Shoe upper with a layered structure for a sports shoe

Abstract

The present invention relates to a shoe upper, in particular for a sports shoe, comprising a layered structure with a first layer, a second layer and an intermediate foam layer between the first layer and the second layer, wherein the intermediate foam layer comprises a polyamide, PA, foam material. The present invention also relates to a sports shoe comprising such a shoe upper.

Description

1. Technical field

[0001] The present invention relates to a shoe upper, in particular for a sports shoe, comprising a layered structure with a first layer, a second layer and an intermediate foam layer between the first layer and the second layer, wherein the intermediate foam layer comprises a polyamide, PA, foam material.

[0002] The present invention also relates to a sports shoe comprising such a shoe upper. 2. State of the art

[0003] A shoe is generally described as the combination of an upper and a sole. The upper typically covers areas such as the instep, toes, medial side, lateral side, and heel of the wearer's foot and provides an opening for the wearer to step into the shoe. The upper typically serves several different functions, such as protection, support, and comfort. The sole is attached to the upper in such a way that its top surface faces the underfoot section of the upper, and its underside touches the ground during normal use of the shoe.

[0004] Foam materials have become a crucial component in the design and manufacture of modern footwear, particularly in the soles of athletic and sports shoes. The development and use of foam in shoes stems from the need for enhanced comfort, cushioning, support, and performance. Over time, the technology and materials used in foam manufacturing have evolved significantly. Manufacturers have developed various types of foam, each with unique properties tailored to specific performance requirements. For example, memory foam offers a customized fit by molding to the shape of the foot, while polyurethane (PU) foam provides greater durability and energy return.

[0005] EP 3 253 247 A1 discloses a footwear article with a multi-layered upper, wherein the outermost layers of the upper are cut into a pattern. The cut sections of the upper are mounted on a continuous substrate layer, so that the edges of the cut sections are visible and perceptible to the touch. The upper remains durable with respect to abrasion resistance, layer adhesion, tensile strength, and flexural strength.

[0006] EP 3 765 640 A1 discloses a method for producing a layered material comprising a substrate layer and a polyurethane layer bonded to the substrate layer, wherein a leather, preferably a sanded grain leather, a textile material, preferably a woven or knitted fabric, a bonded leather material or a microfiber nonwoven fabric is used as the substrate layer and is bonded to the layer.

[0007] US 10 499 706 B2 discloses a method for manufacturing an upper for a footwear article, which includes the steps of forming a foam layer, forming a temporary upper by laminating an outer layer, an inner layer and the foam layer between the outer layer and the inner layer; and shaping the temporary upper into a form having a contour to substantially fit at least one section of a foot in order to provide at least one section of an upper for a footwear article.

[0008] US 2006 / 051566 A1 relates to a comfort element for a footwear article or garment, a method for manufacturing the same, and a footwear article or garment incorporating such an element. The comfort element is manufactured by layering a first layer of material having a melting point theta1, a layer of foam material having a melting point theta2, and a second layer of material having a melting point theta3, where the temperature theta2 is lower than theta1 and theta3, on top of each other, and welding the three layers together along predetermined weld lines, thereby bringing the foam layer to a temperature theta4, which lies between theta2 and theta1, and theta3 along the weld lines.At least one sheet of heat-melting adhesive, pre-cut along predetermined welding lines and having a melting temperature theta5 on the order of theta2, is inserted between one of the material layers and the foam material layer.

[0009] While the above documents claimed to represent an improvement over the previously known state of the art, the proposed solutions still exhibit some shortcomings in meeting the aforementioned requirements for a shoe upper. A common disadvantage of the known shoe upper is that some foam materials are considered relatively stiff and not as flexible as desired for high-quality football boots.

[0010] Against this background, it is an object of the present invention to provide an improved shoe upper. 3. Summary of the invention

[0011] The aforementioned problems are at least partially solved by the subject matter of the independent claims. Preferred embodiments are the subject matter of the dependent claims, and other suitable aspects of the present invention are described by the overall disclosure of this application. It should be noted that any headings in this disclosure are provided solely to aid in maintaining an overview while reading. The headings do not imply that features of the respective embodiments cannot be combined.

[0012] In one aspect, the problems of the present disclosure are at least partially solved by a shoe upper, in particular for a sports shoe, comprising a layered structure with (a.) a first layer, (b.) a second layer and (c.) an intermediate foam layer between the first layer and the second layer, wherein the intermediate foam layer comprises a polyamide, PA, foam material.

[0013] This improves several properties, such as flexibility and cushioning. For example, PA foam is known for its high tensile strength and abrasion resistance, which significantly improves the overall durability of the footwear. The foam layer helps protect the layers from wear, thus extending the shoe's lifespan.

[0014] Furthermore, the PA foam layer provides additional structural support for the shoe upper, helping it maintain its shape and form over time. This is particularly important to prevent deformation or sagging of the upper during extended use.

[0015] Furthermore, PA foam offers excellent cushioning properties that contribute to the wearer's comfort by absorbing shocks and impacts during movement. This makes the shoe more comfortable for extended wear, reducing foot fatigue.

[0016] Furthermore, despite its density, PA foam is lightweight, which helps to reduce the overall weight of the shoe. This contributes to improved performance, especially in sports shoes, by minimizing the energy required for movement.

[0017] Furthermore, the PA foam layer can be tailored in terms of density and thickness to achieve specific performance characteristics, such as flexibility or stiffness in certain areas of the shoe. This allows for a customized fit and feel. Unlike other foam materials that can compress or lose their elasticity over time, PA foam retains its properties longer, ensuring consistent performance throughout the shoe's lifespan.

[0018] Furthermore, the PA foam layer can also provide thermal insulation, helping to maintain a comfortable temperature inside the shoe. This is beneficial in various weather conditions, keeping the foot warm in cold environments and cool in hot environments.

[0019] Furthermore, PA foam can be engineered to have moisture-wicking properties, which helps manage perspiration and keep the foot dry. This contributes to improved hygiene and comfort.

[0020] In some embodiments, the PA foam layer may include perforations, preferably microperforations, to further improve the moisture-absorbing properties and thereby aid in the handling of sweat and keeping the foot dry.

[0021] In summary, integrating an intermediate foam layer with a PA foam material between the first and second layers in a shoe upper provides a balanced combination of durability, comfort, lightweight construction and thermal regulation, making it a superior choice for high-performance footwear.

[0022] In a preferred embodiment of the shoe upper as described herein, at least one of the following applies: the first layer is designed to be turned inwards from the shoe upper, the second layer is designed to be turned outwards from the shoe upper, or the intermediate layer is designed to provide elasticity and cushioning for ball contact.

[0023] This multi-layered upper design offers a blend of comfort, durability, flexibility, and performance, making it ideal for athletic shoes where both protection and functionality are paramount. For example, the first layer, when turned inward, makes direct contact with the foot, providing a soft and comfortable inner surface. This design reduces friction against the skin, minimizing the risk of blisters and irritation, thus enhancing overall comfort. Furthermore, the second layer, when turned outward, faces the external environment, providing a robust and durable exterior. This layer protects the upper from abrasion, wear, and environmental factors such as dirt and moisture, ensuring the shoe maintains its appearance and longevity.Furthermore, the midsole, designed to provide stretch and cushioning, enhances the shoe's performance during ball contact. The foam's elasticity allows for greater adaptability and flexibility during dynamic movements, while the cushioning absorbs impact, improving control and comfort when the foot strikes the ball. This is particularly beneficial for sports like soccer, where precise ball control is crucial. Additionally, the midsole's elasticity allows the shoe to adapt to the foot's natural movements, providing a snug yet flexible fit. This feature is essential for athletic footwear where freedom of movement and foot flexibility are critical for optimal performance.Furthermore, the cushioning provided by the intermediate layer offers superior shock absorption, protecting the foot from impacts during activities like running or jumping. This reduces the risk of injury and improves the wearer's comfort and safety. The layered structure with a cushioned intermediate layer can also contribute to thermal insulation, keeping the foot warm in cool conditions. Additionally, if the layers are made of breathable materials, the shoe can effectively manage moisture, keeping the foot dry and comfortable. Moreover, the different layers allow for customization in terms of materials and properties. For example, the outer textile layer could be made of a durable, water-resistant material, while the inner layer could be a soft, moisture-wicking fabric.This flexibility in design makes the shoe adaptable to different conditions and user preferences.

[0024] In a preferred embodiment of the shoe upper as described herein, the first layer forms the innermost surface of the shoe upper. Placing the first layer as the innermost surface of the shoe upper provides a soft and smooth interface directly against the foot. This reduces the likelihood of irritation, chafing, or discomfort, especially during prolonged wear. Furthermore, the first layer can be designed with moisture-wicking properties, which helps draw perspiration away from the skin and into the outer layers of the shoe. This keeps the foot dry, improving comfort and reducing the risk of blisters. Breathable material as the innermost layer promotes air circulation around the foot, helping to regulate temperature and prevent overheating. This contributes to the overall health and comfort of the foot, particularly in warm conditions.Furthermore, this layer, as the innermost layer, can provide a protective barrier between the foot and other structural components of the shoe, such as stiffeners or reinforcing materials, ensuring that the foot is cushioned and shielded from potentially hard or rigid elements.

[0025] In a preferred embodiment of the shoe upper as described herein, the second layer forms the outermost surface of the shoe upper. This second layer, being the outermost surface, serves as the first line of defense against environmental elements such as abrasion, dirt, and moisture, thereby protecting the inner layers and extending the shoe's lifespan. Furthermore, the outermost layer can be designed with various textures, colors, and patterns, allowing for greater design flexibility and customization. This enhances the shoe's visual appeal and makes it more attractive to consumers. Additionally, treating the second layer with water-repellent or stain-resistant coatings helps keep the shoe clean and dry in wet or dirty conditions, thus improving the overall usability of the footwear.Furthermore, depending on the material chosen for the second layer, it can contribute to the breathability of the shoe, allowing air to circulate and keeping the foot cool and comfortable.

[0026] In a preferred embodiment of the shoe upper as described herein, the layered structure is arranged in a vamp area of ​​the shoe upper. The vamp area, which covers the top of the foot and includes the area over the toes, experiences significant pressure and movement. A layered structure with padding, such as foam, provides added comfort by distributing pressure more evenly across the foot. Furthermore, the vamp area must accommodate different foot shapes and sizes. A layered structure allows the material to better conform to the contours of the foot, providing a snug and secure fit that adapts to individual foot shapes. The vamp area is subject to frequent bending and flexing. A reinforced layered structure improves the durability of the upper and prevents premature wear in this critical area.By incorporating materials that effectively manage moisture, the layered structure can improve breathability in the upper. This is crucial for maintaining foot comfort and reducing the risk of blisters or odors caused by trapped moisture. Furthermore, the upper plays a key role in controlling foot movement during walking or running. A well-designed layered structure can provide the necessary support to maintain stability and prevent excessive movement that could lead to discomfort or injury.

[0027] In a preferred embodiment of the shoe upper as described herein, the layered structure is arranged in a forefoot area of ​​the shoe upper. The forefoot is subjected to considerable pressure and impact during walking, running, and other activities. The layered structure provides additional cushioning and shock absorption in this critical area, thereby protecting the foot from injury and discomfort. By incorporating a layered structure with cushioning properties in the forefoot, the shoe can provide better energy return with each step. This can improve the efficiency of movement, making the shoe more responsive and enhancing performance, particularly in athletic footwear.

[0028] In a preferred embodiment of the shoe upper as described herein, the layered structure is arranged in the toe area of ​​the shoe upper. The layered structure in the toe area provides additional cushioning and protection against impacts, thereby reducing the risk of injury from bumps or external forces. Furthermore, the toe area is subject to considerable wear, particularly during activities such as running or hiking. The layered structure reinforces this area, thereby increasing the durability of the shoe and preventing premature wear.

[0029] In a preferred embodiment of the shoe upper as described herein, the first layer is a textile layer. By incorporating a textile layer, manufacturers can produce a shoe upper that balances breathability, comfort, and durability while maintaining flexibility in both function and design. For example, a textile layer can enhance breathability, allowing air to circulate through the shoe and keeping the foot cool and dry. Furthermore, a textile layer allows for greater flexibility and adaptability to the foot's movements. This flexibility can result in a more natural fit and improved comfort, particularly in areas that experience significant flexion, such as the forefoot and midfoot.

[0030] In a preferred embodiment of the shoe upper as described herein, the first layer comprises a coating, a film, synthetic leather, or leather. This combination of materials allows shoe designers to optimize the shoe for specific performance requirements, such as making it better suited for athletic, recreational, or outdoor use. For example, coatings, films, and synthetic or natural leather offer improved wear resistance, protecting the shoe from environmental factors such as water, dirt, or abrasion. These materials can extend the shoe's lifespan, particularly in high-wear areas such as the toe or sides of the upper. Furthermore, coatings and films can be engineered to provide water resistance, preventing moisture from penetrating the shoe.This is crucial for outdoor or athletic footwear where water exposure is common. Leather and synthetic leather naturally offer a degree of water resistance. Furthermore, the use of films and coatings can add lightweight structural support without the need for heavier materials. This helps maintain the shoe's shape and fit while still allowing flexibility and movement in certain areas.

[0031] In a preferred embodiment of the shoe upper as described herein, the second layer is a second textile layer. The advantages mentioned above for the first textile layer also apply to the second textile layer.

[0032] In a preferred embodiment of the shoe upper as described herein, the second layer comprises a coating, a film, synthetic leather, or leather. The advantages mentioned above for the first layer also apply to the second layer.

[0033] In a preferred embodiment of the shoe upper as described herein, one or more of the first and second layers comprise a fabric, preferably a knitted fabric. Knitted fabrics offer a high degree of flexibility and elasticity compared to woven fabrics. This flexibility allows the shoe upper to conform more comfortably to the shape of the foot, providing a better fit and improved comfort. The open structure of knitted fabrics enhances airflow and ventilation within the shoe. This breathability helps maintain a cooler and more comfortable environment for the foot, reducing moisture buildup and increasing overall foot comfort. The softness and elasticity of knitted fabrics contribute to a more comfortable wearing experience.The tissue's ability to stretch and adapt to the foot's movements can reduce pressure points and friction, resulting in less foot fatigue and discomfort.

[0034] In some embodiments, the knitted fabric can be weft-knitted or warp-knitted.

[0035] In some embodiments, one or more of the first and second textile layers may also comprise a woven and / or a non-woven textile. Woven fabrics are known for their durability and resistance to wear. The interlacing of fibers in a woven fabric provides greater strength compared to non-woven fabrics, which helps the layers resist abrasion and extends the life of the shoe. The use of woven fabrics in critical areas can provide additional reinforcement and support, improving the overall performance and longevity of the shoe. Non-woven fabrics are often designed to be more breathable compared to conventional woven fabrics. This improves air circulation within the shoe, which helps regulate temperature and reduce moisture buildup, thus enhancing overall foot comfort.Furthermore, non-woven fabrics can be lighter than woven alternatives due to their unique manufacturing process. This helps to reduce the overall weight of the shoe, contributing to improved performance and comfort for the wearer.

[0036] In a preferred embodiment of the shoe upper as described herein, one or more of the first and second layers comprise a PA material. This provides advantages such as improved durability, strength, moisture management, thermal regulation, and comfort, making it a favorable choice for creating high-quality, high-performance footwear. For example, the use of PA in the textile layers improves the overall durability of the shoe upper, making it more resistant to wear and tear, thus extending the lifespan of the footwear. Furthermore, PA fabrics exhibit good moisture-wicking properties, which help manage perspiration and keep the foot dry. This moisture management contributes to better comfort and hygiene, thereby reducing the likelihood of foot odor and fungal infections.In this way, PA textiles are flexible and can be designed to provide a comfortable fit. The material's ability to stretch and adapt to the shape of the foot improves the overall comfort of the shoe, reducing pressure points and enhancing wearability. Furthermore, using the same material class as the intermediate PA foam layer improves the manufacturing of the layered structure.

[0037] Furthermore, one or more of the first layer and the second layer may also comprise a polyurethane (PU) material and / or a thermoplastic polyurethane (TPU) material.

[0038] In a preferred embodiment of the shoe upper as described herein, one or more of the first textile layer and the second textile layer comprise a thickness between 0.05 mm and 1.0 mm, preferably a thickness between 0.1 mm and 0.8 mm, more preferably a thickness between 0.2 mm and 0.6 mm, and most preferably a thickness of approximately 0.3 mm. Textile layers in this thickness range contribute to effective breathability, which aids in moisture management and temperature regulation. This thickness is sufficient to allow air circulation while still providing adequate coverage and protection. A textile layer thickness within this range allows for an optimal balance between flexibility and support. Thicker layers provide more cushioning and support, while thinner layers ensure better flexibility and breathability.A specific thickness of approximately 0.3 mm offers a good compromise between these two factors, improving comfort without restricting movement. Furthermore, this thickness provides sufficient durability to resist wear and tear while maintaining the overall integrity of the shoe upper. This thickness helps prevent premature damage or fraying, thus extending the footwear's lifespan.

[0039] In a preferred embodiment of the shoe upper as described herein, the intermediate foam layer comprises a thickness between 0.5 mm and 1.5 mm, preferably a thickness between 0.7 mm and 1.2 mm, and more preferably a thickness of approximately 1.0 mm. The specified thickness ranges, with a preference for approximately 1.0 mm, ensure that the intermediate foam layer provides optimal cushioning, support, flexibility, and durability while maintaining a lightweight design. For example, the thickness ranges offer an optimal balance between cushioning and support. They provide sufficient cushioning to absorb impacts and enhance comfort without compromising the structural integrity of the shoe. This specific thickness contributes to achieving effective shock absorption while maintaining responsiveness.At this thickness, the intermediate foam layer retains sufficient flexibility to adapt to the foot's movement. This flexibility is crucial for athletic and casual shoes, allowing for natural foot movement while providing support. Furthermore, the thickness variations ensure that the foam layer adds minimal weight to the shoe. This is important for performance shoes, where weight reduction can improve speed and agility without compromising comfort or support.

[0040] In a preferred embodiment of the shoe upper as described herein, the intermediate foam layer comprises a thickness between 1.0 mm and 7.0 mm, preferably a thickness between 2.5 mm and 6.0 mm, more preferably a thickness of approximately 4.5 mm or a thickness of approximately 6.0 mm.

[0041] In a preferred embodiment of the shoe upper as described herein, the material of the intermediate foam layer is produced by a supercritical foaming process. A supercritical foaming process is a technique used to create foams with specific properties by employing supercritical fluids, where a supercritical fluid is a substance at a temperature and pressure above its critical point. Thus, the supercritical foaming process allows precise control over the structure and properties of the foam, resulting in a material with improved mechanical properties, such as higher strength-to-weight ratios and better impact resistance. This contributes to the overall durability and performance of the intermediate layer. Furthermore, supercritical foaming typically produces a more uniform cell structure compared to conventional foaming methods.This uniformity can improve the consistency of the foam's cushioning and support properties, resulting in more predictable and reliable performance in footwear. The fine and uniform cell structure of the foam produced by supercritical foaming often provides superior thermal insulation. This can help maintain a comfortable temperature inside the shoe, contributing to improved wearer comfort across various environments. The supercritical foaming process can also produce foam with enhanced breathability, as the uniform pore structure facilitates better air circulation. This can help manage moisture and temperature within the shoe, keeping the foot dry and comfortable.In summary, the use of a material for the intermediate layer produced through a supercritical foaming process offers several advantages, including improved mechanical properties, uniform cell structure, lightweight properties and improved breathability, all of which contribute to better performance, comfort and durability in footwear.

[0042] In a preferred embodiment of the shoe upper as described herein, the shoe upper further comprises a film layer on the second layer, which is designed to provide a coating for the shoe upper.

[0043] Adding a film layer to the second layer of a shoe upper offers a number of benefits, including improved durability, water resistance, aesthetic appeal, and ease of maintenance, while also enhancing the overall functionality and performance of the shoe. The film layer acts as a protective coating, increasing the overall durability of the shoe upper. It shields the underlying textile from wear, abrasion, and environmental factors such as moisture, UV rays, and dirt. Furthermore, a film layer can provide effective water resistance, preventing water from penetrating the shoe upper. This keeps the wearer's feet dry and comfortable, especially in wet conditions. Additionally, film coatings can enhance the visual appeal of the shoe upper by adding a smooth, polished surface or a unique texture.This can enhance the design and give the shoe a more premium or fashionable look. Furthermore, the foil layer can make the shoe upper easier to clean and maintain. Its smooth surface repels dirt and stains, allowing for easier wiping or washing compared to untreated textile surfaces. Depending on the type of foil used, it can also be designed to maintain or improve the breathability of the shoe upper. Advanced foil materials can offer a balance between protection and ventilation, ensuring comfort. In addition, modern foil materials are designed to be flexible, ensuring that the shoe upper retains its suppleness and does not compromise the shoe's comfort or fit.

[0044] In a preferred embodiment of the shoe upper as described herein, the film layer comprises a thermoplastic polyurethane (TPU) material. TPU is known for its high durability and resistance to abrasion. The film layer provides enhanced protection against wear, thereby extending the product's lifespan. TPU also retains flexibility even at low temperatures, contributing to overall comfort. The film layer can flex and stretch with the movement of the shoe, providing a comfortable fit without compromising durability. TPU exhibits excellent resistance to chemicals, oils, and greases. This makes the film layer more resistant in environments where the shoe might be exposed to such substances, ensuring longevity and maintaining the shoe's appearance.TPU is inherently water-resistant, which helps prevent water penetration and keeps the shoe's internal materials dry. This is particularly beneficial for footwear used in wet conditions. TPU exhibits a high degree of elasticity and resilience, contributing to improved shock absorption and impact resistance. This enhances the shoe's performance characteristics, especially in high-impact or sporting applications. Furthermore, TPU remains stable over a wide temperature range, maintaining its properties and performance across diverse environmental conditions. This ensures the shoe performs consistently in both hot and cold environments.

[0045] In a preferred embodiment of the shoe upper as described herein, the film layer comprises a thickness between 0.01 mm and 0.1 mm, preferably a thickness between 0.02 mm and 0.07 mm, and more preferably a thickness of approximately 0.05 mm. A film thickness in this range ensures that the material is flexible enough to conform to various shapes and surfaces without being too rigid or cumbersome. This is particularly advantageous in applications where the film must conform to complex geometries or movements. The specified thickness range provides a balance between durability and weight. Films that are too thin may be prone to tearing or punctures, while those that are too thick may be unnecessarily heavy or stiff. The selected thickness range ensures that the film possesses adequate strength while remaining practical for its intended use.Furthermore, at the specified thickness, the film can effectively serve as a barrier against various environmental factors, such as moisture, gases, or chemicals, depending on the material. This thickness is typically sufficient to provide effective protection while maintaining lightness. The chosen thickness also ensures effective thermal or electrical insulation, if required, without compromising the overall design and functionality of the product.

[0046] In a preferred embodiment of the shoe upper as described herein, the film layer is extruded. Extrusion enables the production of a film layer with a uniform thickness and consistent material properties throughout. This ensures consistent performance of the film layer, avoiding weak points or variations in thickness that could affect the overall quality and functionality of the product. The extrusion process can produce a smooth and high-quality surface finish on the film layer. This can be advantageous for applications where appearance and surface texture are important, such as in consumer products or high-visibility components. Extruded film layers can be produced in various shapes and sizes, including complex geometries.This flexibility allows for the design of components that fit precisely into the desired application or product, thus providing more design options.

[0047] In a preferred embodiment of the shoe upper as described herein, the film layer has a hardness between 40 and 90 Shore A, preferably between 50 and 70 Shore A, and more preferably approximately 65 Shore A. A film layer with this hardness range provides a desirable combination of flexibility, durability, impact resistance, and aesthetic quality, making it suitable for a wide range of applications while ensuring consistent and reliable performance. For example, film materials within this hardness range offer good wear resistance without being too rigid. This level of hardness ensures that the film can withstand abrasion and physical stress over time, contributing to the product's longevity.

[0048] In a preferred embodiment of the shoe upper as described herein, the shoe upper further comprises a resin layer as the outermost layer made of polyurethane material. A polyurethane resin layer as the outermost layer provides a combination of durability, flexibility, water resistance, and ease of maintenance, making it an excellent choice for improving the performance and longevity of a product. For example, PU is known for its high durability and resistance to wear. As an outermost layer, PU resin provides a robust protective barrier that can withstand daily use and harsh environmental conditions, thereby extending the product's lifespan. Furthermore, PU resin offers excellent abrasion resistance, which is critical for applications where the surface is subject to friction and rough surfaces.This helps prevent the outer layer from deteriorating or showing signs of wear, thus maintaining the aesthetic and functional integrity of the product. Furthermore, PU resins can be formulated to provide a flexible yet supportive layer. This flexibility allows the product to conform to the shape of the foot or other parts, improving comfort and reducing the likelihood of discomfort or pressure points. Additionally, using PU resin as the outermost layer allows for a wide variety of colors and other visual effects. For example, a surface texture can be achieved, such as by debossing the PU resin layer. Preferably, the resin layer can be applied in a liquid state by rolling the polyurethane material onto the adjacent layer of the layered structure.

[0049] In a preferred embodiment of the shoe upper as described herein, the first and / or second layer is a polyurethane resin layer. Due to its durability, flexibility, and abrasion resistance, a PU resin layer as a first and / or second layer provides sufficient protection and comfort.

[0050] In a preferred embodiment of the shoe upper as described herein, the resin layer comprises a thickness between 0.01 mm and 0.1 mm, preferably a thickness between 0.02 mm and 0.07 mm, and more preferably a thickness of approximately 0.05 mm. A resin layer with a carefully controlled thickness offers numerous technical advantages, including precise control, improved bonding, minimal weight gain, enhanced flexibility, cost-effectiveness, optimized curing time, and consistent performance. For example, a resin layer with a controlled thickness, such as the aforementioned thickness ranges, allows for precise application and ensures uniform coverage. This level of control helps achieve consistent performance across the entire surface, which is critical for applications where a uniform distribution of material properties is essential.Furthermore, a resin layer of this thickness can provide optimal bonding between different layers or components. It ensures strong adhesion without adding excessive bulk, thus improving the overall structural integrity and durability of the final product. Optimizing the resin layer thickness minimizes material usage, leading to cost savings in resin procurement and processing. This also contributes to more efficient manufacturing processes. Additionally, thinner resin layers often cure faster than thicker ones, reducing overall processing time and improving manufacturing efficiency. This can be advantageous in manufacturing environments where time is a critical factor.

[0051] In a preferred embodiment of the shoe upper as described herein, one or more of the layers are bonded by adhesive films, preferably polyamide, PA, or hot melt adhesive films. The use of polyamide hot melt adhesive films for bonding layers offers a combination of strong, durable bonds, lightweight construction, and efficient manufacturing, while maintaining aesthetic quality and providing resistance to environmental factors. For example, PA hot melt adhesive films provide a strong and durable bond between layers. This ensures that the layers remain securely bonded throughout the product's life cycle, even under stress or strain. Furthermore, the use of polyamide adhesives contributes to the overall durability of the product.Polyamide is known for its high mechanical strength and resistance to wear, which helps maintain the integrity of the layered structure. Furthermore, hot melt adhesives, including those based on polyamide, are flexible and can conform to the shapes of the layers they bond. This flexibility is advantageous in applications where the bonded layers need to move or flex without compromising the bond.

[0052] In a preferred embodiment of the shoe upper as described herein, the layered structure is arranged in a midfoot area and / or a tongue area of ​​the shoe upper. Placing the layered structure with polyamide foam in the midfoot and / or tongue areas of the shoe upper provides a number of advantages, including improved support, enhanced comfort, pressure point relief, and increased durability. This strategic placement addresses key areas of the foot that experience significant stress and wear, contributing to a better overall shoe experience. For example, the layered structure in the midfoot area provides additional support and stability for the arch and midfoot. This helps distribute pressure evenly during movement and reduces the risk of foot fatigue and injury.Furthermore, the shoe offers improved cushioning in these areas by incorporating a foam layer, providing enhanced support where it's most needed. The midfoot area experiences significant stress during activities, and the cushioning helps absorb impact, resulting in a more comfortable experience. In the tongue area, the layered structure improves the shoe's fit by providing additional padding. This helps reduce pressure points and discomfort caused by the laces or the shoe's internal structure, thus enhancing overall comfort. The foam layer acts as a buffer, minimizing pressure points commonly found in the midfoot and tongue areas. This is particularly beneficial in preventing blisters and other foot problems caused by friction or pressure.For sports and athletic footwear, improved support and cushioning in the midfoot area contribute to better performance by improving foot control and reducing the impact of high-intensity activities.

[0053] In a preferred embodiment of the shoe upper as described herein, the layered structure further comprises a tread element, preferably created by debossing. Incorporating a tread element, such as a debossed tread element, into a layered structure provides several advantages, including improved grip, increased structural integrity, functional design benefits, and durability. These advantages contribute to both the performance and the appeal of the product. For example, debossing allows intricate and precise patterns or logos to be permanently embedded in the material. This not only adds a unique and visually appealing design element to the product but also enhances its overall appearance and branding opportunities. Furthermore, a debossed tread element can provide additional grip and traction.The raised or recessed patterns created by debossing can increase surface contact and friction with the ground, improving stability and reducing the risk of slippage. Furthermore, the debossed profile can contribute to the structural strength and stability of the layered material. By creating raised or recessed areas, the profile element can help distribute loads and forces more evenly, reducing the likelihood of material deformation or failure under pressure. The debossing process often involves compressing the material, which can increase its density and resistance to wear. This added durability helps maintain the integrity of the design elements over time, even with regular use.Debossed elements can also serve as functional decorations, such as indicators or guides for the user. For example, debossed patterns in a shoe could guide foot placement or indicate pressure points for optimal comfort.

[0054] In some embodiments, there may be several types of profile elements, preferably arranged on the outermost layer. For example, there may be rubber ridges and / or printed ridges. There may also be several profile elements of other types to achieve the advantages mentioned above.

[0055] Furthermore, the profile elements can be arranged on the outermost layer, preferably glued to the outermost layer, like rubber ridges. Another example would be printed ridges.

[0056] In a preferred embodiment of the shoe upper as described herein, the upper further comprises multiple openings in the intermediate foam layer. Multiple openings in an intermediate foam layer offer several advantages, including improved breathability, reduced weight, enhanced flexibility, optimized cushioning, better thermal regulation, and effective moisture management, all contributing to a more comfortable, efficient, and sustainable product. For example, openings in the foam layer facilitate airflow, thereby improving ventilation within the shoe. This helps reduce the build-up of moisture and heat, keeping the foot cooler and drier, which is particularly beneficial for athletic and everyday footwear.Furthermore, incorporating openings can reduce the overall weight of the foam layer by removing excess material. This lightweight design can improve comfort and performance, especially in high-performance athletic footwear where weight minimization is crucial. Additionally, the openings can enhance the flexibility of the foam layer, allowing it to flex more easily and conform more readily to the shape of the foot. This results in a more comfortable and adaptive fit, reducing pressure points and improving overall wearability. Furthermore, the foam layer can be strategically placed to provide targeted cushioning and support. The design can be optimized to offer better shock absorption and impact protection in specific areas of the foot, thereby improving overall comfort and performance.By using openings to reduce the required foam volume, manufacturers can achieve cost savings and reduce material consumption. This can contribute to more sustainable manufacturing practices and lower production costs. "Multiple" can refer to a number that may be more than one and often implies a larger or unspecified number to achieve the aforementioned technical effects.

[0057] In a preferred embodiment of the shoe upper as described herein, the multiple openings are also included in the first layer and / or the second layer. The inclusion of multiple openings in the layers of a shoe upper offers several advantages, including improved breathability, enhanced moisture management, weight reduction, flexibility, and overall comfort, while also enabling innovative design possibilities. For example, the inclusion of openings in the layers improves airflow and ventilation within the shoe. This helps maintain a comfortable internal temperature by allowing heat and moisture to escape, thereby reducing the likelihood of overheating and excessive sweating. Furthermore, the openings facilitate better moisture evaporation from the foot.This contributes to improved hygiene and comfort by helping to keep the foot dry and reducing the risk of bacterial growth and odor. Integrating openings directly into the layers can reduce the overall weight of the shoe. Fewer or smaller sections of material are needed to achieve the same structural support, which can improve the shoe's performance, particularly in athletic applications. Strategically placed openings can reduce the amount of textile material required, leading to potential cost savings in material usage without compromising the structural integrity of the shoe upper.

[0058] In a preferred embodiment of the shoe upper as described herein, the first layer, the second layer, and the intermediate layer form a one-piece structure extending from an upper surface of the shoe upper to a lower surface of the shoe upper. In use, the one-piece structure can completely surround the wearer's foot. The one-piece structure can be located in the forefoot area of ​​the shoe upper. All these embodiments allow the PA foam material to provide cushioning under the foot, and in particular between the foot and the more rigid sole and / or outsole, without adding excessive compressibility and material, which could be detrimental to stability during soccer-like ball control. Furthermore, the one-piece structure can completely surround the foot, thus providing a sock-like fit.This design minimizes pressure points and creates a snug, secure fit, thereby improving overall comfort for the wearer. By completely surrounding the foot, the structure provides even pressure distribution, reducing hot spots and irritation. Positioning the one-piece structure in the forefoot area ensures flexibility and responsiveness where it's needed most. This can enhance athletic performance by providing better energy transfer and natural movement.

[0059] In another aspect of the present disclosure, the problems are solved at least partially by a shoe upper, particularly for a sports shoe, comprising a polyamide (PA) foam layer extending from the top of the shoe upper to the underside of the shoe upper to surround the wearer's foot. In other words, the PA foam layer extends along the sides and top of the wearer's foot.

[0060] In a preferred embodiment of the shoe upper as described herein, the PA foam layer comprises a thickness between 1.0 mm and 7 mm, preferably a thickness between 2.5 mm and 6.0 mm, more preferably a thickness of approximately 4.5 mm or a thickness of approximately 6.0 mm.

[0061] In a preferred embodiment of the shoe upper as described herein, the PA foam layer comprises a first part in the forefoot area and a second part in the heel area of ​​the shoe upper. The second part may be thicker than the first part.

[0062] In a preferred embodiment of the shoe upper as described herein, the first part may have a thickness between 1.0 mm and 5.0 mm, preferably a thickness of approximately 4.5 mm. The second part may be thicker than the first part. The second part may have a thickness between 1.0 mm and 7 mm, preferably a thickness of approximately 6.0 mm.

[0063] The thinner upper in the forefoot offers improved flexibility, breathability, weight reduction, and ground feel, making it ideal for both performance and comfort. For example, the forefoot is the most active part of the foot during walking, running, and other movements, so a thinner upper layer allows for greater flexibility, enabling the shoe to move and flex naturally with the foot, thus improving overall performance. Furthermore, thinner materials contribute to a lighter shoe, which is particularly important in sports and athletic footwear, as the weight reduction improves speed and endurance.

[0064] The advantage of the thicker second part is a greater cushioning effect for the side walls of the heel area and the underside of the heel, resulting in greater shock absorption in the heel area when running and the corresponding rearfoot and ankle section of the foot being comfortably enclosed by the upper part of the shoe.

[0065] In a preferred embodiment of the shoe upper as described herein, the first part and the second part are joined by thermal or adhesive bonding. This avoids an uncomfortable seam on the inside of the shoe upper in the heel area. Alternatively, the first part and the second part can be joined by sewing, preferably zigzag stitching.

[0066] In a preferred embodiment of the shoe upper as described herein, the first part comprises at least two sections which are linked or connected as previously mentioned.

[0067] In a preferred embodiment of the shoe upper as described herein, the PA foam layer is a part that is debossed, e.g., hot-pressed, to provide a reduced thickness, as previously mentioned, for the first part. This reduces the manufacturing effort required to join / bond two (or more) parts of the shoe upper to the PA foam layer.

[0068] In this way, a single (or continuous) one-piece structure can be provided for this aspect, as previously explained for the previous aspect.

[0069] The upper of this shoe can also be combined with one or more of the previous upper features, comprising a layered structure with a first layer, a second layer, and an intermediate foam layer between the first and second layers, the intermediate foam layer comprising a polyamide (PA) foam material. Here, the intermediate foam layer is similar to the PA foam layer described above.

[0070] In another aspect of the present disclosure, the problems are at least partially solved by a shoe upper, particularly for a sports shoe, comprising a polyamide (PA) foam layer. The shoe upper can be combined with a first layer and / or a second layer as defined in one or more of the preceding embodiments. It is also conceivable that the shoe upper comprises only the PA foam layer and no further layers. The shoe upper of this aspect can also be combined with one or more of the preceding features of the shoe upper, comprising a layered structure with a first layer, a second layer, and an intermediate foam layer between the first layer and the second layer, wherein the intermediate foam layer comprises a polyamide (PA) foam material.

[0071] The PA foam layer offers the same advantages as described for the previous embodiments. In particular, the PA foam layer provides sufficient structural support for the shoe upper while offering excellent cushioning properties that contribute to the wearer's comfort by absorbing shocks and impacts during movement. Furthermore, the foam's elastic nature allows for better adaptability and flexibility during dynamic movements, as well as improved conformability of the upper to the wearer's foot shape, resulting in a snug fit and a comfortable wearing experience.

[0072] In a preferred embodiment of the shoe upper as described herein, the PA foam layer is arranged in a forefoot and / or midfoot area of ​​the shoe upper. The forefoot and midfoot areas are subject to considerable pressure and movement. The cushioning of a PA foam layer provides additional comfort by distributing pressure more evenly across the foot. Furthermore, the forefoot and midfoot areas must accommodate different foot shapes and sizes. A PA foam layer allows the material to better conform to the contours of the foot, thus providing a snug and secure fit that adapts to individual foot shapes.

[0073] In a preferred embodiment of the shoe upper as described herein, the PA foam layer material is produced by a supercritical foaming process, as previously mentioned. The supercritical foaming process allows for precise control over the structure and properties of the foam, resulting in a material with improved mechanical properties, such as higher strength-to-weight ratios and better impact resistance. This contributes to the overall durability and performance of the PA foam layer. Furthermore, supercritical foaming typically produces a more uniform cell structure compared to conventional foaming methods. This uniformity can improve the consistency of the foam's cushioning and support properties, leading to more predictable and reliable performance in footwear.The fine and uniform cell structure of the foam produced by supercritical foaming often provides superior thermal insulation properties. This can help maintain a comfortable temperature inside the shoe, contributing to improved wearer comfort across various environments. The supercritical foaming process can also produce foam with enhanced breathability, as the uniform pore structure facilitates better air circulation. This can help manage moisture and temperature within the shoe, keeping the foot dry and comfortable.In summary, the use of a material for the PA foam layer produced through a supercritical foaming process provides several advantages, including improved mechanical properties, uniform cell structure, lightweight properties and improved breathability, all of which contribute to better performance, comfort and durability in footwear.

[0074] In a preferred embodiment, the PA foam layer comprises polyamide 11, PA 11, polyamide 12, PA 12 and / or polyether block amide, PEBA.

[0075] In another aspect of the present disclosure, the problems are solved at least partially by a sports shoe comprising a shoe upper, as described in one of the embodiments described herein.

[0076] Since the sports shoe in this aspect includes the upper part of the shoe, as described elsewhere, it is understood that the technical characteristics shown or described for the upper part, the advantages and improvements over the state of the art are equally applicable to the sports shoe and vice versa.

[0077] In a preferred embodiment of the shoe as described herein, the sports shoe is a soccer shoe. The upper part of a soccer shoe is designed to provide enhanced ball control. Features such as textured surfaces or grip-enhancing materials help the player to better control and manipulate the ball, thereby facilitating more precise passing, dribbling, and shooting.

[0078] In a preferred embodiment of the shoe, as described herein, the soccer cleat is laceless. By eliminating laces, the shoe can provide a cleaner and more consistent striking surface for the ball. This can improve accuracy and control when kicking, passing, or shooting, as there are no laces to interfere with ball contact. Without laces, there is a reduced risk of injury from lace-related problems, such as laces coming loose and causing a trigger pull, or laces exerting pressure on the foot. Additionally, the laceless design minimizes the risk of lace-related chafing or discomfort. Overall, laceless soccer cleats offer a combination of functional and performance benefits, making them an attractive option for players seeking a blend of comfort, style, and enhanced on-field performance.

[0079] In a preferred embodiment of the athletic shoe as described herein, the intermediate foam layer is located only in one neck region of the shoe upper. By placing the foam layer only in the neck region, which is the area around the opening of the shoe through which the foot enters, the cushioning is concentrated where it is most needed. This can improve comfort during initial foot entry and while securing the shoe, providing a plush and supportive feel. The neck region often experiences the most stress from foot movement and adjustments. The foam layer can help accommodate different foot shapes and provide a snug fit, thereby reducing pressure points and improving overall comfort.Furthermore, limiting the foam layer to the collar area helps keep the overall weight of the shoe lower compared to using foam throughout the entire upper. This can improve performance, especially in athletic or running shoes where weight reduction is crucial. 4. Brief description of the characters

[0080] The invention is described in more detail below with reference to the following figures: Fig. Figure 1 shows a layered structure for a shoe upper, in particular for a sports shoe, according to an embodiment of the present disclosure. Fig. Figure 2 shows a lateral side view of a football boot with a laceless upper according to an embodiment of the present disclosure. Fig. Figure 3 shows a lateral side view of a football boot with a laceless upper according to another embodiment of the present disclosure. Fig. Figure 4 shows a top view of a shoe upper according to another embodiment of the present disclosure. 5. Detailed description of preferred embodiments

[0081] Only a few possible embodiments of the invention are described in detail below. However, the present invention is not limited to these, and a multitude of other embodiments are applicable without deviating from the scope of the invention. The embodiments shown can be modified and combined with one another in various ways, whenever they are compatible, and certain features can be omitted if they appear dispensable. In particular, the disclosed embodiments can be modified by combining certain features of one embodiment with one or more features of another embodiment.

[0082] It is understood that not all features of the described aspects / embodiments need to be present to realize the technical advantages provided by the present disclosure, which is defined by the subject matter of the claims. The disclosed aspects / embodiments can be modified by combining certain features of one aspect / embodiment with one or more features of another aspect / embodiment. In particular, a person skilled in the art will understand that features and / or functional elements of one aspect / embodiment can be combined with technically compatible features and / or functional elements of any other aspect / embodiment of the present disclosure, provided that the resulting combination falls within the definition of the present disclosure.

[0083] While the following embodiments are mainly described with reference to a shoe upper for a sports shoe, such as a soccer cleat, those skilled in the art will recognize that the disclosure of the invention can be applied equally to a multitude of different technical fields and / or applications. For example, other sports shoes for basketball, soccer, tennis, golf, cross-training, hiking, cycling, trail running, or snowboarding are also conceivable. The expression "sports shoe, such as a soccer cleat" means that sports shoes are mentioned without mentioning applications not related to athletic use, such as dress shoes, chess shoes, or slippers.

[0084] In the figures and descriptions presented here, the same reference numerals refer to the same elements. For the sake of clarity and brevity, certain features, parts, elements, aspects, components and / or steps of certain embodiments are presented without undue detail if such detail would be obvious to a person skilled in the art, taking into account the teachings herein, and / or if such detail would obscure an understanding of more relevant aspects of the embodiments.

[0085] As understood by the expert and / or to avoid redundancies, reference is also made to the explanations in the preceding sections, which also apply to the following detailed description. Furthermore, for the sake of brevity and clarity, not all features, parts, elements, aspects, components, and / or steps are explicitly indicated by reference symbols. This applies in particular if the expert recognizes that such features, parts, elements, aspects, components, and / or steps are present in multiples. Definitions

[0086] The term "forefoot area" of a shoe upper, as used herein, can refer to the front part of the shoe upper, e.g., the forefoot section of the shoe upper that surrounds the area from the ball of the foot to the toes. It is the part of the shoe upper that contacts the foot during the propulsion and toe-out phases of the gait cycle.

[0087] The term "toe box" of a shoe upper, as used herein, can refer to the front part of the shoe upper that covers and protects the wearer's toes. This area is typically designed to provide space and comfort for the toes while also offering protection from external elements.

[0088] The term "midfoot area" of a shoe upper, as used herein, can refer to the central section of the shoe upper that surrounds the area between the ball of the foot (forefoot) and the heel. It is located approximately in the middle of the foot's longitudinal axis.

[0089] The term “flange area” of a shoe upper, as used herein, may refer to the section of the shoe upper that covers the top of the foot and includes the area over the toes.

[0090] The term “supercritical foaming process”, as used herein, may refer to a technique used to produce foams with specific properties by using supercritical fluids, where a supercritical fluid is a substance at a temperature and pressure above its critical point.

[0091] The term "lateral" of a shoe or shoe upper, as used herein, can refer to the outside of the shoe or shoe upper. This outside may be farther from the midline of the wearer's body when the shoe is worn with the upper facing down, compared to the medial side, which is the inside of the shoe. This outside may extend from the toe area to the heel area.

[0092] Unless otherwise specified, the term "approximately," as used in this context, can be understood to mean to a large or significant extent, or for the most part, or substantially. In particular, manufacturing tolerances are included in this term. Therefore, any values ​​or arrangements described using the term "approximately" may differ slightly from the values ​​or arrangements described.

[0093] The term "and / or" is simply a relationship of association that describes associated objects and indicates that three relationships can exist. For example, A and / or B can represent three conditions: the independent existence of A, the existence of both A and B, and the independent existence of B. Furthermore, the sign " / " in Revelation usually indicates that preceding and next associated objects form an "or" relationship.

[0094] The terms “above”, “above”, “below”, “below” and the like, as used in the present invention to indicate a relative position in space, are used to facilitate the explanation of a sole, a shoe, an element, a part, an object and / or a feature shown in the drawings in relation to another shoe, element, part, object and / or feature. Description of the characters

[0095] Fig. Figure 1 shows a layered structure 105 for a shoe upper (not shown), in particular for a sports shoe, according to an embodiment of the present disclosure.

[0096] The layered structure 105 is explained from the inside to the outside of a shoe upper. The layered structure 105 has (or includes) a first layer 110, which is a first textile layer 110, but other materials such as a coating, a film, synthetic leather, or leather are also conceivable. This first textile layer 110 can be designed to be turned inside out from the shoe upper. The first textile layer 110 can form an innermost surface of the shoe upper; that is, this surface refers to the inside of the shoe upper, which directly contacts the foot when the shoe is worn.

[0097] The layered structure 105 also has a second layer 120, which is a second textile layer 120, but other materials such as a coating, a film, synthetic leather, or leather are also conceivable. In some embodiments, the second textile layer 120 can be designed to be turned outwards from the shoe upper. The second textile layer 120 can form an outermost surface of the shoe upper, i.e., this surface refers to the outermost layer or the outer surface of the shoe upper, so that a further layer is now arranged on top of it.

[0098] The first textile layer 110 and the second textile layer 120 can comprise a polyamide (PA) material. As previously explained, the use of PA in layers such as textile layers improves the overall durability of the shoe upper, making it more resistant to wear and tear, thus extending the footwear's lifespan. Other (specific) materials could be a polyamide (PA) material, a polyurethane (PU) material, and / or a thermoplastic polyurethane (TPU) material.

[0099] The first textile layer 110 and the second textile layer 120 can have a thickness between 0.05 mm and 1.0 mm, preferably between 0.1 mm and 0.8 mm, more preferably between 0.2 mm and 0.6 mm, and most preferably approximately 0.3 mm. These values ​​contribute to effective breathability, which aids in moisture management and temperature regulation, and provide an optimal balance between flexibility and support. Both the first textile layer 110 and the second textile layer 120 can have a thickness of approximately 0.3 mm.

[0100] The first textile layer 110 and the second textile layer 120 can also comprise a woven fabric, preferably a knitted fabric. As explained above, the first textile layer 110 and / or the second textile layer 120 can also comprise a woven and / or a non-woven textile. Other (specific) materials could be those mentioned above.

[0101] The layered structure 105 also features an intermediate foam layer 130 between the first textile layer 110 and the second textile layer 120, with the intermediate foam layer 130 comprising a PA foam material. As explained above, this provides high tensile strength and abrasion resistance, as well as additional structural support for the shoe upper. For example, polyamide 11, PA 11, can be used as the raw material for the foaming process of the PA foam material. In another example, PA 12 could be used. In yet another example, polyether block amide, PEBA, could be used. Another (specific) material could be TPEE (thermoplastic polyester elastomer) foam.

[0102] Alternatively or additionally, the intermediate foam layer can comprise a thermoplastic polyurethane, TPU, foam instead of or together with the PA foam.

[0103] The intermediate foam layer 130 can have a thickness between 0.5 mm and 1.5 mm, preferably a thickness between 0.7 mm and 1.2 mm, more preferably a thickness of approximately 1.0 mm.

[0104] The material for the intermediate foam layer 130 can be produced through a supercritical foaming process, creating foams with specific properties by using supercritical fluids. This improves the overall durability and performance of the intermediate layer. For example, polyamide 11 (PA 11) can be used as the raw material. PA 11 is a type of nylon, and Rilsan® is the brand name used by Arkema. Alternatively, PA 12 or polyether block amide (PEBA) could be used.

[0105] Furthermore, the three layers, namely the first textile layer 110, the second textile layer 120 and the intermediate foam layer 130, can be laminated together on a film roll.

[0106] The layered structure 105 further comprises a film layer 140 on the second textile layer 120. The film layer 140 can be designed to provide a coating for the shoe upper, particularly when applied as the outermost layer. A “coating” can refer to a thin layer of material applied to the surface of the shoe upper to enhance its properties or to impart specific characteristics such as waterproofness, durability, breathability, protection against degradation due to exposure to sunlight (UV radiation), or dirt and stain resistance.

[0107] The film layer 140 comprises a thermoplastic polyurethane (TPU) material, which exhibits high durability and abrasion resistance. The advantage of TPU film layer 140 is that various types of coatings, such as printed layers or raised areas of any kind, can be easily applied to it. Furthermore, TPU film layer 140 can be advantageous as the outermost layer for bonding the shoe upper to the sole, which is typically a relatively stiff sole for soccer cleats. Another (specific) material for film layer 140 could be PA (polyamide).

[0108] The foil layer 140 comprises a thickness between 0.01 mm and 0.1 mm, preferably a thickness between 0.02 mm and 0.07 mm, more preferably a thickness of approximately 0.05 mm.

[0109] The film layer 140 can be extruded. Other (specific) manufacturing processes, such as coating processes, are also conceivable.

[0110] The foil layer 140 comprises a hardness between 40 and 90 Shore A, preferably between 50 and 70 Shore A, more preferably approximately 65 Shore A.

[0111] The layered structure 105 further includes a resin layer as the outermost layer made of polyurethane (PU) material. As mentioned, PU resin offers excellent abrasion resistance.

[0112] The resin layer can have a thickness between 0.01 mm and 0.1 mm, preferably a thickness between 0.02 mm and 0.07 mm, more preferably a thickness of approximately 0.05 mm.

[0113] The five layers 110, 120, 130, 140, and 150 are each bonded together by adhesive films such as PA hot melt adhesive films. Other (specific) materials could be TPU hot melt adhesive films or PU hot melt adhesive films.

[0114] Fig. Figure 2 shows a lateral side view of a football boot 200 with a laceless upper 201 according to an embodiment of the present disclosure.

[0115] The shoe upper 201 comprises a layered structure 205 with a first layer 210, a second layer 220, and an intermediate foam layer 230 between the first layer 210 and the second layer 220, wherein the intermediate foam layer 230 comprises a PA foam material. These layers can be distinguished from the first layer 110, the second layer 120, and the intermediate foam layer 130 with respect to Fig. resemble 1.

[0116] The first layer 210 is a first textile layer 210, but other materials such as a coating, a film, an artificial leather or a leather are also conceivable.

[0117] The second layer 220 is a second textile layer 220, but other materials such as a coating, a film, an artificial leather or leather are also conceivable.

[0118] The layered structure 205 also includes a foil layer 240, which is related to the foil layer 140 in terms of Fig. 1 resembles.

[0119] The layered structure 205 can also include a resin layer, which is similar to the resin layer 150 in terms of Fig. 1 resembles.

[0120] The layered structure 205 is arranged in a leaf area 201a, a forefoot area 201b, and a toe area 201c of the shoe upper 201 and is covered by the film layer 140. Alternatively, the film layer 140 can be omitted in these areas. As explained above, the layered structure 205 provides additional cushioning and protection against impacts in these specific areas of the shoe upper 201, thereby reducing the risk of injury from impacts or external forces.

[0121] Since the shoe upper 201 is laceless, the layered structure 205 with the film layer 140 is also arranged in a neck area 201d of the shoe upper 201. For a shoe upper with laces, the layered structure 205 with the film layer 140 would also be arranged in a tongue area of ​​the shoe upper 201. As mentioned previously, the film layer 140 can also be omitted in these areas for a shoe upper with laces.

[0122] There are several openings 260 in the intermediate foam layer 230 on the lateral side of the midfoot area of ​​the shoe upper 201. 'Several' can refer to a number that may be more than one and often implies a larger or indefinite number to achieve the aforementioned technical effects.

[0123] Further openings 260 are enclosed in the first textile layer 210 and / or the second textile layer 220. However, the openings 260 can also be enclosed only in the intermediate foam layer 230.

[0124] Alternatively or additionally, the openings 260 can also be arranged on the medial side of the shoe upper 201.

[0125] Fig. Figure 3 shows a lateral side view of a sports shoe 300 with a laceless shoe upper 301 according to an embodiment of the present disclosure.

[0126] The shoe upper 301 comprises a layered structure 305 with a first layer 310, a second layer 320, and an intermediate foam layer 330 between the first layer 310 and the second layer 320, wherein the intermediate foam layer 330 comprises a PA foam material. These layers can be distinguished from the first layer 110, the second layer 120, and the intermediate foam layer 130 with respect to Fig. 1 as well as the first layer 210, the second layer 220 and the intermediate foam layer 230 with regard to Fig. 2 resemble each other.

[0127] The first layer 310 is a first textile layer 310, but other materials such as a coating, a film, an artificial leather or a leather are also conceivable.

[0128] The second layer 320 is a second textile layer 320, but other materials such as a coating, a film, an artificial leather or leather are also conceivable.

[0129] The layered structure 305 can also include a foil layer, which is similar to the foil layer 240 in terms of Fig. 2. The layered structure 305 can also include a resin layer, which is similar to the resin layer 150 in terms of Fig. 1 resembles.

[0130] The layered structure 305 is arranged in a forefoot area 301b, a toe area 301c and a midfoot area 301e of the shoe upper 201.

[0131] The layered structure 205 further incorporates one or more profile elements 370 through debossing to provide a specific pattern in the toe area 301c and the forefoot area 301b. As mentioned previously, there can be several types of profile elements 370, such as rubber ridges and / or printed ridges.

[0132] Fig. Figure 4 shows a top view of a shoe upper 401 according to another embodiment of the present disclosure.

[0133] The upper part of shoe 401 has a two-dimensional shape before it is hardened to achieve its three-dimensional shape.

[0134] The shoe upper 401 comprises a polyamide (PA) foam layer 430 that extends from the top of the shoe upper 401 to the bottom of the shoe upper 401 to surround the wearer's foot. As mentioned, the PA foam layer extends along the sides and top of the wearer's foot when it assumes its three-dimensional shape.

[0135] The PA foam layer 430 comprises a thickness between 1.0 mm and 7.0 mm, preferably a thickness between 2.5 mm and 6.0 mm, more preferably a thickness of approximately 4.5 mm or a thickness of approximately 6.0 mm.

[0136] The PA foam layer 430 comprises a first part 440 in the forefoot area and a second part 450 in the heel area of ​​the shoe upper 400.

[0137] The first part 440 has a thickness between 1.0 mm and 5.0 mm, namely approximately 4.5 mm.

[0138] The second part 450 covers a thickness between 1.0 mm and 7 mm, namely a thickness of approximately 6.0 mm.

[0139] As mentioned, different thicknesses offer advantages such as flexibility in the forefoot area and cushioning in the heel area of ​​the shoe upper 401.

[0140] The first part 440 and the second part 450 are partially joined by thermal or adhesive bonding. This can be done in an "edge-to-edge, no-seam" manner, thus avoiding an unsightly seam on the inside of the shoe upper 400 in the heel area. The lower sections of the first part 440 and the second part 450 are joined by sewing, specifically zigzag stitching. Other sewing techniques are also conceivable.

[0141] In this way, a single (or continuous) piece for the shoe upper 401 can be provided from the PA foam layer 430.

[0142] The shoe upper 401 may also include a foil layer (not shown) which corresponds to the foil layer 240 in terms of Fig. 2 resembles.

[0143] A method for manufacturing such a shoe upper 400 can comprise the steps of wrapping the shoe upper 401 with the PA foam layer 430 and its first part 440 and second part 450 around a shoe last (not shown) and joining the lower sections of the two parts directly along an edge to the upper sections of the two parts. The joining is preferably carried out by sewing.

[0144] The sole can then be adhesively bonded to the lower sections of the two parts. Other bonding techniques for the sole to the shoe upper 401 are also conceivable. QUOTES INCLUDED IN THE DESCRIPTION

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

[0000] EP 3 253 247 A1

[0005] EP 3 765 640 A1

[0006] US 10 499 706 B2

[0007] US 2006 / 051566 A1

[0008]

Claims

Shoe upper, in particular for a sports shoe, comprising a layered structure with a. a first layer; b. a second layer; and c. an intermediate foam layer between the first layer and the second layer, wherein the intermediate foam layer comprises a polyamide, PA, foam material. Shoe upper according to claim 1, wherein at least one of the following applies: the first layer is designed to be turned inwards from the shoe upper; the second layer is designed to be turned outwards from the shoe upper; the intermediate foam layer is designed to provide elasticity and cushioning for ball contacts. Shoe upper according to claim 1 or 2, wherein the first layer forms an innermost surface of the shoe upper. Shoe upper according to one of the preceding claims, wherein the second layer forms an outermost surface of the shoe upper. Shoe upper according to one of the preceding claims, wherein the layered structure is arranged in a leaf area of ​​the shoe upper. Shoe upper according to the preceding claim, wherein the layered structure is arranged in a forefoot area of ​​the shoe upper. Shoe upper according to claim 5 or 6, wherein the layered structure is arranged in a toe area of ​​the shoe upper. upper shoe according to one of the preceding claims, wherein the first layer is a first textile layer. Shoe upper according to any one of claims 1 to 7, wherein the first layer comprises a coating, a film, an artificial leather or a leather. upper shoe according to one of the preceding claims, wherein the second layer is a second textile layer. Shoe upper according to any one of claims 1 to 9, wherein the second layer comprises a coating, a film, an artificial leather or a leather. Shoe upper according to one of the preceding claims, wherein one or more of the first layer and the second layer comprise a woven fabric, preferably a knitted fabric. Shoe upper according to one of the preceding claims, wherein one or more of the first layer and the second layer comprise a polyamide, PA, material, a polyurethane, PU, ​​material and / or a thermoplastic polyurethane, TPU, material. Shoe upper according to one of the preceding claims, wherein one or more of the first layer and the second layer comprise a thickness between 0.05 mm and 1.0 mm, preferably a thickness between 0.1 mm and 0.8 mm, more preferably a thickness between 0.2 mm and 0.6 mm, most preferably a thickness of approximately 0.3 mm. Shoe upper according to one of the preceding claims, wherein the intermediate foam layer comprises a thickness between 0.5 mm and 1.5 mm, preferably a thickness between 0.7 mm and 1.2 mm, more preferably a thickness of approximately 1.0 mm. Shoe upper according to one of the preceding claims, wherein the material of the intermediate foam layer is produced by a supercritical foaming process. Shoe upper according to one of the preceding claims, further comprising a film layer on the second layer designed to provide a coating for the shoe upper. upper shoe according to the preceding claim, wherein the film layer comprises a thermoplastic polyurethane, TPU, material. Shoe upper according to one of claims 17 or 18, wherein the foil layer comprises a thickness between 0.01 mm and 0.1 mm, preferably a thickness between 0.02 mm and 0.07 mm, more preferably a thickness of approximately 0.05 mm. Shoe upper according to one of claims 17 - 19, wherein the film layer is extruded. Shoe upper according to one of claims 17-20, wherein the film layer comprises a hardness between 40 and 90 Shore A, preferably between 50 and 70 Shore A, more preferably approximately 65 Shore A. Shoe upper according to one of the preceding claims, further comprising a resin layer as the outermost layer with a polyurethane, PU, ​​material. Shoe upper according to the preceding claim, wherein the resin layer comprises a thickness between 0.01 mm and 0.1 mm, preferably a thickness between 0.02 mm and 0.07 mm, more preferably a thickness of approximately 0.05 mm. Shoe upper according to one of the preceding claims, wherein one or more of the layers are joined by adhesive films, preferably polyamide, PA, or hot melt adhesive films. Shoe upper according to one of the preceding claims, wherein the layered structure is arranged in a midfoot area and / or a tongue area of ​​the shoe upper. Shoe upper according to one of the preceding claims, wherein the layered structure further comprises a profile element, preferably by debossing. Shoe upper according to one of the preceding claims, further comprising several openings in the intermediate foam layer. Shoe upper according to the preceding claim, wherein the multiple openings are also included in the first layer and / or the second layer. Shoe upper according to one of the preceding claims, wherein the first layer, the second layer and the intermediate layer form a one-piece structure extending from an upper surface of the shoe upper to a lower surface of the shoe upper. Shoe upper according to the preceding claim, wherein the one-piece structure completely surrounds a wearer's foot in use. Shoe upper according to one of claims 29 or 30, wherein the one-piece structure is arranged in a forefoot area of ​​the shoe upper. Sports shoe comprising a shoe upper according to any of the preceding claims. Sports shoe according to the preceding claim, wherein the sports shoe is a football shoe. Sports shoe according to the preceding claim, wherein the football shoe is laceless. Sports shoe according to one of claims 32 - 34, wherein the intermediate foam layer is arranged only in a neck area of ​​the shoe upper.

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