thermoplastic styrene block copolymer (TPE-S or TPS), thermoplastic polyurethane (TPE-U or TPU), thermoplastic vulcanizate (TPE-V or TPV), rubber, or ethylene-vinyl acetate copolymer (EVA).

[0119] In the second step 1020, a solvent is provided. The solvent is a mixture selected from the group consisting of solvent-based solvents. The solvent may also be a mixture based on water-based solvents. Preferably, the solvent is selected from the group consisting of solvent-based solvents, more preferably from the group consisting of C1-C6 ethers, ... 10 Esters, C1-C8 ketones, C1-C8 alkanes and / or combinations thereof.

[0120] In the next step 1030, the polymer is mixed with a solvent. In this way, a liquefied polymer is formed. In step 1030, the polymer-to-solvent ratio is in the range of 10 wt% to 90 wt%. Preferably, this ratio can be 20 wt% to 80 wt%, more preferably 30 wt% to 70 wt%. Subsequently, in step 1040, the liquefied polymer is disposed onto a substrate layer. When the liquefied polymer is disposed, its dynamic viscosity is 10,000-50,000 mPa⋅s, preferably 20,000-40,000 mPa⋅s.

[0121] Subsequently, in step 1050, the disposed liquefied polymer is cured onto the substrate layer. Curing is carried out at a temperature between 20°C and 150°C. Preferably, curing is carried out at 30°C to 100°C, more preferably at 40°C to 50°C, and the curing time is between 2 minutes and 750 minutes, preferably between 5 minutes and 390 minutes, more preferably between 10 minutes and 30 minutes.

[0122] In this manner, in step 1060, a sole structure is provided having a pattern comprising first and second regions. In step 1050, the arrangement of the liquefied polymer provides an alternating arrangement of the first and second regions 35, 45, such that the longitudinal extensions of the first and second regions 35, 45 are substantially perpendicular to the longitudinal axis of the sole structure.

[0123] Additionally or alternatively, the surface area of ​​the first region 35 is at least twice the surface area of ​​the second region 45.

[0124] Method 1000 further includes a texturing step 1070, which occurs prior to the curing of the liquefied polymer 1050. The texturing step 1070 includes: adding an additive, and additionally or alternatively, mechanically post-treating the cured polymer.

[0125] Alternatively or additionally, the pattern is obtained by post-processing the cured polymer in step 1080. Post-processing 1080 includes laser treatment. In this way, the second region 45 is provided by post-processing the sole structure 10.

[0126] It should be noted that, as those skilled in the art will understand, the above embodiments and / or examples can be combined with other aspects described herein, and details of the embodiments and / or examples may be omitted. The scope of protection is determined by the claims and is not limited to the embodiments and / or examples disclosed in the above drawings.

Claims

1. A sole structure (10), preferably used in athletic shoes (20), comprising: a. Basal layer (40); as well as b. A polymer layer (30) arranged in a pattern (50) on the ground-facing side of the base layer (40); The pattern (50) includes one or more first regions (35) and one or more second regions (45). Wherein, the one or more second regions (45) have a smaller thickness than the one or more first regions (35); and The pattern (50) includes an alternating arrangement of a first region (35) and a second region (45), such that the longitudinal extensions of the first region (35) and the second region (45) are substantially perpendicular to the longitudinal axis of the sole structure, and / or The surface area of ​​the first region (35) is at least twice the surface area of ​​the second region (45).

2. The sole structure (10) according to the preceding claim, wherein, The thickness of the polymer layer (30) in one or more first regions (35) is 0.1 mm-0.9 mm, preferably 0.2 mm-0.8 mm, more preferably 0.3 mm-0.7 mm, even more preferably 0.4 mm-0.6 mm, and most preferably 0.5 mm.

3. The sole structure (10) according to any one of the preceding claims, wherein, The polymer layer (30) has a thickness of 0 mm in one or more second regions (45).

4. The sole structure (10) according to any one of the preceding claims, wherein, The pattern (50) is a grid, lattice, line, spiral, honeycomb, dot, wave, sine wave pattern or any combination thereof.

5. The sole structure (10) according to any one of the preceding claims, wherein, Each of the one or more first regions (35) contains a higher amount of polymer than each of the one or more second regions (45).

6. The sole structure (10) according to any one of the preceding claims, wherein, The surface area of ​​the one or more first regions (35) is at least 2.5 times, preferably at least 3 times, the surface area of ​​the one or more second regions (45).

7. The sole structure (10) according to any one of the preceding claims. in, The pattern (50) includes an alternating arrangement of a first region (35) and a second region (45), such that the longitudinal extensions of the first region (35) and the second region (45) are substantially perpendicular to the longitudinal axis of the outsole. The first region (35) has the following length, depth, and / or width in a direction substantially perpendicular to the longitudinal extension: at least 1.0 mm, preferably at least 2.0 mm, more preferably at least 2.5 mm, most preferably at least 3.0 mm; and / or at most 9.0 mm, preferably at most 7.0 mm, more preferably at most 5.0 mm, most preferably at most 3.5 mm, and / or The second region (45) has the following length, depth and / or width in a direction substantially perpendicular to the longitudinal extension: at least 0.2 mm, preferably at least 0.3 mm, more preferably at least 0.4 mm, most preferably at least 0.5 mm; and / or at most 3.0 mm, preferably at most 2.5 mm, more preferably at most 2.0 mm, most preferably at most 1.5 mm.

8. The sole structure (10) according to any one of the preceding claims, wherein the polymer in the polymer layer (30) is selected from the group consisting of polyurethane (PU), thermoplastic polyamide (TPE-A or TPA), thermoplastic polyester (TPE-E or TPE), thermoplastic styrene block copolymer (TPE-S or TPS), thermoplastic polyurethane (TPE-U or TPU), thermoplastic vulcanized rubber (TPE-V or TPV), rubber or ethylene-vinyl acetate copolymer (EVA), preferably thermoplastic polyurethane (TPE-U or TPU), and / or combinations thereof.

9. The sole structure (10) according to any one of the preceding claims, wherein, The one or more first regions (35) and the one or more second regions (45) have undulating shapes.

10. The sole structure (10) according to claim 9, wherein, The undulating shape has the following amplitude: at least 1 mm, preferably at least 2 mm, more preferably at least 3 mm, most preferably at least 3.5 mm; and / or at most 9 mm, preferably at most 8 mm, more preferably at most 7 mm, even more preferably at most 6 mm, even more preferably at most 5 mm, and most preferably at most 4.5 mm.

11. The sole structure (10) according to claim 9 or 10, wherein, The undulating shape essentially corresponds to a sine wave.

12. The sole structure (10) according to any one of claims 9-11, wherein, The undulating shape has the following wavelengths: at least 2 mm, preferably at least 4 mm, more preferably at least 6 mm, most preferably at least 7 mm; and / or at most 14 mm, preferably at most 12 mm, more preferably at most 10 mm, most preferably at most 9 mm.

13. The sole structure (10) according to any one of claims 9-12, wherein, The ratio between amplitude and wavelength is: at least 0.1:4, preferably at least 0.2:3, more preferably at least 0.3:2, most preferably at least 0.8:3.5, and / or at most 3:0.5; preferably at most 2:1, more preferably at most 1:1, and most preferably at most 1:

2.

14. The sole structure (10) according to any one of claims 1 to 8, wherein, The pattern is a linear pattern, and the width of the first region (35) in one or more of the first regions (35) is at least 1 mm, preferably at least 1.5 mm, more preferably at least 2 mm, most preferably at least 3 mm, and / or wherein, The second region (45) of the one or more second regions (45) has a width of at least 0.3 mm, preferably at least 0.7 mm, and most preferably at least 1 mm.

15. The sole structure (10) according to any one of the preceding claims, wherein, The shoe (20) is a running shoe (25).

16. The sole structure (10) according to any one of the preceding claims, wherein, The base layer is the midsole (65) or a portion thereof of the athletic shoe (20).

17. The sole structure (10) according to any one of the preceding claims, wherein, The polymer layer (30) is disposed in one or more segments corresponding to the segments of the athletic shoe (20), the segments including the toe segment (21), the forefoot segment (22), the heel segment (23), the midfoot segment (24), the sidewall segment (27) and / or the upper segment (28).

18. A sports shoe (20) comprising a sole structure (10) according to any one of the preceding claims.

19. The athletic shoe (25) according to the preceding claim, wherein, The athletic shoe (25) is a running shoe (26).

20. A method (1000) for manufacturing a sole structure (10), the sole structure preferably used in athletic shoes (20), the method comprising the following steps: a. Provide polymer (1010). b. Provide solvent (1020). c. The polymer is mixed with the solvent to form a liquefied polymer (1030). d. Arrange the liquefied polymer from step c) onto the substrate layer (1040). e. The liquefied polymer (1050) arranged on the cured substrate layer, and f. This provides a patterned sole structure, wherein the pattern includes one or more first regions and one or more second regions (1060). Wherein, in step d), the liquefied polymer is arranged in a pattern on the substrate layer, and / or wherein, after step e), the pattern is obtained by post-processing and curing the polymer, and The arrangement of the liquefied polymer provides an alternating arrangement of a first region (35) and a second region (45), such that the longitudinal extension of the first region (35) and the second region (45) is substantially perpendicular to the longitudinal axis of the sole structure, and / or The surface area of ​​the first region (35) is at least twice the surface area of ​​the second region (45).

21. The method (1000) according to the preceding claim, further comprising a texturing step (1070), wherein the texturing step occurs prior to the step of curing the liquefied polymer; and The texturing step includes adding additives and / or mechanically post-treating the cured polymer.

22. The method (1000) according to any one of claims 20 or 21, further comprising: The cured polymer is mechanically post-processed (1080).

23. The method (1000) according to claim 20, wherein, The cured polymer is then subjected to post-processing including laser treatment.

24. The method (1000) according to any one of claims 20 to 23, wherein the solvent is a mixture selected from the group consisting of solvent-based and / or water-based solvents, the mixture preferably selected from the group consisting of solvent-based solvents, more preferably selected from the group consisting of C1-C6 ethers, ... 10 Esters, C1-C8 ketones, C1-C8 alkanes, and / or combinations thereof.

25. The method (1000) according to any one of claims 20 to 24, wherein in step e) (1050), curing is carried out at a temperature of 20°C to 150°C, preferably 30°C to 100°C, more preferably 40°C to 50°C, and the curing time is 2 minutes to 750 minutes, preferably 5 minutes to 390 minutes, more preferably 10 minutes to 30 minutes.

26. The method (1000) according to any one of claims 20 to 25, wherein during step c) (1030), the ratio of polymer to solvent in the mixture is in the range of 10 wt% to 90 wt%, preferably 20 wt% to 80 wt%, more preferably 30 wt% to 70 wt%.

27. The method (1000) according to any one of claims 20 to 26, wherein the liquefied polymer of step c) is disposed on a substrate layer (1040) at a dynamic viscosity of 10,000 to 50,000 mPa⋅s, preferably 20,000 to 40,000 mPa⋅s.

28. The method (1000) according to any one of claims 20 to 27, wherein, The sole structure is the sole structure according to any one of claims 1 to 19, and the sole structure is an outsole.

29. An outsole (10) obtained by the method (1000) of any one of claims 20 to 28.

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