Liquid polymer application on sporting goods

Abstract

The present invention relates to a method (100) for producing a component (240), preferably for a sporting goods article (260), comprising the following steps: (a.) providing (110) a polymer (210); (b.) providing (120) a solvent (220); (c.) mixing (130) the polymer (210) with the solvent (220), thereby producing a liquefied polymer (230); and (d.) hardening (170) the liquefied polymer (230), thereby producing the component (240). Further aspects of the invention relate to an outsole and a sports shoe obtained by the method according to the invention.

Description

1. Technical area

[0001] The present invention relates to a method for producing a component, preferably for a sporting article, an outsole produced by such a method and a method for producing a sports shoe with such an outsole and the sports shoe. 2. State of the art

[0002] The manufacturing of sporting goods, such as athletic shoes, involves several steps and processes. Various manufacturing methods are known in the art. For example, in an athletic shoe, the first step is designing the outsole, which involves determining its shape, dimensions, tread pattern, and other features. This includes the choice of materials used in manufacturing. Today, outsoles are typically made from various types of rubber or synthetic compounds. The choice of material depends on factors such as the desired traction, durability, flexibility, weight, and specific performance requirements.

[0003] Outsoles, as well as other sporting goods, are typically manufactured by injection molding. For this purpose, the molding material is prepared by mixing the selected rubber or synthetic compound with fillers, plasticizers, stabilizers, and colorants known in the art. The manufactured material is then injected into the mold cavity using an injection molding machine. After the mold has cooled to solidify the material, the sole is further processed, for example, by cutting. In a subsequent process step, the manufactured outsole is then integrated into the shoe manufacturing process by attaching it to the midsole, shoe upper, or other elements using adhesives, stitching, or other assembly techniques.

[0004] Some prior art documents, such as WO 2005 090 062 A1, CN 216 416 187 U and WO 2019 106 837 A1, relate to sporting goods, such as outsoles for shoes, produced by injection molding.

[0005] Another approach in this regard is described in the prior art, in particular by prior art documents IT1402354, CN109228445, and US11278081. IT1402354 describes a method for reinforcing and waterproofing a shoe, as well as a shoe comprising a coating. CN109228445 discloses a dip-glue-type shoe sole processing method. US11278081 describes a sole for a footwear article comprising a continuously dispensed component forming a first layer and a second layer.

[0006] However, a common disadvantage of these soles is that the final sole has a specific weight and thickness to provide the required durability and performance of the shoe, which significantly impacts the overall weight of the shoe. Another common disadvantage of the soles is that they are not sustainable, as the shoe is designed to be disposed of after use. Furthermore, it is not easily possible to change the material properties during the manufacturing process to adapt the sole to the diverse requirements of the sporting goods. Furthermore, soles are typically manufactured in several independent steps, resulting in an overall labor-intensive and inefficient process.

[0007] Therefore, the object of the present invention is to provide improved methods and sporting articles to at least partially overcome the above-mentioned deficiencies of the prior art. 3. Summary of the invention

[0008] The above-mentioned object is at least partially achieved by a method for producing a component, preferably for a sporting article, comprising the following steps: a.) Providing a polymer; b.) Providing a solvent; c.) Mixing the polymer with the solvent to form a liquefied polymer; and d.) Curing the liquefied polymer to form the component.

[0009] While in the above-mentioned prior art the production of a component, for example an outsole for a sporting article, is usually carried out by, for example, injection molding a first component with a second component, such a process is not flexibly adaptable to the specific needs of the product. The present invention is based on a different approach, namely the production of a liquefied polymer by mixing the polymer and the solvent, which is applied to the sporting article and cured. In this way, the liquefied polymer can be applied to the sporting article more precisely and effectively, since no material waste is generated, for example, by cutting excess material. In this way, the process according to the invention represents an improved process for producing a component, for exampleof a sporting goods item, using only as much material as needed and avoiding any waste production.

[0010] Furthermore, manual assembly is eliminated and glueless application is possible, providing an efficient process with reduced material consumption and consequently reduced overall costs, which is applicable to automated processes. Bonding can require complex pretreatment of the components, and in addition, adhesives used to bond plastic components are often harmful or environmentally hazardous.

[0011] According to this approach, the component can be provided and cured more than once, enabling the strategic manufacturing of components with different thicknesses and weights, while significantly improving the performance and durability of the sporting article and maintaining or even increasing its damping properties. In this way, the method enables a formless manufacturing process while flexibly addressing different needs and requirements of the product. Therefore, the claimed invention significantly simplifies the overall process for manufacturing components, preferably for a sporting article, and increases the overall durability of the process, as renewal of worn products, i.e., recoating and reapplying the component, is possible. This contributes significantly to extending the service life of the sporting article by renewing the respective component.Ultimately, this further contributes to reducing overall consumer waste. By choosing sustainable starting materials (polymer, solvent) in the process, the manufactured component and sporting goods are recyclable and produced sustainably. Furthermore, the inventors have discovered that the component can provide a shimmering and / or glossy appearance, which is considered advantageous from a visual perspective.

[0012] Therefore, the entire manufacturing process of the sporting article can be more efficient and sustainable using the method according to the invention. The method according to the invention provides the possibility of easily adjusting the curing process provided to different sections of the sporting article, so that the component on the sporting article is cured without excessive waste of energy and time. Furthermore, the method according to the invention enables the possibility of creating patterns and designs through the use of the component, which can vary in their design and shape. For example, the component can be transparent, opaque, single- or multi-colored, and customized by the consumer.

[0013] A "component" according to the present disclosure is, but is not limited to, a unit or module that performs a specific function within a larger system. For example, a component is a component used in the manufacturing process of a sporting goods article, such as a sole unit, a midsole, an outsole, an outsole element, a film or foil material, a sole plate, a shoe upper, or a functional element.

[0014] A "sporting article" as used herein is understood to mean, but is not limited to, a device, piece of equipment, or a product specifically designed and / or used for sports. Sporting articles include, for example, sportswear, sports shoes, sports accessories, and / or sports equipment.

[0015] A "polymer" as used herein is, but is not limited to, a large molecule based on repeating subunits (monomers) that are bonded together to form a network structure. Polymers can be classified as: synthetic polymers, natural polymers, biodegradable polymers, and composite polymers.

[0016] A "solvent" as used herein is, but is not limited to, a compound capable of dissolving, dispersing, or extracting other compounds. Solvents can be polar or nonpolar. Common solvents are in liquid form, but can also be a gas or a solid.

[0017] “Mixing” as used herein is understood to mean, but is not limited to, a process of combining one or more substances resulting in a mixture of the individual substances.

[0018] "Hardening" as used herein is understood, but is not limited to, a chemical and / or physical process of a substance that typically promotes its hardening, setting, and / or solidification. Hardening is based on chemical reactions, heat influences, and / or other external or internal factors.

[0019] In some embodiments, the method may further comprise a step of depositing the liquefied polymer obtained in the mixing step, which may be a first component of the sporting article, onto a second component of a sporting article. The depositing step precedes the curing step. "Deposition" or "deposition" according to the present disclosure is to be understood as, but is not limited to, a process of applying one or more elements to one or more other elements. Such embodiments can significantly simplify the process of manufacturing the component. For example, the liquefied polymer with different physical properties can be deposited before the polymer is cured on the sporting article, thereby improving the efficiency of the manufacturing process.Furthermore, these process steps can be performed in one device or can be carried out on different units to provide a high degree of flexibility and automation in the manufacturing process.

[0020] The method may further comprise the step of texturing the liquefied polymer obtained in the mixing step, which may precede the curing step. "Texturing" or "structuring" according to the present disclosure is understood, but is not limited to, a process of manipulating physical properties of an element through external influence, e.g., shape, pattern, and / or surface. The inventors have found that adding textures and structures can significantly improve the performance and durability of the sporting article, as the thickness of the applied layer can be adapted to product requirements, such as weight, abrasion resistance, and design. Texturing can be performed using conventional texturing devices, e.g., pattern brushes and / or pattern rollers.The choice of texturing device depends on the desired pattern and / or the physical property of the liquefied polymer.

[0021] In some embodiments, the sporting goods may be a sports shoe. Examples of sports shoes include soccer shoes, basketball shoes, running shoes, tennis shoes, motorsport shoes, hiking shoes, and so on. The inventors have found that the method according to the invention, when applied to a sports shoe, significantly improves its service life and durability, as well as reducing the overall weight of the sports shoe.

[0022] The component may be the sole, preferably the outsole, of the sports shoe. Thus, the sole is manufactured by the method of the present disclosure and enables the same or more consistent and durable properties by using one or more lighter and thinner soles and / or outsoles compared to conventional soles known in the art.

[0023] In some embodiments, the athletic shoe may be a soccer shoe. In particular, the inventors have found that this approach makes the soccer shoe lighter while maintaining the same or even better performance characteristics than conventional soccer shoes.

[0024] In some embodiments, the component may be a stud of the athletic shoe. In addition to the advantage of being lighter while maintaining the same or even better performance characteristics than conventional studded athletic shoes, it allows for the ability to recoat and / or renew each stud individually. Depending on the diverse requirements of the product and / or the consumer, the studs can be individually molded and textured. This allows each athletic shoe incorporating studs to be strategically and conceptually designed, providing an improved process.

[0025] In some embodiments, the liquefied component can be deposited onto one or more portions of the athletic shoe. The portions can include a toe portion, a forefoot portion, a heel portion, a midsole portion, a sidewall portion, and / or an upper portion. The "liquefied component" is understood to include, but is not limited to, the component having semi-solid physical properties and / or the liquefied polymer according to the present invention. In this way, the athletic shoe can include individual sole elements that can be customized and reapplied. The liquefied component can be deposited onto predetermined portions of the athletic article. For example, the liquefied component can include different physical properties on each of the predetermined portions.In this way, the sporting goods can be adapted conceptually, while enabling a lighter overall weight of the sporting goods and improving its durability and performance characteristics.

[0026] The one or more predetermined sections of the sporting article can be determined using a torsion map, an abrasion map, and / or a pressure map. The inventors have found that using this approach, the component can be applied in defined areas where it is most needed. These predetermined areas or defined areas can be described, for example, as "the highest general wear zones." The deposition application is tailored to each map by adjusting the physical properties and, in particular, the thickness of the liquefied polymer and / or the component based on the zones derived from the maps. These zones are characterized, for example, by high pressure, traction, and / or abrasion.The liquefied polymer can be applied to predetermined areas in varying thickness and weight to meet abrasion and traction requirements. Furthermore, the weight reduction, performance, lifespan, and / or durability of the sporting goods are improved.

[0027] In some embodiments, the liquefied component can be deposited in a pattern onto the second component. The advantage of this process is an individualized and customized application of the liquefied component, which requires less material and is therefore cost-effective. Furthermore, the liquefied component can provide a shimmering and / or glossy appearance. The pattern can comprise a laminar and / or linear pattern. In this way, the process can be applied to both linear shapes and designs and large, uniform laminar designs. This has the advantage of creating islands of more or less liquefied components that are tailored to the individual requirements of the product and / or consumer.

[0028] The first component can be deposited onto the second component at a thickness of 1-10 mm, preferably 2-4 mm, and most preferably 3 mm. The inventors have found that applying the component at the specific thickness improves the performance of the sporting goods and achieves the same or even improved results for its durability properties compared to commercial components.

[0029] The thickness of the first component after the curing step can be 0.3 mm–0.7 mm, preferably 0.5 mm. This specific thickness of the component has the advantage of providing the same or even better performance and / or durability properties while maintaining reduced weight and thickness.

[0030] In some embodiments, the deposition step can be performed by at least one of the following methods: brushing, coating, dipping, painting, automated dispensing, automated printing, or controlled dispensing. The inventors have determined that these specific deposition methods represent the best way to deposit the liquefied polymer. The choice of deposition method depends on the properties of the liquefied polymer and the second component of the sporting goods.

[0031] In some embodiments, the second component can be manufactured by 3D printing, wherein preferably the second component can be a midsole and / or a shoe upper and / or parts thereof. The liquefied polymer can then be applied to the second component, wherein the liquefied polymer can preferably be an outsole. 3D printing includes additive manufacturing processes, such as stereolithography processes and laser sintering. In stereolithography processes, light causes chemical monomers and oligomers to crosslink to form layered polymers that make up the 3D-printed article. In laser sintering, a laser causes powdered material to sinter due to heat. When the laser is directed at points in space defined by a 3D model, the bonding of the materials together creates a solid structure.Another example of an additive manufacturing process is fused deposition modeling, where the part is created by extruding small beads or streams of material that instantly harden to form layers. If both the midsole and upper are manufactured using a 3D printing process, the midsole and upper can be manufactured using separate 3D printing processes and then joined, e.g., by gluing, welding, etc. Alternatively, the midsole and upper can be manufactured together in a single manufacturing step.

[0032] In another embodiment, the second component is a midsole made of a polymer material, and the liquefied polymer is applied to the midsole, forming an outsole. In this embodiment, the polymer material can be ethylene vinyl acetate (EVA), a thermoplastic urethane (TPU), or a supercritical foam. These materials provide good cushioning properties while being relatively lightweight.

[0033] In some embodiments, the liquefied polymer can be deposited in a first portion of the sporting article with a dynamic viscosity of 30,000 to 50,000 mPa s and in a second portion of the sporting article with a dynamic viscosity of 10,000 to 30,000 mPa s. Different viscosities can be achieved by varying the mixing ratio of the solvent and the polymer. In this way, it is possible to deposit different viscous materials on the second component using a single process step. The method allows for flexible adaptation of the process step based on the needs of the product.

[0034] The first portion may be an outer edge of the second portion of the sporting article. This feature enables quick and easy deposition on the second component using only one step for deposition of a pattern on the sporting article.

[0035] In some embodiments, the contact angle θ between the liquefied polymer and the second component is 30° to 110°, preferably 40° to 90°, more preferably 50° to 70°. The inventors have determined that these wettability properties represent the best way to deposit the liquefied polymer onto the second component.

[0036] The curing step can be performed using radiation. In this way, the liquefied component deposited on the second component is cured on the second component while simultaneously removing the solvent and drying the deposited liquefied component.

[0037] In some embodiments, the polymer can be selected from the group of polyurethanes (PU), thermoplastic polyamides (TPE-A or TPA), thermoplastic polyesters (TPE-E or TPE), thermoplastic styrene block copolymers (TPE-S or TPS), thermoplastic polyurethanes (TPE-U or TPU), thermoplastic vulcanizates (TPE-V or TPV), rubber or ethylene-vinyl copolymer (EVA), preferably thermoplastic polyurethanes (TPE-U or TPU), and / or combinations thereof. The inventors have found that the use of these polymers enables a time-efficient and sustainable process in the manufacture of the component. Suitable polymer materials can be elastic foam materials, such as thermoplastic elastomers and / or elastomers. Preferred materials used in the present disclosure are thermoplastic elastomers.More preferred materials used in the present disclosure are urethane-based thermoplastic elastomers (TPU), polyester-based thermoplastic elastomers (TPE), and / or polyamide-based thermoplastic elastomers (TPA).

[0038] In some embodiments, the solvent is a mixture selected from the group of solvent-containing and / or water-containing solvents, preferably from the group of solvent-containing solvents, more preferably from the group of (C1-C6) ethers, (C1-C 10 )-esters, (C1-C8)-ketones, (C1-C8)-alkanes, and / or combinations thereof. These solvents have demonstrated the best compatibility with the component's manufacturing process while allowing flexible adaptation of the polymer's physical properties to product and process requirements.

[0039] The solvent can be a mixture of one or more of tetrahydrofuran (THF), methyl ethyl ketone (MEK), cyclohexane (CYC), ethyl acetate, butyl acetate, preferably THF and / or CYC. These solvents have the advantage of being time-efficiently removed during the curing process and enable a manufacturing process capable of adapting to different physical properties of the liquid polymer.

[0040] The ratio of the mixture can range from 10 to 90 vol%, preferably 20 to 80 vol%, more preferably 30 to 70 vol%. In some embodiments, the ratio of the mixture can range from 10 to 90 wt%, preferably 20 to 80 wt%, more preferably 30 to 70 wt%. The inventors have found that the ratio of the mixture to the solvent provides the best compatibility for both mixing the polymer and modifying / adapting the physical properties of the liquefied polymer to the specific product and process requirements.

[0041] In some embodiments, the liquefied component may comprise a dynamic viscosity of 10,000 to 50,000 mPa s, preferably 20,000 to 40,000 mPa s. The use of the liquid polymer comprising the specific dynamic viscosity enables its use in automated and / or manual deposition processes.

[0042] The polymer can be characterized by a Shore A and / or Shore D value, where 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. The use of a polymer having these Shore A and / or Shore D values ​​provides the durable properties of the final component. Suitable polymer materials are elastic foam materials, such as thermoplastic elastomers (TPE) and / or elastomers.

[0043] The ratio of polymer to solvent in the mixing step may range from 2:98 to 40:60 vol%, preferably 5:95 to 30:70 vol%, more preferably 10:90 to 20:80 vol%. The inventors have found that the specific ratio of solvent to polymer allows for convenient use in the deposition process and flexible adaptation to the requirements of the product and / or process.

[0044] In some embodiments, the liquefied polymer may further comprise pigments and / or fibers. This allows for increased stiffness and durability in selected applications. "Fibers" include, but are not limited to, threads or filaments based on natural and / or synthetic materials.

[0045] The liquefied polymer may further comprise granules. This improves the traction and grip properties in selected areas of the sporting goods based on the use of the granules. "Granules" are understood to mean, but are not limited to, particles of varying size and shape that may exhibit specific physical properties based on natural and / or synthetic materials.

[0046] In some embodiments, the curing step may have a curing temperature of between 20°C to 150°C, preferably 30°C to 100°C, more preferably 40°C to 50°C, and the curing time of between 2 min to 750 min, preferably 5 min to 390 min, more preferably 10 min to 30 min. The inventors have found that these curing conditions enable the cost- and energy-efficient process for manufacturing the component.

[0047] In a further aspect, the present invention relates to a method for manufacturing a sports shoe, comprising the method of the present disclosure, wherein the first component is an outsole of the sports shoe and the second component is a midsole of the sports shoe. The advantages of the method for manufacturing a sports shoe are the avoidance of, for example, glue- and injection-mold-based application of the outsole to the midsole of the sports shoe.

[0048] In another aspect, the present invention relates to an outsole manufactured according to the method of the present disclosure. The inventors have discovered that the component can be specifically used to create a lighter and thinner outsole while still providing the same and / or even improved performance and durability.

[0049] The outsole can feature a pattern. This allows the outsole to be customized based on the needs and requirements of the product and / or consumer.

[0050] In another aspect, the present invention relates to an athletic shoe comprising an outsole according to the present disclosure. The inventors have found that the athletic shoe comprising the outsole according to the present disclosure is lighter and thinner, thereby making the athletic shoe more desirable overall. Furthermore, the athletic shoe exhibits the same and / or even improved durability and performance characteristics than athletic shoes known in the prior art.

[0051] The outsole can be located in at least a toe section, a midfoot section, and / or a heel section of the athletic shoe. This has the advantage that the outsole can be placed in specific sections of the athletic shoe, enabling weight reduction and material and cost savings.

[0052] In another aspect, the present invention relates to an athletic shoe comprising a first component and a second component, the first component being manufactured according to a method of the present disclosure, the first component being disposed on an upper of the athletic shoe. The inventors have found that the athletic shoe comprising the component according to the present disclosure is lighter and thinner, thereby making the athletic shoe more desirable overall while maintaining the same and / or even improved durability and performance characteristics than athletic shoes known in the art. 4. Short description of the characters

[0053] Possible embodiments of the present invention are further described in the following detailed description with reference to the following figures: Fig. 1: represents a flow diagram illustrating an exemplary method for manufacturing a component, preferably for a sporting goods article. Fig. 2: illustrates an exemplary athletic shoe incorporating the component according to the present invention. Fig. 3 and Fig. 4: show two exemplary embodiments of the component, in particular as a sole. Fig. 5 and Fig. 6: represent exemplary embodiments of the component, in particular as studs. Fig. 7: shows an exemplary embodiment of a sports shoe according to the invention. Fig. 8 - Fig. 11: represent illustrative and exemplary zones for deposition of the liquefied polymer. 5. Detailed description of preferred embodiments

[0054] Possible embodiments and variations of the present invention are described below with particular reference to a sporting article, in particular a sports shoe. However, the concept of the present invention is not limited to these embodiments. The method described herein can be applied identically or similarly to the production of any sporting article in general, such as sportswear or sports equipment.

[0055] It should also be noted that individual embodiments of the invention are described in more detail below. However, it will be apparent to those skilled in the art that the design possibilities and optional features described with respect to these specific embodiments can be further modified and combined in other ways within the scope of the present invention, and that individual steps or features can also be omitted if they appear unnecessary to those skilled in the art. To avoid redundancies, reference is made to the explanations in the preceding sections, which also apply to the embodiments of the following detailed description.

[0056] Fig. 1 depicts a flow chart illustrating exemplary process steps for a process 100 for manufacturing a component 240 according to the invention, preferably for a sporting goods article 260. The process 100 begins with process step 110 of providing a polymer. The polymer is selected from the group of elastomers and / or thermoplastic elastomers. Preferred materials from the group of elastomers are slabstock foams, such as ethylene-vinyl acetate (EVA), polyurethanes (PU), and / or rubber. Thermoplastic elastomers (TPE) are bead, slabstock foams, crosslinked and / or uncrosslinked, and are classified using the following groups: TPE-O or TPO; TPE-V or TPV; TPE-U or TPU; TPE-E or TPE or TPC; TPE-S or TPS; TPE-A or TPA. Polymer materials from the group of TPE-O or TPO are polypropylene (PP), ethylene propylene diene rubber or ethylene propylene diene monomer rubber (EPDM).Preferred polymer materials from the TPE-V or TPV group are thermoplastic vulcanizates such as Sarlink. ® Polymer materials from the TPE-U or TPU group are further classified into ester-based, ether-based, or linear UP materials. For example, a preferred ester-based TPU material is Huntsman-H Foam. ® For example, a preferred ether-based TPU material is Elastollan ® 11XX (BASF). Preferred polymer materials from the TPE-E or TPC group include Hytrel ® (DuPont), Keyflex ® (LG) and / or Arnitel ® (DSM). A preferred polymer material from the group of TPE-S or TPS is, for example, Styroflex ® (BASF). Preferred polymer materials from the group of TPE-A or TPA are from the group of polyether block amides, such as PEBAX ® , and / or Vestamid ®The polymer in process step 110 is characterized by having a Shore A and / or D value. 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.

[0057] The second step in the process 100 is the process step 120 of providing a solvent. Suitable solvents are solvents selected from the group of solvent-containing and / or water-containing solvents, preferably from the group of solvent-containing solvents, more preferably from the group of (C1-C6) ethers, (C1-C 10)-esters, (C1-C8)-ketones, (C1-C8)-alkanes, and / or combinations thereof. The solvent is preferably a mixture of one or more of tetrahydrofuran (THF), methyl ethyl ketone (MEK), cyclohexane (CYC), ethyl acetate, butyl acetate, preferably THF and / or CYC. The ratio of the solvent mixture is in the range of 10 to 90 vol%, preferably 20 to 80 vol%, more preferably 30 to 70 vol%.

[0058] In the third process step 130 of the process 100, the polymer and the solvent are mixed, forming a liquefied polymer 230. The ratio of the polymer to the solvent in the mixing step is in the range of 2:98 to 40:60 vol%, preferably 5:95 to 30:70 vol%, more preferably 10:90 to 20:80 vol%. The ratio of the polymer to the solvent in the mixing step is in the range of 10 to 90 wt%, preferably 20 to 80 wt%, more preferably 30 to 70 wt%.

[0059] As in Fig. 1, the method 100 may include optional process steps 150 and 160. These steps precede the curing step 170. In process step 150, the liquefied polymer 230 is deposited onto a second component 250. The liquefied component 230 is deposited onto the second component 250 at a thickness of 1-10 mm, preferably 2-4 mm, most preferably 3 mm. Further, the liquefied component 230 is deposited onto one or more portions of the athletic shoe. These portions include a toe portion, a forefoot portion, a heel portion, a midsole portion, a sidewall portion, and / or an upper portion. In particular, the liquefied component 230 is deposited in predetermined portions, which is determined using a torsion map, an abrasion map, and / or a pressure map, as described in more detail below.The liquefied polymer is deposited in the deposition step 150, which is carried out by at least one of the following methods: brushing, coating, dipping, painting, automated dispensing, automated printing, or controlled dispensing. The second component 250 is deposited, preferably by automated printing, wherein the second component is a midsole and / or a shoe upper or parts thereof, preferably both. The deposition of the second component as a shoe upper and / or midsole is carried out in a single process step, preferably by 3D printing. The liquefied polymer is then applied to the second component, wherein the liquefied polymer is the outsole 290. The preferred deposition step is carried out by an automated method. The liquefied component 230 for deposition has a dynamic viscosity of 10,000 to 50,000 mPa s, preferably 20,000 to 40,000 mPa s.

[0060] In particular, and to accelerate the deposition process, the outer edge of the area of ​​the sporting article targeted during the deposition step is dispensed using a thinner nozzle and using a liquefied polymer with a higher viscosity to create a more rigid edge. Second, the area within the edge is dispensed in a faster process using a wider nozzle and a liquefied polymer with a lower viscosity. Therefore, the liquefied polymer is deposited in a first section of the sporting article with a dynamic viscosity of 30,000 to 50,000 mPa s and in a second section of the sporting article with a dynamic viscosity of 10,000 to 30,000 mPa s. The second section is the area positioned between the first section. The first section is the outer edge of the second section of the sporting article 260.

[0061] In some embodiments, the contact angle θ between the liquefied polymer 230 and the second component 250 during deposition is 30° to 110°, preferably 40° to 90°, more preferably 50° to 70°. The preferred deposition is an automated deposition process. In some embodiments, the liquefied polymer comprises granules. In addition, it may further comprise pigments and / or fibers. In some embodiments, such as in the Fig. 2 and Fig. As shown in Figure 4, the liquefied component 230 is deposited in a pattern onto the second component 250. The pattern includes a laminar and / or linear pattern.

[0062] After deposition, the liquefied polymer 230 may be textured during optional process step 160. The addition of textures to the deposited liquefied polymer 230 is performed using texturing devices known in the art, such as a pattern brush and / or a pattern roller. The addition of textures and structures may further be performed by pressing patterns via pattern devices into the deposited semi-dried liquefied polymer 230.

[0063] In the final process step 170 of the process 100, the liquefied polymer is cured. In this way, the liquefied polymer 230, which in some embodiments may be deposited on a second component 250, is cured while simultaneously removing the solvent(s) present in the liquefied polymer 230. The solvent may be removed via condensation, and the condensates may be recycled. The curing temperature in the curing step 170 is between 20°C to 150°C, preferably 30°C to 100°C, more preferably 40°C to 50°C, and the curing time is between 2 min to 750 min, preferably 5 min to 390 min, more preferably 10 min to 30 min. In some embodiments, the curing step 170 is performed using radiation. The curing 170 is preferably performed using infrared radiation (IR). However, other types of radiation are applicable.The thickness of component 240 after the curing step is 0.3 mm-0.7 mm, preferably 0.5 mm.

[0064] In some embodiments, the sporting article 260 is partially defined by the Fig. 1, a sports shoe 260. In particular, the component 240 is a sole, preferably an outsole of the sports shoe. Furthermore, the sports shoe partially obtained by the method 100 is a soccer shoe. In this context, the component is a stud of the sports shoe. The sports shoe 260 may comprise at least two components, a first and a second component. The first component is an outsole 290, which is manufactured according to the method illustrated in Fig. 1 illustrated and in relation to Fig. 1. The second component is a midsole 350 of the sports shoe 260.

[0065] The Fig. 2 The sporting goods 260 shown is a sports shoe 260. Fig. Figure 2 illustrates an exemplary outsole of the athletic shoe 260 manufactured by the method of the present invention according to certain aspects of the present disclosure. For a better understanding of the invention, three different views of the athletic shoe 260 are shown, namely two side views (left and right figures) and a bottom view (middle figure). Fig. 2 it is shown that the component 240 is an outsole 290 of the sporting article 260. The component 240, ie the outsole 290 of the shoe, is manufactured according to the method described with respect to Fig. 1 described method 100.

[0066] Back to Fig. 2, the liquefied polymer 230 is deposited onto the second component 250 following a continuous delivery path. In this way, the outsole 290 comprises a linear arrangement. The liquefied polymer 230 is deposited onto a second component 250, which is Fig. 2 is not directly connected to the shoe upper. It is conceivable that the second component 250, onto which the liquefied polymer 230 is deposited, is directly connected to the shoe upper. The pattern according to Fig. 2 is obtained by using a thin nozzle during the deposition of the liquefied polymer 230, which follows the path indicated by the black line. In this way, the outsole 290 receives the pattern 300, as in Fig. 2, where the white areas do not contain any liquefied polymer. Accordingly, the second component 250 shimmers through the outsole 290.

[0067] In Fig. 2, the outsole 290 comprises a different material than the midsole. However, it is conceivable that the midsole and the outsole comprise the same material and / or the same shape. In some embodiments, the midsole and the shoe upper are manufactured by the method described above. In this way, the entire sports shoe 260 is manufactured by the method according to the invention. In some embodiments, an outsole 290 according to aspects of the present invention is combined with such a midsole, which is manufactured in a one-step process together with the shoe upper. In this context, the deposition is carried out using 3D printing.

[0068] Back to Fig. 2, the outsole 290 has a pattern 300. As in Fig. 2, the deposited component 240 has a linear pattern. The athletic shoe 260 can be manufactured using the above-described method for manufacturing the component 240 according to the present disclosure, which as such is arranged on the midsole 350 of the athletic shoe 260. As shown in Fig. 2, the outsole 290 is arranged in a toe section 10, a midfoot section 15 and a heel section 20 of the sports shoe.

[0069] In Fig. 3 shows an exemplary embodiment of the outsole. As in Fig. As can be seen in Figure 3, the outsole 290 has a pattern 300 that is laminar. Furthermore, the outsole 290 provides a shiny and shimmering appearance. The outsole 290 in Fig. 3 has two different colors, ie a dark color in the midfoot and forefoot portion and a light color in the heel portion. It is conceivable that the outsole 290 comprises only one color or more than two colors. Furthermore, and as in Fig. 3, the outsole 290 is arranged in three segments, i.e., a larger laminar segment positioned on the midfoot and forefoot portions and two smaller laminar segments positioned on the heel portion.

[0070] To obtain this pattern or appearance, the polymer is mixed with the solvent to obtain the liquefied polymer 230, which is deposited onto the second component 250, i.e., the midsole, in a uniform manner.

[0071] The liquefied component 230 is deposited onto one or more different portions of the sporting article 260, such as the toe portion, forefoot portion, heel portion, midsole portion, sidewall portion, and / or the upper portion. The liquefied polymer is deposited by at least one of the following methods: brushing, coating, dipping, painting, automated dispensing, automated printing, or controlled dispensing. The preferred deposition mode is performed by an automated process. In some embodiments, the second component 250 is a midsole and / or a shoe upper, or parts thereof, preferably both, and the second component can be manufactured by a 3D printing process. 3D printing includes additive manufacturing processes, such as stereolithography processes and laser sintering.In stereolithography processes, light causes chemical monomers and oligomers to crosslink to form layered polymers that comprise the 3D-printed object. In laser sintering, a laser causes powdered material to sinter due to heat. When the laser is directed at points in space defined by a 3D model, the bonding of the materials together creates a solid structure. Another example of an additive manufacturing process is fused deposition modeling, in which the part is created by extruding small beads or streams of material that instantly harden to form layers.

[0072] In a subsequent step, the liquefied polymer 230 used to create the outsole 290 is applied to the 3D-printed midsole and / or the shoe upper. If both the midsole and upper are manufactured using a 3D printing process, the midsole and upper can be manufactured using separate 3D printing processes and then joined, e.g., by gluing, welding, etc. Alternatively, the midsole and upper can be manufactured together in a single manufacturing step.

[0073] In the embodiment of Fig. 3, the second component is a midsole made of a polymer material, and the liquefied polymer is applied to the midsole, forming the outsole 290. In this embodiment, the polymer material may be an ethylene vinyl acetate (EVA), a thermoplastic urethane (TPU), or a supercritical foam.

[0074] In Fig. 4, the outsole 290 has a pattern 300 that is linear. To obtain this pattern, the liquefied polymer 230 is deposited in a continuous dispensing mode. The linear pattern is characterized by having a consistent width, which is achieved by using a dispensing nozzle, resulting in consistent dispensing during deposition. In this way, the liquefied polymer 230 is dispensed without interruption of the deposition process. Preferably, the liquefied polymer 230 comprises unchanged physical properties throughout the deposition process. The outsole 290 is deposited according to the method described with respect to Fig. 1. Component 240 has a thickness of 0.3 mm-0.7 mm, preferably 0.5 mm, after curing.

[0075] Also in the embodiment of Fig. 3, the second component is a midsole made of a polymer material, and the liquefied polymer is applied to the midsole, forming the outsole 290. In this embodiment, the polymer material may be an ethylene vinyl acetate (EVA), a thermoplastic urethane (TPU), or a supercritical foam.

[0076] In the Fig. 5 and Fig. 6, the component 240 manufactured according to the method of the present invention as described above is used as a stud 285 for a sports shoe, which is a football shoe 275. As shown in the Fig. 5 and Fig. As can be seen in Figure 6, the studs 285 are arranged on the sole of the football boot 275. In Fig. 5, the studs 285 have a different shape and appearance than the sole of the soccer shoe 275. In some embodiments, the studs 285 and the sole of the soccer shoe 275 are manufactured in several separate steps, e.g., separately manufacturing the studs and the sole according to aspects of the present invention and subsequently applying the studs 285 to the sole. In this context, the studs 285 are manufactured using different materials than the sole. In some embodiments, the material of the sole and the studs 285 of the sports shoe 275 is the same as in Fig. 6 can be seen in more detail. Furthermore, the studs 285 and the sole are shown in Fig. 6 in a one-step process according to the process of the present invention.

[0077] In some embodiments, the component 240 manufactured according to aspects of the present invention is applied in transition zones of the sporting article 260, which in Fig. 7. The component 240 is applied in more than one section of the sporting goods 260. As shown in Fig. As can be seen in Figure 7, the sports shoe 260 comprises an outsole 290 and a midsole 350, wherein the component 240 is arranged on both shoe elements, ie, on the sole 280, ie, the midsole and the outsole 290, as well as on the upper of the sports shoe 260. To obtain this pattern, the liquefied polymer 230 is additionally deposited on the midsole 350 and the upper. Fig. 7, the midsole 350 and the outsole 290 have the same shape and / or the same material. However, it is also possible that in some embodiments, the midsole 350 and the outsole 290 comprise a different pattern 300 and / or material. In this context, the liquefied polymer 230 is textured after deposition. The addition of textures to the deposited liquefied polymer 230 is carried out using texturizing devices, such as a pattern brush and / or a pattern roller. The addition of textures and structures is further carried out by pressing patterns via pattern devices in the deposited semi-dried liquefied polymer 230. Furthermore, the component 240 is deposited in the transition zone of the outsole 290 and in particular in the heel segment 20 of the outsole 290.Using this approach, the component 240 may be arranged as such to create a pattern 300 on more than one portion of the sporting article 260.

[0078] As discussed at the beginning of the present disclosure, the liquefied component can be measured using a torsion map, an abrasion map and / or a pressure map included in the Fig. 8 to Fig. 11, deposited on predetermined portions of the sporting article 260. In this way, the liquefied polymer 230 is applied to the areas where the greatest abrasion, traction, or torsion is measured.

[0079] In Fig. 8, the predetermined zones of the sole 280 are measured using an abrasion map according to aspects of the present invention. Preferably, the abrasion map is used to determine the zones of an outsole 290 to which the liquefied polymer is applied, as described herein. In this manner, the liquefied polymer 230 is applied, for example, in sidewalls, toe caps 10, and heel counters 20. The midfoot regions 15 can be recessed with the liquefied polymer 230. However, in some embodiments, the liquefied polymer 230 is also applied to the midfoot region 15. Using this approach, the liquefied polymer 230 can be applied to the predetermined regions with different physical properties, such as thickness, weight, color, and / or viscosity.In this way, each measured area with its specific needs can be individually addressed during the deposition of the liquefied polymer 230 onto the second component 250 (e.g., a midsole, an upper, or the like). This approach can be used, for example, to improve the durability of a sporting item based on the varying traction, abrasion, and / or pressure applied to it during use. In some embodiments, the liquefied polymer 230 is deposited using a mask. In this way, the liquefied polymer 230 is deposited onto the sporting item in a desired zone and / or pattern.

[0080] It should be noted that the abrasion, traction, and / or pressure map varies based on the sporting item and further based on the type of sport (e.g., basketball, soccer, tennis, etc.) in which the sporting item may be used. For example, the sole, and preferably the outsole, of a basketball shoe is enhanced by applying component 240 in the one or more areas where the greatest lateral traction is recorded. Likewise, component 240 is preferably applied in the sidewall areas of the sole of a tennis shoe to support those areas exhibiting the greatest traction and / or abrasion.

[0081] With reference to Fig. 9, two maps for the outsole 290 according to aspects of the present invention are shown, comprising predetermined zones. These predetermined zones are determined / measured using a traction, abrasion, and / or pressure map. Specifically, in the first map (top), the outsole 290 comprises thicker layers of component 240 in the heel "midfoot to forefoot" zone. The thickness of the component 240 located at the edge may vary compared to the component 240 located in the central region. Furthermore, the adjacent regions surrounding these thicker regions may also comprise component 240 in layers of varying thickness. The edge margins of both the "thickest" regions and the "adjacent" regions may further vary, i.e., comprise component 240 with a varying thickness. The rest regions may comprise a thinner layer or no layers of component 240.

[0082] Specifically, in the second map (below), the outsole 290 includes thicker layers of component 240 in the "heel to sidewall" zone and the "midfoot to sidewall" zone. As in the upper map, the thickness may vary at the edge and in the central region of the deposited component 240. Furthermore, the adjacent regions surrounding these thicker regions may also include component 240 in layers of varying thickness. The edge margins of both the "thickest" regions and the "adjacent" regions may further include component 240 with varying thicknesses. The rest regions may include a thinner layer or no layers of component 240. As a result, component 240 reduces the overall weight of the outsole and the sporting goods while simultaneously improving the durability of the sporting goods.

[0083] Fig. 10 shows an exemplary traction map for determining predetermined zones of an outsole 290 according to aspects of the present invention. Using this approach, the component 240, and in particular the liquefied polymer 230, is applied with different thicknesses and viscosities to the second components 250 in different zones, e.g., the toe cap 10, the midfoot zone 15, and / or the heel zone 20. These predetermined zones can be separated from zones that can be measured by another map, for example, a pressure map, as in Fig. 11 shown, vary.

[0084] In Fig. 11, an exemplary pressure map is shown that can be used to determine predetermined zones of an outsole 290 according to aspects of the present invention. As in Fig.11, which is self-explanatory, the heel portion 20 shows increased pressure compared to the midfoot portion 15. This difference can be addressed by applying the component 240 in these “high pressure zones”, i.e. depositing thicker layers of the liquefied polymer onto these “high pressure areas”.

[0085] It should be noted that the above embodiments and / or examples may be combined with other aspects as described herein, and details of the embodiments and / or examples may also be omitted, as will be understood by those skilled in the art. The scope of protection is determined by the claims and is not limited by the embodiments and / or examples disclosed in the above figures. QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] WO 2005 090 062 A1

[0004] CN 216 416 187 U

[0004] WO 2019 106 837 A1

[0004] IT 1402354

[0005] CN 109228445

[0005] US 11278081

[0005]

Claims

[1] Method (100) for producing a component (240), preferably for a sporting article (260), comprising the following steps: a. Providing (110) a polymer (210); b. Providing (120) a solvent (220); c. Mixing (130) the polymer (210) with the solvent (220), thereby producing a liquefied polymer (230); and d. Curing (170) the liquefied polymer (230), thereby producing the component (240). [2] The method (100) according to the preceding claim, wherein the component is a first component of the sporting article, and the method further comprises the step of depositing (150) the liquefied polymer (230) obtained in the mixing step (130) onto a second component (250) of the sporting article (260), wherein the depositing step (150) precedes the curing step (170). [3] The method (100) according to the preceding claim, further comprising the step of texturing (160) the liquefied polymer (230) obtained in the step of mixing (130), wherein the step of texturing (160) precedes the step of curing (170). [4] Method (100) according to one of the preceding claims, wherein the sporting article (260) is a sporting shoe (270). [5] Method (100) according to the preceding claim, wherein the component (240) is a sole (280), preferably an outsole (290) of the sports shoe (270). [6] The method (100) according to any one of claims 4-5, wherein the sports shoe (270) is a football shoe (275). [7] The method (100) according to any one of claims 4-6, wherein the component (240) is a stud (285) of the athletic shoe (270). [8] The method (100) of any of claims 4-7, wherein the liquefied component (230) is deposited onto one or more portions of the athletic shoe (270), including a toe portion, a forefoot portion, a heel portion, a midsole portion, a sidewall portion, and / or an upper portion. [9] The method (100) of any of claims 2-8, wherein the liquefied component (230) is deposited onto one or more predetermined portions of the sporting article (260). [10] Method (100) according to the preceding claim, wherein one or more predetermined portions of the sporting article (260) are determined using a torsion map, an abrasion map and / or a pressure map. [11] The method (100) of any of claims 2-10, wherein the liquefied component (230) is deposited onto the second component in a pattern (300). [12] Method (100) according to the preceding claim, wherein the pattern (300) comprises a laminar and / or a linear pattern. [13] The method (100) of any of claims 2-12, wherein the first component (240) is deposited onto the second component with a thickness of 1-10 mm, preferably 2 mm-4 mm, most preferably 3 mm. [14] Method (100) according to any one of claims 2-13, wherein the thickness of the first component (240) after the curing step is 0.3 mm-0.7 mm, preferably 0.5 mm. [15] The method (100) of any one of claims 2-14, wherein the step of depositing (150) is performed by at least one of the following methods: brushing, coating, dipping, painting, automated dosing, automated printing, controlled dispensing. [16] Method (100) according to any one of claims 2-15, wherein the second component (250) is produced by 3D printing, wherein preferably the second component (250) is a midsole and / or a shoe upper and / or parts thereof. [17] The method (100) of any one of claims 2-16, wherein the liquefied polymer (230) is deposited in a first portion of the sporting article (260) with a dynamic viscosity of 30,000 to 50,000 mPa·s and in a second portion of the sporting article (260) with a dynamic viscosity of 10,000 to 30,000 mPa·s. [18] The method (100) of the preceding claim, wherein the first portion is an outer edge of the second portion of the sporting article (260). [19] The method (100) according to any one of claims 2-18, wherein the contact angle θ between the liquefied polymer (230) and the second component (250) is 30° to 110°, preferably 40° to 90°, more preferably 50° to 70°. [20] The method (100) of any preceding claim, wherein the curing step (170) is performed using radiation. [21] Method (100) according to one of the preceding claims, wherein the polymer (210) is selected from the group of polyurethanes (PU), thermoplastic polyamides (TPE-A or TPA), thermoplastic polyesters (TPE-E or TPE), thermoplastic styrene block copolymers (TPE-S or TPS), thermoplastic polyurethanes (TPE-U or TPU), thermoplastic vulcanizates (TPE-V or TPV), rubber or ethylene-vinyl copolymer (EVA), preferably thermoplastic polyurethanes (TPE-U or TPU), and / or combinations thereof. [22] Method (100) according to one of the preceding claims, wherein the solvent (220) is a mixture (225) selected from the group of solvent-containing and / or water-containing solvents, preferably from the group of solvent-containing solvents, more preferably from the group of (C1-C6) ethers, (C1-C 10 )-esters, (C1-C8)-ketones, (C1-C8)-alkanes and / or combinations thereof. [23] The method (100) according to the preceding claim, wherein the solvent (220) is a mixture (225) of one or more of tetrahydrofuran (THF), methyl ethyl ketone (MEK), cyclohexane (CYC), ethyl acetate, butyl acetate, preferably THF and / or CYC. [24] Method (100) according to the preceding claim, wherein the ratio of the mixture (225) is in the range of 10 to 90 vol%, preferably 20 to 80 vol%, more preferably 30 to 70 vol%. [25] Method (100) according to the preceding claim, wherein the ratio of the mixture (225) is in the range of 10 to 90 wt%, preferably 20 to 80 wt%, more preferably 30 to 70 wt%. [26] Method (100) according to one of the preceding claims, wherein the liquefied component (230) has a dynamic viscosity of 10,000 to 50,000 mPa·s, preferably of 20,000 to 40,000 mPa·s. [27] Method (100) according to one of the preceding claims, wherein the polymer (210) is characterized by a Shore A value (190) and / or Shore D value (195), wherein the Shore A value (190) is in the range of 20 to 120, preferably 40 to 100, more preferably 60 to 80; and the Shore D value (195) is in the range of 2 to 80, preferably 5 to 75, more preferably 8 to 70. [28] The method (100) according to any one of the preceding claims, wherein the ratio of the polymer (210) to the solvent (220) in the mixing step (130) is in the range of 2:98 to 40:60 vol%, preferably 5:95 to 30:70 vol%, more preferably 10:90 to 20:80 vol%. [29] The method (100) of any preceding claim, wherein the liquefied polymer (230) further comprises pigments and / or fibers. [30] The method (100) of any preceding claim, wherein the liquefied polymer (230) further comprises granules. [31] Method (100) according to one of the preceding claims, wherein in the curing step (170) a curing temperature between 20 °C to 150 °C, preferably 30 °C to 100 °C, more preferably 40 °C to 50 °C is used and the curing time is between 2 min to 750 min, preferably 5 min to 390 min, more preferably 10 min to 30 min. [32] A method (1000) for manufacturing an athletic shoe (270), comprising the method (100) according to any one of claims 2-31, wherein the first component is an outsole (290) of the athletic shoe (270) and the second component is a midsole (350) of the athletic shoe (270). [33] Outsole manufactured by the method (100) according to any one of the preceding claims. [34] Outsole according to the preceding claim, wherein the outsole has a pattern (300). [35] A sports shoe comprising an outsole according to any one of claims 33-34. [36] Sports shoe according to the preceding claim, wherein the outsole (290) is arranged at least in a toe portion (10), a midfoot portion (15) and / or a heel portion (20) of the sports shoe. [37] A sports shoe comprising a first component and a second component, wherein the first component is manufactured according to a method according to any one of claims 2-32, wherein the first component is arranged on an upper of the sports shoe.

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