Footwear article and apparatus for the manufacture of at least one part of a footwear article

Abstract

Footwear article manufactured using a process (100) comprising the following steps: - Providing (103) a mold (1) defining an open cavity (2), wherein the shape of at least part of the cavity (2) corresponds to the shape of a sole (3) of the shoe article (10), wherein the cavity (2) is configured to open into the cavity (2) via at least one injection channel (4, 4', 4'', 4''') to receive a mixture comprising a molten material and a supercritical fluid; - Arranging (105) an edge (5) of an opening of the cavity (2) which is in contact with a contact area (6) of a surface (7) of at least one part of a shaft (9) of the shoe article (10), such that the surface (7) of the at least one part of the shaft (9) ensures a closure of the cavity at the contact point between the contact area (6) and the edge (5); - Applying negative pressure (105 bis) to the cavity (2); - Injecting (107) the mixture into the cavity (2); - Pressure relief (108) of the cavity (2) of the mold to trigger an expansion of the mixture in the cavity (2) and to form the sole (3) from a foamed material resulting from the expansion of the mixture, wherein at least a part of the surface (7) of the at least a part (9) of the shaft is enclosed in the foamed material of the sole (3).

Description

[0001] The present invention relates to the field of manufacturing a shoe article, for example shoes, and in particular the manufacturing of a shoe article with a light and cushioning sole, especially a shoe article for sports.

[0002] It is known to first produce a sole and then, in a second step, to bond it to an upper, particularly one made at least partially of textile. The production of footwear with a lightweight and cushioning sole requires numerous steps, as the sole is manufactured separately, usually from cross-linked ethylene vinyl acetate (EVA), and then bonded to the upper.

[0003] The disadvantage of this well-known method is that it requires numerous manual gluing processes, which are very energy-intensive.

[0004] On the other hand, two methods for direct injection onto the shaft are already known: - Direct injection molding of thermoplastics, PVC, or other elastomers. In this process, the material can be foamed using a chemical or physical blowing agent. However, the disadvantage of this method is that the material of the resulting shoe sole does not possess the properties expected of a lightweight and cushioning sole. The lowest sole density achievable with this method is above 0.5 g / cm³. 3 Furthermore, the cushioning and comfort properties desired for running shoe soles, for example, cannot be achieved with this manufacturing process. - Direct injection of polyurethane onto the upper. In this case, the foam is created through a chemical reaction of two compounds (polyol and isocyanate). The disadvantage of this method is that the density of the sole remains high (at best > 0.35 g / cm³). 3 ).

[0005] Furthermore, the non-thermoplasticity of polyurethane significantly hinders its recyclability.

[0006] The invention therefore aims to offer a solution for all or some of these problems.

[0007] For this purpose, the present invention relates to a method for manufacturing at least one part of a shoe article, for example a shoe, in particular a shoe article for practicing a sport, comprising the following steps: - Providing a mold defining an open cavity, wherein the shape of at least part of the cavity corresponds to the shape of a sole of the shoe article, wherein the cavity is configured to receive a mixture of a molten material and a supercritical fluid via at least one injection channel opening into the cavity; - Applying an edge of an opening of the open cavity to a contact area of ​​a surface of at least one part of an upper of the shoe article, so that the surface of the at least one part of the upper ensures a closure of the cavity at the contact point between the contact area and the edge; - Applying negative pressure to the cavity; - Injecting the mixture into the cavity; - Relieving pressure on the cavity of the mold to trigger an expansion of the mixture in the cavity and to form the sole from a foamed material resulting from the expansion of the mixture, wherein at least one part of the surface of at least one part of the shaft is enclosed in the foamed material of the sole.

[0008] These measures enable the process to produce a lightweight and cushioning sole of the shoe article in a single injection step, which is connected to part of an upper of the shoe article and exhibits good separation resistance of the sole and the upper.

[0009] According to one embodiment, the dimensions of the shape of at least one part of the cavity correspond to the dimensions of the sole of the shoe article on a scale between 1:0.98 and 1:1.02, preferably 1:1.

[0010] According to one embodiment, the pressurization of the cavity is accompanied by the simultaneous generation of a counter-pressure, preferably with a substantially identical value, in an area of ​​at least one part of the shaft on the other side of the closure with respect to the cavity.

[0011] These measures prevent the counter-pressure, preferably of an essentially identical value, from escaping the cavity at the contact point between the contact area and the edge.

[0012] Advantageously, the area of ​​at least one part of the shaft on the other side of the closure can be depressurized simultaneously with the pressure relief of the cavity of the mold in order to trigger an expansion of the mixture in the cavity and to form the sole during the method according to the invention.

[0013] These measures allow for a build-up of pressure in the cavity, followed by a pressure release in the cavity, an expansion of the mixture and the creation of the lightweight, cushioning foam material of the sole.

[0014] These measures result in a sole density of between 0.1 g / cm³. 3 and 0.4 g / cm² 3 , preferably between 0.15 g / cm³ 3 and 0.25 g / cm² 3 .

[0015] According to one embodiment, the invention comprises one or more of the following features, alone or in a technically acceptable combination.

[0016] According to one embodiment, the pressure for vacuuming the cavity is between 3 bar and 50 bar, preferably between 10 bar and 30 bar, preferably at 15 bar.

[0017] According to one embodiment, the method additionally includes the following step before the step of applying negative pressure to the cavity: - Placing a lid on the mold so that a closed volume is formed with the mold, comprising the cavity and a complementary part of the cavity in the closed volume, wherein at least one part of the shaft is located inside the closed volume, and wherein the complementary part and the cavity are located on both sides of the closure of the cavity at the contact point between the contact area and the edge.

[0018] A pressure in the complementary part of the closed volume, which is preferably identical to the pressure of the cavity, makes it possible to generate a counter-pressure to prevent the escape of pressurized gas from the cavity at the contact point between the contact area and the edge.

[0019] According to one embodiment, the lid is configured in such a way that it forms a closed, in particular gas-tight, volume around at least one part of the shaft in order to enable the generation of said back pressure within this closed, tight volume, in particular by absorbing the pressurized gas of the cavity in this tight volume in order to prevent the escape of pressurized gas at the contact point between the contact area and the edge of the cavity.

[0020] According to one embodiment, the method comprises a step of joining the part of the upper connected to the sole with another part of the upper, the connection forming the shoe.

[0021] According to one embodiment, the assembly step includes sewing the other part of the upper to the part of the upper connected to the sole.

[0022] According to one embodiment, the method also includes the following steps, which are carried out before the step of applying the edge of the opening of the open cavity to the contact area of ​​a surface of at least one part of a shaft: - Providing a holder with a shape that corresponds to a foot shape, - at least partially covering an outer surface of the holder with at least part of the upper of the shoe article, wherein at least part of the surface of the upper covers part of the outer surface of the holder corresponding to a sole of the foot, so that after placing the lid on the mold, the closed volume additionally includes the holder with at least part of the upper.

[0023] According to one embodiment, at least one part of the shaft is a complete shaft.

[0024] According to one embodiment, the bracket is made of aluminum, steel or plastic.

[0025] These measures enable the process to produce a complete shoe article, including the sole of the shoe article, which is connected to the complete upper of the shoe, in a single injection molding operation and with a single mold.

[0026] According to one embodiment, the mold consists of a single part.

[0027] According to one embodiment, the mold comprises at least two parts, and the provisioning step includes a step to assemble the at least two parts to form the mold.

[0028] According to one embodiment, the mold comprises a ring part comprising a first ring half and a second ring half, wherein the first half is movable relative to the second ring half in a sliding direction, such that a sliding movement of the first half in the direction of the sliding direction to the second half closes the ring part of the mold, while a sliding movement of the first half and the second half in the opposite direction opens the ring part of the mold by separating the two halves of the ring part from each other.

[0029] According to one embodiment, the mold further comprises a mold base with a cover and a cloche, wherein the cloche is configured to enclose the cover and the first ring half and the second ring half of the mold when the ring part and the mold are closed.

[0030] According to one embodiment, the bell of the mold base comprises a contact surface between the bell of the mold base and the ring part, wherein the contact surface comprises a first inclined surface configured to slide on a first contact surface of a wall of the first ring half, wherein the contact surface comprises a second inclined surface configured to slide over a second contact surface of a wall of the second ring half, wherein the first angle of inclination of the first inclined surface and the second angle of inclination of the second inclined surface are configured such that the step of assembling and closing the mold includes a movement of the bell from the mold base to the two halves of the ring part, which mechanically causes a sliding movement of the two halves in the direction of an approximation of the two halves of the ring part in order to close the ring part in contact with the mold base.

[0031] According to one embodiment, the mold includes an elastic device configured to push the first ring half and the second ring half apart.

[0032] According to one embodiment, the contact surface between the bell of the mold base and the annular part comprises at least one guide configured to accompany the sliding movement of the two parts of the ring when the bell of the mold base moves transversely to the sliding direction.

[0033] These measures cause the mold to be alternately closed and opened by moving the mold base towards the two halves of the ring part or in the opposite direction.

[0034] According to one embodiment, the cavity is configured so that it can receive the mixture via at least two injection channels opening into the cavity.

[0035] These measures enable the process to produce a sole of the shoe article even faster and with a more homogeneous filling of the mold cavity, which is connected to part of the upper of the shoe article.

[0036] According to one embodiment, the mold includes at least one injection channel.

[0037] According to one embodiment, the holder includes at least one injection channel.

[0038] According to one embodiment, the method comprises a step of applying adhesive to at least one part of the surface of at least one part of the shaft, wherein the adhesive application step is carried out before the injection injection step.

[0039] According to one embodiment, at least one part of the surface of at least one part of the shaft comprises thermally fusible threads configured to melt at an injection temperature of the mixture.

[0040] These measures increase the peel resistance of the sole and the upper.

[0041] Depending on the embodiment, the procedure also includes the following steps: - Providing inserts configured to fit into the cavity of the mold; - Positioning the inserts in the mold cavity.

[0042] According to one embodiment, the inserts are positioned so that they are inserted into an outer surface of the sole or embedded in the sole.

[0043] These measures increase the abrasion resistance of the sole or improve the dynamics of the sole, depending on whether the inserts are placed in an outer part of the sole, for example with one or more inserts made of rubber or thermoplastic material, or embedded in the interior of the sole, for example with one or more inserts made of carbon plates or thermoplastic material.

[0044] According to one embodiment, a contact surface between an insert and the sole has a structure.

[0045] According to one embodiment, the texture comprises a multitude of patterns distributed over a portion of the contact surface, the density depending on the mechanical stress on that portion of the contact surface.

[0046] According to one embodiment, the density is determined such that on a section of the contact surface the plurality of patterns occupies a part of the section of the contact surface, wherein this part is between 1% and 15%, preferably 6%, of the section of the contact surface.

[0047] According to one embodiment, the patterns are tubular and / or linear.

[0048] According to one embodiment, the height of the patterns in a direction transverse to the contact surface is between 1 mm and 10 mm, preferably 1.6 mm.

[0049] According to one embodiment, the thickness of the patterns in a direction transverse to the direction of the height is between 1 mm and 2 mm, preferably 1.6 mm.

[0050] These measures increase the adhesion between the insert and the sole through mechanical anchoring, without the need for gluing or surface preparation steps.

[0051] According to one embodiment, an insert positioned so that it can be inserted into an outer surface of the sole comprises at least one through-hole, wherein the at least one through-hole corresponds to a pressure channel so that a pressurized gas can flow through the insert.

[0052] According to one embodiment, at least a part of the surface of at least a part of the shaft is at least partially perforated or open.

[0053] These measures increase the peel resistance of the sole and the upper.

[0054] According to one embodiment, at least one part of the surface of at least one part of the shaft in contact with the contact area is structured or perforated.

[0055] These measures further increase the resistance to separation between the sole and the upper.

[0056] These measures achieve a peel strength of more than 2.5 N / mm, measured according to the standard ISO NF EN 1392.

[0057] According to one embodiment, the molten material is a thermoplastic elastomer polymer.

[0058] According to one implementation mode, the thermoplastic polymer is a thermoplastic polyurethane (TPU) or an ether-amide block copolymer (PEBA) or ethylene vinyl acetate (EVA) or a polyolefin or an ether-ester block copolymer or a styrene-based elastomer or a mixture of these different components.

[0059] Depending on the application mode, the supercritical fluid is nitrogen in a supercritical state, carbon dioxide in a supercritical state, or a mixture of nitrogen and carbon dioxide in a supercritical state.

[0060] Depending on the application mode: a large part of the mass of the shaft consists of a main material of the shaft and, if applicable, of one or more auxiliary material(s) of the shaft; a large part of the sole consists of a main sole material and, if applicable, one or more additional sole materials, wherein the foamed material resulting from the expansion of the mixture comprises the main sole material and the additional sole material(s); The main material of the upper and, where applicable, the auxiliary material(s) of the upper are selected from the following materials: polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, vulcanized thermoplastic elastomers, thermoplastic polyurethane (TPU), polyamides, an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer, and a polyester; and that the main material of the sole and, where applicable, the auxiliary material(s) of the sole belong to the same chemical family as the main material of the upper and, where applicable, the same chemical family as the auxiliary material(s) of the upper, or that the main material of the sole and, where applicable, the auxiliary material(s) of the sole are chemically compatible with the main material of the upper and, where applicable, with the auxiliary material(s) of the upper.

[0061] The main material of the sole can therefore belong to the same chemical family as the main material of the upper. For example, if the main material of the upper is a polyolefin, the main material of the sole will also be a polyolefin. If the main material of the upper is a polyamide, the main material of the sole will also be a polyamide.

[0062] For the purposes of the invention, two polymers are considered to be “chemically compatible” if they form a homogeneous medium at the microscopic level and no different phases can be observed.

[0063] This results in a lightweight, cushioning and recyclable shoe that preferably requires no adhesives or binders between the upper and the sole.

[0064] In one embodiment, the main material of the sole and optionally the auxiliary material(s) of the sole is identical to the main material of the upper and optionally identical to the auxiliary material(s) of the upper.

[0065] Since the main material of the upper and, where applicable, the auxiliary material(s) of the upper, as well as the main material of the sole and, where applicable, the auxiliary material(s) of the sole, are selected from the same materials or are chemically compatible with each other, their adhesion, as well as the manufacture and recycling of the footwear, is facilitated. In fact, it is not necessary to separate all components of the footwear for recycling. Recycling can be carried out in a single step by shredding the footwear and producing granules from the shredded parts. The applicant has surprisingly found that the main materials listed above for soles and uppers have the advantage of being usable in very different forms in footwear and being recyclable multiple times.

[0066] Advantageously, the main and, if applicable, auxiliary materials for the upper and sole are selected such that the at least partially recycled granules are suitable for any plastic forming technique (especially hot forming), for example, by injection molding, injection foaming, extrusion molding, extrusion blow molding, thermoforming, or thermomolding. The granules from the recycled shoe article according to the invention can be used to manufacture a sole or a shoe component (such as a heel counter, a hard toe cap, or a lateral reinforcement), or to produce yarn (e.g., by extrusion spinning) for the manufacture of a textile component (e.g., the production of an upper component or an entire upper by knitting or weaving) or a foam component. The granules from the shoe article can also be used to manufacture a boot.

[0067] The granules can also be processed into a nonwoven fabric, for example by a so-called meltblown or spunbond process or by a combination of these processes, such as to a so-called SMS nonwoven fabric (spunbond / meltblown / spunbond).

[0068] The main material of the shaft can be selected from polyesters, thermoplastic polyurethanes (TPU), polyolefins and block copolymers consisting of rigid polyamide blocks and soft polyether blocks.

[0069] The main material of the sole can be selected from polyesters, thermoplastic polyurethanes (TPU), polyolefins and block copolymers consisting of rigid polyamide blocks and flexible polyether blocks.

[0070] The shaft may comprise a yarn containing a material selected from the following: polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, vulcanized thermoplastic elastomers, thermoplastic polyurethane (TPU), an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer, and a polyester.

[0071] The upper can include a textile component, and the textile component can include a yarn that comprises the main material of the upper.

[0072] The upper can comprise a textile part forming a foot-enclosing area with an outer surface, and at least one part, in particular a band, comprising a thermoplastic olefin elastomer, wherein the band is connected to the outer surface of the textile part and to the sole.

[0073] The sole may include a honeycomb component and / or foam beads made of a material selected from: polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, thermoplastic polyurethane (TPU), an ether amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether ester block copolymer, a styrene-based elastomer, and a polyester.

[0074] The stock may include a hard front cap, comprising the main material of the stock or an auxiliary material of the stock, and / or a rear reinforcement, comprising the main material of the stock or an auxiliary material of the stock.

[0075] The shaft can include at least one eyelet for passing through at least one lacing element, wherein the at least one eyelet comprises a textile band comprising at least one yarn comprising the main material of the shaft, in particular the main material of the shaft is a polyolefin.

[0076] The shaft may include a foam component comprising the main material of the shaft, wherein in particular the main material of the shaft is a polyolefin.

[0077] In one embodiment, the upper and / or the sole each comprise a recycled material from a sole and / or upper of another shoe and / or a recycled material from a sole and / or upper of a boot.

[0078] Advantageously, the ratio of the mass of the main material of the shaft and, where applicable, the mass of the auxiliary material or materials of the shaft to the total mass of the shaft is at least 40%.

[0079] Advantageously, the ratio of the mass of the main material of the shaft and the mass of the auxiliary material or materials of the shaft to the total mass of the shaft is at least 50%.

[0080] Advantageously, the ratio of the mass of the main material of the sole and, where applicable, the mass of the auxiliary material or materials of the sole to the total mass of the sole is at least 40%.

[0081] Advantageously, the ratio of the mass of the main material of the sole and the mass of the auxiliary material or materials of the sole to the total mass of the sole is at least 50%.

[0082] The footwear article may contain a maximum of 10% by mass of one or more contaminating materials that are not made from polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, vulcanized thermoplastic elastomers, thermoplastic polyurethane (TPU), an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer and a polyester, in particular a maximum of 10% by mass of one or more thermoplastic contaminating materials and / or a maximum of 5% by mass of one or more thermoset contaminating materials.

[0083] Advantageously, the main material of the sole and, if applicable, the auxiliary material(s) of the sole are at least partially derived from the recycling of at least one other shoe item.

[0084] The process may also include collecting the shoe article and converting the shoe article into thermoplastic granules.

[0085] Advantageously, the processing step includes: - a step of crushing at least one shoe to obtain crushed particles; - a step of compacting the crushed particles to obtain crushed and compacted particles, especially by cold or hot compaction, - an extrusion granulation step of the crushed and compacted particles to obtain granules that can be processed by a hot processing method for plastic(s).

[0086] The process may include a step of hot processing at least a part of the thermoplastic granules to produce a plastic part, which in particular forms at least a part of an object for the practice of a sport.

[0087] The invention also relates to a plastic part, in particular one that at least partially forms an object for the practice of a sport and can be manufactured by this method, wherein the part is in particular a fin.

[0088] In one embodiment, the invention also relates to a shoe article, for example a shoe, in particular a shoe article for practicing a sport, which is obtained by the method according to one of the embodiments described above.

[0089] The main materials selected in the present invention for the upper and the sole, and optionally the auxiliary material(s) for the upper and / or the sole, can be thermoplastic materials that have the advantage of being derived from olefins. These materials can therefore advantageously undergo multiple thermal processing cycles without significant impairment of their properties, particularly through oxidation by air and / or moisture. This property allows them to extend the lifespan of their recycling cycle, unlike certain polymer materials, such as polyurethanes, which oxidize over time. The footwear can thus be advantageously recycled multiple times.

[0090] The auxiliary material(s) for the upper may differ from the main material of the upper and / or the main material of the sole.

[0091] The auxiliary materials for the shaft can differ from one another.

[0092] The auxiliary material(s) for the sole may differ from the main material of the sole and / or the main material of the upper.

[0093] The auxiliary materials for the sole can differ from one another.

[0094] The phrase "the main or auxiliary material of the upper is identical to the main or auxiliary material of the sole" means that the main / auxiliary material of the upper consists of the same polymer base material as the main / auxiliary material of the sole.

[0095] The same argument applies to two auxiliary materials for the upper or sole, whether identical or different.

[0096] The phrase "the main or auxiliary material of the upper differs from the main or auxiliary material of the sole" means that the main / auxiliary material of the upper is not made of the same base polymer material as the main / auxiliary material of the sole.

[0097] Preferably, the main material of the upper and / or the main material of the sole is / are selected from polyolefins and / or thermoplastic olefin elastomers and / or thermoplastic styrene elastomers and / or vulcanized thermoplastic elastomers.

[0098] In one embodiment, the main material of the shaft is a thermoplastic polyurethane (TPU) or an ether-amide block copolymer (PEBA) or ethylene vinyl acetate (EVA) or a polyolefin or an ether-ester block copolymer or a thermoplastic styrene elastomer or a thermoplastic olefin elastomer or a vulcanized thermoplastic elastomer or a styrene-based elastomer or a polyester or a mixture of these different components.

[0099] In one embodiment, the main material of the sole is a thermoplastic polyurethane (TPU) or an ether-amide block copolymer (PEBA), or ethylene vinyl acetate (EVA), or a polyolefin, or an ether-ester block copolymer, or a thermoplastic styrene elastomer, or a thermoplastic olefin elastomer, or a vulcanized thermoplastic elastomer, or a styrene-based elastomer, or a polyester, or a mixture of these different components.

[0100] Preferably, a vulcanized thermoplastic elastomer is used only in the outsole and not in the midsole. Thus, in one embodiment, only the outsole is the sole part of the sole that can contain a thermoplastic vulcanizate (TPV).

[0101] Preferably, the auxiliary material(s) for the shaft is / are selected from polyolefins and / or thermoplastic styrene elastomers and / or thermoplastic olefin elastomers and / or vulcanized thermoplastic elastomers.

[0102] Preferably, the auxiliary material(s) for the sole is / are selected from polyolefins and / or thermoplastic styrene elastomers and / or thermoplastic olefin elastomers and / or vulcanized thermoplastic elastomers. shaft

[0103] Preferably, the shaft comprises a forefoot area configured to cover the forefoot completely or partially, and / or a rearfoot area configured to cover the rearfoot completely or partially, and / or a medial area configured to cover a medial side of the foot completely or partially, and / or a lateral area configured to cover a lateral side of the foot completely or partially, and / or an instep area configured to cover the instep completely or partially, and / or a leg area configured to cover the leg completely or partially.

[0104] Advantageously, the shaft comprises (or may consist of) the main material of the shaft and, where applicable, one or more auxiliary materials of the shaft, wherein, in particular, the auxiliary material(s) of the shaft differ from the main material of the shaft and, where applicable, from each other.

[0105] For example, the main material of the shaft may be a thermoplastic polyurethane (TPU) or an ether-amide block copolymer (PEBA) or ethylene vinyl acetate (EVA) or a polyolefin or an ether-ester block copolymer or a thermoplastic styrene elastomer, a thermoplastic olefin elastomer, a vulcanized thermoplastic elastomer, a styrene-based elastomer, a polyester or a mixture of these different components, and a first auxiliary material of the shaft may be a thermoplastic olefin elastomer or a vulcanized thermoplastic elastomer.

[0106] For example, the main material of the shaft can be polypropylene or polyethylene, and the shaft includes a first auxiliary material for the shaft that differs from the main material and is selected from polypropylene and polyethylene. Thus, the main material of the shaft can be polypropylene, and the first auxiliary material for the shaft can be polyethylene.

[0107] In one embodiment, the shoe article is a shoe, and the main material of the upper is a thermoplastic polyurethane (TPU) or an ether-amide block copolymer (PEBA) or ethylene vinyl acetate (EVA) or a polyolefin or an ether-ester block copolymer or a thermoplastic styrene elastomer or a thermoplastic olefin elastomer or a vulcanized thermoplastic elastomer or a styrene-based elastomer or a polyester or a mixture of these different components and preferably a polyolefin, preferably polypropylene or polyethylene.

[0108] In one embodiment, the main material of the upper differs from the main material of the sole, and the sole also comprises a first auxiliary material for the sole that is identical to the main material of the upper (in particular, the first auxiliary material for the sole does not constitute the largest mass fraction of the sole). Preferably, the main material of the upper is a polyolefin, the main material of the sole is a thermoplastic styrene elastomer, and the first auxiliary material of the sole is a polyolefin.

[0109] The main material of the upper and / or the main material of the sole and / or the auxiliary material(s) of the upper and / or the auxiliary material(s) of the sole may be one or more recycled materials from a sole and / or the upper of another shoe or boot and / or plastic(s) and / or derived from biomass.

[0110] The shaft may comprise one or more shaft components (in particular, consist of) which comprise the main material of the shaft and / or one or more auxiliary materials for the shaft (in particular, consist of).

[0111] A shaft component can be a textile component, a reinforcement component, a lacing component, a cushioning component, a cellular component such as a foam, a shoelace, an eyelet, a hard toe cap, a rear or side reinforcement, or a combination thereof.

[0112] The textile component can be a woven fabric, a knitted fabric, a nonwoven fabric, a braid, a cable, a yarn spun from fibers, a multifilament yarn, a monofilament yarn, a fiber bundling or a combination thereof.

[0113] The textile component can be a three-dimensional textile (e.g., a knitted or woven fabric), i.e., it can comprise an upper and a lower textile web connected by intermediate threads extending between the textile webs.

[0114] The textile component can be a knitted component, for example knitted on a flat knitting machine, a warp knitting machine or a circular knitting machine, especially with a small diameter.

[0115] The textile component can be a knitted tube, in particular a knitted sock with a knitted heel section.

[0116] Preferably, the shaft comprises one or more shaft components that are joined together by gluing, sewing or welding (e.g. by ultrasound or radio frequency).

[0117] Preferably, the shaft comprises a textile component with a uniform textile structure, in particular with a uniform knitted or woven structure, wherein the component comprises a forefoot area and / or a rearfoot area and / or a lateral area and / or a medial area and / or an instep area.

[0118] The term "uniform textile structure" means that the textile component has no seams or welds, except those that may be necessary for its shaping, for example to join edges.

[0119] In one embodiment, the shaft comprises a cellular component, in particular a foam, and / or foam beads comprising a material selected from polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, vulcanized thermoplastic elastomers, thermoplastic polyurethanes (TPU), polyamides, an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer, and a polyester, preferably a thermoplastic olefin elastomer or a polyolefin, more preferably a polyolefin. The material can be the main material of the shaft or an auxiliary material of the shaft.

[0120] Preferably, the shaft comprises a cellular component, in particular a foam, and / or foam beads, which comprise the main material of the shaft.

[0121] In one embodiment, the mass fraction of the main material of the shaft in the shaft is at least 20%, preferably at least 30% and even more preferably at least 40%.

[0122] Preferably, the mass fraction of the main material of the shaft in the shaft is less than or equal to 90%, in particular less than or equal to 80%, in particular less than or equal to 70%, in particular less than or equal to 60%.

[0123] Alternatively, the mass fraction of the main material of the shaft in the shaft can be greater than or equal to 60%, preferably greater than or equal to 70%, even more preferably greater than or equal to 80% and preferably greater than or equal to 90%.

[0124] In one embodiment, the area fraction occupied by the main shaft material in the shaft is 30% or more, preferably 40% or more, more preferably 50% or more.

[0125] Preferably, the proportion of the area occupied by the main material of the shaft is less than or equal to 90%, in particular less than or equal to 80%, in particular less than or equal to 70%.

[0126] Alternatively, the area fraction occupied by the main material of the shaft can be greater than or equal to 60%, preferably greater than or equal to 80%, even more preferably greater than or equal to 90%.

[0127] Preferably, the area fraction occupied by the main material of the shaft and one or more auxiliary materials of the shaft is greater than or equal to 60%, more preferably greater than or equal to 70%, and preferably greater than or equal to 80%.

[0128] In one embodiment, the shaft comprises the main material of the shaft and a first auxiliary material of the shaft, wherein the mass fraction of the first auxiliary material of the shaft in the shaft is greater than or equal to 5%, preferably greater than or equal to 20%.

[0129] The mass fraction of the first auxiliary material of the shaft in the shaft is preferably less than or equal to 60%, preferably less than or equal to 50%, and more preferably less than or equal to 40%.

[0130] In one embodiment, the shaft comprises the main material of the shaft and one or more auxiliary materials of the shaft, in particular a first and / or a second auxiliary material of the shaft; the ratio of the mass of the main material of the shaft and the mass of the auxiliary material(s) of the shaft to the total mass of the shaft is at least 50%, preferably at least 60%, more preferably 70% or more, preferably 80% or more, in particular 90% or more.

[0131] Optionally, the ratio of the mass of the main material of the shaft and the mass of the auxiliary material(s) of the shaft to the total mass of the shaft is less than or equal to 90% or 80%.

[0132] Advantageously, the shaft comprises a first auxiliary material of the shaft selected from polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, vulcanized thermoplastic elastomers, thermoplastic polyurethanes (TPU), polyamides, an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer and a polyester; preferably a polyolefin or a thermoplastic olefin elastomer or a vulcanized thermoplastic elastomer; more preferably a polyolefin.

[0133] Advantageously, the shaft comprises a first auxiliary material of the shaft and a second auxiliary material of the shaft selected from polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, vulcanized thermoplastic elastomers, thermoplastic polyurethanes (TPU), polyamides, an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer and a polyester; preferably a polyolefin or a thermoplastic olefin elastomer or a vulcanized thermoplastic elastomer; more preferably a polyolefin.

[0134] Preferably, the first auxiliary material for the shaft differs from the second auxiliary material for the shaft.

[0135] In one embodiment, the shoe article is a shoe, and the main material of the upper is selected from polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, vulcanized thermoplastic elastomers, thermoplastic polyurethanes (TPU), polyamides, an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer, and a polyester.

[0136] Preferably, the mass fraction of the main stem material in the stem is at least 40% and at most 80%, more preferably at most 60%.

[0137] Preferably, the mass fraction of the first auxiliary material of the shaft in the shaft is at least 5%, more preferably at most 40%, and even more preferably at most 30%; for example, between 25% and 40%.

[0138] Preferably, the surface area fraction of the main material of the shaft, which is a polyolefin, in particular polypropylene, is 45% or more. Even more preferably, the surface area fraction of the main material of the shaft and of a first auxiliary material of the shaft, which is a polyolefin, in particular polyethylene, is 70% or more, preferably 70% to 90%. In particular, the surface area fraction of a second auxiliary material of the shaft, which is a thermoplastic olefin elastomer or a thermoplastic styrene elastomer or a vulcanized thermoplastic element, is 15% or more, in particular 30% or less.

[0139] In one embodiment, the shoe article is a shoe, and the main material of the upper is a thermoplastic olefin elastomer or a vulcanized thermoplastic elastomer; optionally, the upper additionally comprises a first auxiliary material for the upper, in particular a polyolefin, for example polypropylene or polyethylene.

[0140] Preferably, the mass fraction of the main material of the shaft in the shaft is more than or equal to 40% and less than or equal to 80%, more preferably less than or equal to 60%.

[0141] Preferably, the mass fraction of the first auxiliary material of the shaft in the shaft is greater than or equal to 5%, more preferably greater than or equal to 20%, in particular greater than or equal to 30% and less than or equal to 50%, in particular greater than or equal to 35% and less than or equal to 45%. sole

[0142] The sole comprises (in particular consists of) the main material of the sole and, if applicable, one or more auxiliary materials for the sole, which differ in particular from the main material of the sole.

[0143] The additional sole material(s) mentioned are preferably selected from polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, vulcanized thermoplastic elastomers, thermoplastic polyurethanes (TPU), polyamides, an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer and a polyester.

[0144] For example, the main material of the sole may be a thermoplastic styrene elastomer and the sole may include a first auxiliary material for the sole, which is a polyolefin, such as polypropylene or polyethylene.

[0145] Advantageously, the sole comprises a first auxiliary material of the sole selected from polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, vulcanized thermoplastic elastomers, thermoplastic polyurethanes (TPU), polyamides, an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer and a polyester; preferably a polyolefin or a thermoplastic styrene elastomer or a vulcanized thermoplastic elastomer.

[0146] Preferably, the mass fraction of the main material of the sole in the sole is at least 25%, more preferably at least 40%, more preferably at least 50%, and preferably at least 60%.

[0147] Preferably, the mass fraction of the main material of the sole in the sole is less than or equal to 80%.

[0148] Preferably, the mass fraction of the first auxiliary material of the sole in the sole is at least 10%, more preferably less than or equal to 40%, preferably less than or equal to 30%, for example between 15% and 25% (including upper and lower limits).

[0149] In one embodiment, the sole comprises the main material of the sole and optionally one or more auxiliary materials of the sole, in particular a first and / or a second auxiliary material of the sole, wherein the ratio of the mass of the main material of the sole and optionally the mass of the auxiliary material or auxiliary materials of the sole to the total mass of the sole is greater than or equal to 30%, preferably greater than or equal to 40%, even more preferably greater than or equal to 50%, more preferably greater than or equal to 60%, even more preferably greater than or equal to 70%, more preferably greater than or equal to 80%, and in particular greater than or equal to 90%.

[0150] Optionally, the ratio of the mass of the main material of the sole and, where applicable, the mass of the main material or auxiliary materials of the sole to the total mass of the sole is less than or equal to 90%, in particular less than or equal to 80%, in particular less than or equal to 70%.

[0151] In one embodiment, the shoe article is a shoe, and the main material of the sole is selected from polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, vulcanized thermoplastic elastomers, thermoplastic polyurethanes (TPU), polyamides, an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer, and a polyester.

[0152] Preferably, the mass fraction of the main material of the sole is at least 55% and at most 70%.

[0153] Preferably, the mass fraction of the first auxiliary material of the sole is at least 5% and at most 35%, in particular at least 10% and at most 30%.

[0154] In one embodiment, the main material of the sole is selected from polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, vulcanized thermoplastic elastomers, thermoplastic polyurethanes (TPU), polyamides, an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer, and a polyester; preferably a thermoplastic styrene elastomer, preferably SEBS or SBS; and the sole comprises a first auxiliary material of the sole selected from polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, vulcanized thermoplastic elastomers, thermoplastic polyurethanes (TPU), polyamides, an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer, and a polyester;preferably a thermoplastic styrene elastomer (different from the main material of the sole), preferably SEBS or SBS. The sole may comprise a second auxiliary material of the sole, which is a polyolefin, for example PP or PE.

[0155] In one embodiment, the main material of the sole is a vulcanized thermoplastic elastomer; optionally, the sole additionally comprises a first auxiliary material of the sole, in particular a thermoplastic styrene elastomer, for example SEBS or SBS, which may optionally be grafted.

[0156] Preferably, the mass fraction of the main material of the sole in the sole is more than or equal to 40% and less than or equal to 85%, more preferably more than or equal to 30%, more preferably more than or equal to 40%, and in particular more than or equal to 55%.

[0157] Preferably, the mass fraction of the first auxiliary material of the sole in the sole is at least 8%, more preferably at most 30%, for example between 15% and 25%.

[0158] In one embodiment, the main material of the sole is polypropylene.

[0159] Preferably, the mass fraction of the main material of the sole in the sole is at least 50%, more preferably at least 80%, in particular at least 90%, for example on the order of 100%.

[0160] If the sole comprises one or more auxiliary materials of the sole, these are preferably embedded like fillers in a polymer matrix formed by the main material of the sole.

[0161] The sole according to the invention can be / comprise an outsole or a midsole or a combination thereof.

[0162] In one embodiment, the shoe article comprises an outsole and a midsole, wherein in particular the midsole is a removable insole.

[0163] The midsole can be removable and arranged in a receiving space for the foot of the shoe item, so that it lies under the user's foot.

[0164] The midsole can also serve as an insole.

[0165] The sole according to the invention can comprise (consist of) one or more sole components comprising (in particular consisting of) the main material of the sole and / or one or more auxiliary materials of the sole.

[0166] A sole component can be an outsole, a midsole, an insole, a cushioning heel counter (e.g. a donut), a textile component (as defined above in relation to the upper), a functional device that provides stability, or a reinforcing or cushioning insert or a cellular component, in particular a foam or an arrangement of foamed and optionally agglomerated and / or bonded spheres.

[0167] In one embodiment, the sole comprises or is an intermediate sole with an outer surface that comes into direct contact with the ground.

[0168] Advantageously, the midsole is configured to function as an outsole. Therefore, the shoe does not include an outsole.

[0169] The midsole is preferably a one-piece component.

[0170] Preferably, a foamed midsole with good abrasion resistance is chosen.

[0171] In one embodiment, the sole comprises a tread component, preferably it comprises (or is) a tread with a density (g / cm³). 3 ) of greater than or equal to 0.85, preferably less than or equal to 1.30.

[0172] In one embodiment, the sole comprises a midsole component, preferably it comprises (or is) a midsole with a density (g / cm³). 3 ) of greater than or equal to 0.10, preferably less than or equal to 0.90, more preferably with a density of less than or equal to 0.50; in particular less than or equal to 0.40.

[0173] In one embodiment, the sole comprises a midsole component, preferably it comprises (or is) a midsole with a density (g / cm³). 3) of more than 0.50 and less than or equal to 0.85; in particular less than or equal to 0.75.

[0174] In one embodiment, the shoe article comprises an injected outsole, in particular consisting of the main material of the sole (e.g. optionally grafted SEBS) and optionally a first auxiliary material of the sole (e.g. PP or PE), and an injected midsole, in particular directly onto the outsole which is still in a softened state.

[0175] The midsole comprises the main sole material (e.g., optionally grafted SEBS) and optionally the first auxiliary sole material (e.g., PP or PE) mixed with at least one blowing agent. The outsole and midsole are manufactured using a two-component injection molding process.

[0176] In one embodiment, the shoe includes an insole, which is arranged, in particular, in the foot-receiving cavity of the shoe in such a way that it lies under the foot when the shoe is worn.

[0177] The insole should preferably be removable.

[0178] This arrangement is advantageous when the sole is injection-molded onto the upper. If an insole is already present during the injection molding process, it can be crushed and thus lose its ability to support the foot. Using a removable insole solves this problem.

[0179] The insole may advantageously comprise agglomerated foam beads, wherein the foam beads preferably comprise (in particular are) a material consisting of polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, vulcanized thermoplastic elastomers, thermoplastic polyurethanes (TPU), polyamides, an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer and a polyester or a combination thereof.

[0180] The insole may, in particular, comprise a foam containing a polyolefin, especially polyethylene. The foam may be laminated with a textile, optionally sandwiched between two textiles. The textile(s) comprise polyolefin yarns and / or fibers. Main and / or auxiliary material(s) for upper and / or sole: polyolefins

[0181] The polyolefin(s) mentioned in this text, in particular for the main material of the upper and / or the main material of the sole and / or the auxiliary material(s) of the upper and / or the sole, will be selected from the possibly grafted homopolymers of polyolefins, copolymers or terpolymers of polyolefins, which may be grafted.

[0182] The copolymers of polyolefins comprise two olefinic repeating units, optionally grafted.

[0183] The polyolefin terpolymers comprise three or more olefin repeat units, which may be grafted.

[0184] The olefin repeating units preferably comprise units derived from alkenes, in particular ethylene or propylene.

[0185] The polyolefin(s) used in the present invention are, by definition, thermoplastic.

[0186] The term "grafted" refers to one or more grafted function(s) or group(s), which may be one or more linear or branched alkyl groups with 1 to 10 carbon atoms, preferably 1 to 5 carbon atoms, for example an ethyl or propyl methyl group, an ethyl or propyl group, or one or more ester groups, for example an alkyl ester whose alkyl group comprises 1 to 5 carbon atoms, or one or more acrylate groups (RO-CO-CH=CH2) or acryloyl groups (H2C=CH-CO-R), wherein R is in particular an alkyl group with 1 to 10 carbon atoms.

[0187] The polyolefin(s) mentioned in this text, in particular for the main material of the upper and / or the main material of the sole and / or the auxiliary material(s) of the upper and / or the sole, is / are preferably selected from a list I which (in particular consisting of) polypropylene; polyethylene, in particular high-density polyethylene, very high-density polyethylene, low-density polyethylene and very low-density polyethylene (LLDPE); polymethylpentene (PMP), polybutylene-1 (PB-1), polyisobutene; preferably, among the polypropylenes and polyethylenes, polyethylene from high-density polyethylene, very high-density polyethylene, low-density polyethylene and very low-density polyethylene (LLDPE) is selected.

[0188] The polyolefin(s) mentioned in this text, in particular for the main material of the upper and / or the main material of the sole and / or the auxiliary material(s) of the upper and / or the sole, may / may also be selected from a List II, which consists in particular of poly(ethylene vinyl acetate) (EVA) (in particular of the copolymerization of ethylene and vinyl acetate, it is a copolymer of olefins), in particular uncrosslinked; ethylene polyvinyl alcohol.

[0189] The polyolefin(s) mentioned in this text for the main material of the sole and / or the auxiliary material(s) of the sole may be selected from olefin-based mineral oils, such as polyalphaolefins, in particular those that are plasticizers for thermoplastic styrene elastomers.

[0190] The polyolefin can be a bio-based or a petro-based polyolefin, in particular a bio-based one, i.e. obtained from renewable raw materials, for example a bio-based polyethylene obtained from sugar cane.

[0191] Bio-based material refers to any material that is derived from renewable resources, as opposed to petroleum-based materials.

[0192] Bio-based polyolefins can have a so-called direct origin, meaning they are obtained directly from renewable raw materials, or an indirect origin, meaning they are obtained from a mixture of renewable raw materials and petroleum-based raw materials and / or recycled raw materials. In the latter case, the polyolefin is defined by obtaining a certificate issued according to the "mass balance approach," which specifies the proportion of recycled and / or bio-based materials used in its production. Thermoplastic olefin elastomers

[0193] The thermoplastic olefin elastomer(s) mentioned in this text, in particular for the main material of the upper and / or the main material of the sole and / or the auxiliary material of the upper and / or the sole, will be selected from: - Polyisobutylene (PIB); and / or - Terpolymers of ethylene, propylene, and diene (EPDM); copolymers of ethylene and propylene; copolymers of ethylene and alpha-olefins, for example copolymers of ethylene and butene or copolymers of ethylene and octene, and mixtures thereof; preferably EPDM and copolymers of ethylene and propylene; and / or - Mixtures of a polyolefin, in particular polypropylene, with one or more thermoplastic, non-vulcanized olefin elastomers and optionally one or more plasticizers (e.g. mineral oil(s) or naphthenic or paraffinic oils), wherein the thermoplastic olefin elastomer(s) may be copolymers of ethylene and propylene, terpolymers of ethylene, propylene and diene, copolymers of ethylene and alpha-olefin(s) (e.g. copolymers of ethylene and butene or copolymers of ethylene and octene). Vulcanized thermoplastic elastomers

[0194] The vulcanized thermoplastic elastomer(s) (TPE-V) mentioned in this text, in particular for the main material of the upper and / or the main material of the sole and / or the auxiliary material(s) of the upper and / or the sole, is / are preferably: - a mixture of a vulcanized olefin elastomer (in particular as a rubber phase) and a polyolefin (in particular as defined in the present text, in particular as a thermoplastic phase), in particular polypropylene, or - a mixture of a vulcanized olefin elastomer (in particular as defined in this text and vulcanized, in particular forming the rubber phase) and a thermoplastic styrene elastomer (in particular as defined in this text, in particular forming the thermoplastic phase), in particular SEBS or SBS.

[0195] Vulcanization generally takes place during the extrusion granulation step. Preferably, the highly vulcanized rubber phase is dispersed in the thermoplastic phase. This elastomer has the advantage of exhibiting good adhesion to olefin polymers such as polypropylene and polyethylene. This vulcanization process is known in the art as dynamic vulcanization, in which the elastomer is vulcanized in the molten state with a suitable thermoplastic polyolefin during mixing.

[0196] The vulcanized olefin elastomer is preferably made from terpolymers of ethylene, propylene and diene (EPDM), copolymers of ethylene and propylene, copolymers of ethylene and alpha-olefin(s), for example copolymers of ethylene and butene or copolymers of ethylene and octene, and a mixture thereof; preferably EPDM and copolymers of ethylene and propylene.

[0197] In this text, polyurethanes are not considered to be vulcanized thermoplastic elastomers. Thermoplastic styrene elastomers

[0198] The thermoplastic styrene elastomer(s) mentioned in this text, in particular for the main material of the upper and / or the main material of the sole and / or the auxiliary material(s) of the upper and / or the sole, are preferably selected from thermoplastic elastomers containing styrene repeating units (TPE-S) (in particular a styrene group: -CH(C6H5)-CH2), more preferably from thermoplastic elastomers comprising one or more styrene blocks and optionally one or more olefin blocks (optionally grafted), preferably from poly(styreneethylene-butylene-styrene) (SEBS); poly(styrene-butadiene-styrene) (SBS); poly(styrene-butadiene) (SBC); poly(styrene-isoprene-styrene) (SIS); Poly(styrene-ethylene-propylene-styrene) (SEPS), for example under the brand name Septon SEPS® by Kuraray or Kraton G® by Kraton.

[0199] A thermoplastic styrene elastomer according to the invention can be grafted, for example SEBS can be grafted, for example with one or more acid anhydrides, such as maleic anhydride, and / or one or more carboxylic acids and / or one or more vinyl functionalities.

[0200] The grafting of the thermoplastic styrene elastomer serves to improve the adhesion of the sole, for example the outsole, to another sole, for example a midsole, and / or to the upper when the sole is injected directly onto the upper.

[0201] Advantageously, the thermoplastic elastomers selected within the scope of the present invention exhibit better processability and lower energy costs than thermoset elastomers processed using conventional thermoplastic methods such as injection molding, extrusion, thermoforming, blow molding, etc.

[0202] In particular, polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, vulcanized thermoplastic elastomers, thermoplastic polyurethanes (TPU), polyamides, an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer and a polyester are included. Definitions

[0203] Advantageously, the main material of the upper and / or the main material of the sole and optionally one or more auxiliary materials of the upper and / or one or more auxiliary materials of the sole has or have a melting temperature (Tf) and / or a glass transition temperature (Tg), wherein in particular the melting temperature(s) is / are higher than the glass transition temperature(s).

[0204] In this text, "shoe" refers to any shoe item except boots.

[0205] In this text, "boot" refers to a rain or snow boot or a clog, in particular a footwear article comprising an upper and a sole part containing a common polymer material that constitutes most of the mass of the upper and sole, the upper and sole being molded together.

[0206] In this text, thermoplastic material refers to any material that can be sufficiently softened or melted by heating without being damaged, so that it can be used multiple times in a plastics processing process, such as those mentioned above.

[0207] The mass fraction of the shaft refers to: - the mass fraction of the main material of the shaft, measured against the total mass of the shaft, is greater than the mass fraction of any other material from which the shaft is made; or - the mass fraction of the main material of the shaft, plus the respective mass fraction of the auxiliary material(s) of the shaft, measured in relation to the total mass of the shaft, is greater than the mass fraction of any other material that the shaft contains and is not listed in the main list defined in this text; or - the proportion of the area occupied by the main material of the shaft, measured against the total area of ​​the shaft, is greater than the proportion of the area occupied by any other material from which the shaft is made; or - the area fraction of the main material of the shaft plus the respective area fraction of the auxiliary material or auxiliary materials of the shaft, measured against the total area of ​​the shaft, is greater than the area fraction of any other material of which the shaft is made and which is not listed in the main list defined in this text.

[0208] The main material of the shaft and, if applicable, the auxiliary material(s) of the shaft can thus constitute, for example, 30%, 40%, or even 50% or 60% of the mass of the shaft or the outer surface of the shaft.

[0209] The term "main material of the shaft" means that the mass or area fraction of the main material of the shaft is greater than the mass or area fraction of any auxiliary material of the shaft and, if applicable, greater than the mass or area fraction of any other material of which the shaft is made and which is not listed in the main list defined in this text.

[0210] If, for example, the main material of the shaft constitutes 30% of the mass of the shaft, the auxiliary material(s) (each) constitutes less than 30% of the mass of the shaft.

[0211] The outer surface of the shaft is preferably calculated using a flat projected shaft. This can, for example, be the surface of the shaft pattern before its three-dimensional shaping by sewing, taking into account all shaft components arranged along its outer surface.

[0212] The total mass of the upper refers to the mass of the upper on the finished shoe with all its components.

[0213] The term "mass majority of the sole" refers to: - the mass fraction of the named main material of the sole, measured against the total mass of the sole, is greater than the mass fraction of any other material from which the sole is made; or - The mass fraction of the named main material of the sole, plus the respective mass fraction of the auxiliary material or materials of the sole, measured against the total mass of the sole, is greater than the mass fraction of any other material that the sole contains and that is not listed in the main list defined above in this text.

[0214] The main material of the sole and, if applicable, the auxiliary material(s) of the sole can thus make up 40% or even 50% or 60% of the mass of the sole.

[0215] The term "main material of the sole" means that the mass fraction of the main material of the sole is greater than the mass fraction of any auxiliary material of the sole and, where applicable, greater than the mass fraction of any other material of the sole that is not listed in the main list defined in this text.

[0216] For example, if the main material of the sole makes up 30% of the mass of the sole, the auxiliary material(s) (each) makes up less than 30% of the mass of the sole.

[0217] In this text, the mass fraction of a main or auxiliary material of the shaft in the shaft is the ratio of the mass (g) of the said main or auxiliary material of the shaft to the total mass (g) of the shaft.

[0218] For calculating the total mass of the upper to determine the mass fraction of the main material of the upper and / or the auxiliary material(s) of the upper, all material(s) of the upper that covers the instep, i.e., is / are located above the bearing surface of the foot, is taken into account. Any material(s) of the sole in conjunction with the upper (e.g., part of the sole of a knitted sock) are considered as part of the sole, in particular the midsole or outsole.

[0219] In this text, the proportion of the area occupied by the main or auxiliary material of the shaft is the ratio of the area (cm²). 2 ), which this material occupies, to the entire outer surface (cm² 2 ) of the flat shaft, wherein the outer surface of the shaft is the outwardly facing surface of the shoe.

[0220] In the present text, the mass fraction of a main or auxiliary material of the sole in the sole is the ratio of the mass of the said main or auxiliary material to the total mass of the sole.

[0221] If a first shaft component comprises the main shaft material and a second shaft component comprises said main shaft material, then the first component and the second component each comprise a main shaft material in the same base polymer, which may be selected from polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, vulcanized thermoplastic elastomers, thermoplastic polyurethanes (TPU), polyamides, an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer, and a polyester; and in particular, a polyolefin, for example, PP or PE. However, the base polymer material of the first component may differ with respect to its hardness or intrinsic properties (molar mass, degree of polymerization, amount of monomer(s)) or its dosage form (foam, textile, foamed beads, etc.).) differ from the base polymer material of the second component.

[0222] The footwear article, in particular the upper and / or the sole, may contain approximately 20% or less, in particular 15% or less, more precisely 10% or less, in particular 5% or less, based on its total mass, of one or more contaminating materials; that is, it is / are not selected from polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, and vulcanized thermoplastic elastomers. The contaminating material(s) may be selected from polyurethanes, polyamides, or polyesters (e.g., polyethylene terephthalate (PET) or polybutylene terephthalate (PBT)). These contaminating materials may, for example, be derived from recycled materials.

[0223] In one variation of this design, the shoe is a boot. The boot comprises a sole and an upper. The upper includes a lower part that covers the foot, specifically the forefoot, instep, medial area, lateral area, and hindfoot. The upper also includes a top part that covers at least part of the leg.

[0224] Preferably, the lower part of the shaft and the outsole are injection-molded together.

[0225] In the two preceding sub-variants, the main material of the sole is preferably a thermoplastic styrene elastomer, in particular a SEBS, and the main material of the upper is a thermoplastic styrene elastomer, in particular a SEBS.

[0226] The upper part of the shaft comprises one or more foams and one or more textiles in at least one auxiliary material of the shaft, in particular selected from polyolefins. The shaft may also comprise one or more foams and / or one or more textiles forming an inner boot, which is arranged in the foot area of ​​the boot and wholly or partially covers the inside of the lower part of the injection-molded shaft.

[0227] Preferably, the mass fraction of the main material of the sole in the sole is at least 45%, more preferably at least 50%, and in particular at most 70%.

[0228] The outsole may also include a first auxiliary material of the sole, consisting of polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, vulcanized thermoplastic elastomers, thermoplastic polyurethanes (TPU), polyamides, an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer and a polyester; and, for example, a polyolefin, in particular polypropylene.

[0229] The mass fraction of the first auxiliary material for the sole in the sole is at least 5% and at most 40%, in particular at most 30%.

[0230] Preferably, the mass fraction of the main material of the shaft is at least 40%, more preferably at most 60%.

[0231] The shaft can comprise a first auxiliary material of the shaft, which is a polyolefin, in particular polypropylene, the mass fraction of which in the shaft is greater than or equal to 10%, preferably less than or equal to 35%.

[0232] Preferably, the ratio of the mass of the main material of the shaft and the mass of the first auxiliary material of the shaft to the total mass of the shaft is at least 60%, preferably at least 70%.

[0233] In one embodiment, the main material of the shaft is selected from one of the following materials: a polyolefin, a thermoplastic olefin elastomer or a vulcanized thermoplastic elastomer, preferably from a polyolefin or a thermoplastic olefin elastomer, more preferably from a polyolefin.

[0234] In one design variant, the main material of the sole is selected from one of the following materials: a thermoplastic styrene elastomer, a polyolefin or a vulcanized thermoplastic elastomer.

[0235] In one version, the main material of the sole is a thermoplastic styrene elastomer.

[0236] In one version, the main material of the sole is a polyolefin, in particular polypropylene.

[0237] In one embodiment, the shaft comprises a yarn that includes a material consisting of polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, vulcanized thermoplastic elastomers, thermoplastic polyurethanes (TPU), polyamides, an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer, and a polyester.

[0238] Preferably, the polyolefin is polypropylene or polyethylene.

[0239] Preferably, the yarn comprises the main material of the shaft.

[0240] In one embodiment, the shaft comprises a textile component, and the textile component comprises a yarn comprising the main material of the shaft, wherein in particular the main material of the shaft is selected from polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, vulcanized thermoplastic elastomers, thermoplastic polyurethanes (TPU), polyamides, an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer and a polyester.

[0241] Preferably, the main material of the shaft consists of polypropylene or polyethylene.

[0242] In one embodiment, the upper comprises a textile part forming a foot-enclosing area with an outer surface, and at least one part, in particular a band, comprising a thermoplastic olefin elastomer, wherein this part is connected to the outer surface of the textile part and to the sole.

[0243] Advantageously, the textile part forming a foot-enclosing area comprises a textile component, in particular a yarn, comprising the main material of the upper, selected from polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, vulcanized thermoplastic elastomers, thermoplastic polyurethanes (TPU), polyamides, an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer and a polyester; in particular, the main material of the upper is a polyolefin or a thermoplastic olefin elastomer or a vulcanized thermoplastic elastomer.

[0244] Advantageously, the textile component can be of the type described in this text.

[0245] Preferably, the part is made of imitation leather.

[0246] Advantageously, the part comprises a textile carrier and a polymer layer, which in particular consists essentially, more precisely, of a material comprising polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, vulcanized thermoplastic elastomers, thermoplastic polyurethanes (TPU), polyamides, an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer and a polyester; and in particular the thermoplastic olefin elastomer, wherein the polymer layer is bonded to the textile carrier.

[0247] Advantageously, the side of the part that encompasses the textile carrier is oriented towards the outside of the textile part.

[0248] Preferably, the shaft comprises one or more strips, which are preferably arranged so that they run at least partially along at least one of the following edges of the shoe: the front edge, the inner edge, the side edge and the rear edge.

[0249] Preferably, the part(s), in particular the strip(s), is / are connected to the outside of the textile part that forms a receiving area for the foot and to the sole.

[0250] Preferably the part(s), in particular the strip(s), has (in particular each) a thickness greater than or equal to 0.5 mm and less than or equal to 3 mm.

[0251] Preferably, the at least one part, in particular the strip, is connected by fusing at least one part of its structure to the outside of the textile part and optionally to the sole.

[0252] Preferably, at least one part of the at least one part, in particular the strip, is arranged between the sole and the outside of the textile part that receives the foot.

[0253] Advantageously, the thermoplastic olefin elastomer allows the formation of a reinforcing part, in particular a reinforcing strip, with a leather-like appearance that is compatible with the polymer material(s) of the textile part and the sole, so that it can be bonded by melting.

[0254] In one embodiment, the part is arranged such that it covers part of the entire or part of the top of the foot, in particular it includes an opening for inserting the foot into the covering section.

[0255] In one embodiment, the sole comprises a cellular component, in particular a foam, comprising a material selected from one of the following: polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, thermoplastic polyurethanes (TPU), polyamides, an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer, and a polyester; and in particular a thermoplastic styrene elastomer, a thermoplastic olefin elastomer, or a polyolefin, preferably made from one of the following materials: a thermoplastic olefin elastomer, more preferably a thermoplastic olefin elastomer.

[0256] Preferably, the foam spheres are agglomerated into a block, in particular bonded together at their surfaces by melting.

[0257] Preferably, the cell component has a volume density between 0.1 g / cm³.3 and 0.4 g / cm² 3 , preferably between 0.15 g / cm³ 3 and 0.25 g / cm² 3 .

[0258] Preferably, the cell component is a midsole.

[0259] In one design variant, the stock includes a hard front cap, which comprises the main material of the stock or an auxiliary material of the stock, and / or a rear reinforcement, which comprises the main material of the stock or an auxiliary material of the stock.

[0260] The shaft may include a rear reinforcement or a hard front cap, comprising or consisting of a material consisting of polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, thermoplastic polyurethanes (TPU), polyamides, an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer, and a polyester.

[0261] The shaft may therefore include a posterior reinforcement or a hard anterior tip containing or consisting of a thermoplastic styrene elastomer, for example SEBS, optionally mixed with at least one polyolefin.

[0262] The shaft may include a posterior reinforcement or a hard anterior tip containing or consisting of a vulcanized thermoplastic elastomer.

[0263] In one embodiment, the shaft comprises at least one eyelet for passing through at least one lacing element, wherein the at least one eyelet comprises a textile band comprising at least one yarn comprising the main material of the shaft or an auxiliary material of the shaft, in particular if the main material of the shaft is a polyolefin.

[0264] In one embodiment, the shaft comprises a foam component which includes the main material of the shaft; in particular, the main material of the shaft is selected from polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, thermoplastic polyurethanes (TPU), polyamides, an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer, and a polyester.

[0265] The shaft can comprise one or more complexes, wherein a complex comprises a textile bonded to the foam component, the textile and the foam component preferably comprising (in particular consisting of) the main material of the shaft, selected from polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, thermoplastic polyurethanes (TPU), polyamides, an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer and a polyester; preferably from polyolefin, for example PP or PE.

[0266] The foam component, which may be bonded to a textile, can be positioned in the rear heel area of ​​the upper to provide comfort, and / or in a medial area of ​​the upper and / or in a lateral area of ​​the upper.

[0267] In one version, the upper and / or the sole each comprise a recycled material from a sole and / or upper of another shoe and / or a recycled material from a sole and / or upper of a boot.

[0268] The recycled material preferably includes the main material of the upper and / or the main material of the sole and / or the auxiliary material(s) of the upper and / or the sole.

[0269] The other shoe can be a shoe according to the invention.

[0270] In one embodiment, the mass of the main material of the shaft and, if applicable, the mass of the auxiliary material or materials of the shaft is at least 40%, preferably at least 50%, of the total mass of the shaft.

[0271] In one variant, the ratio of the mass of the main material of the shaft and the mass of the auxiliary material or materials of the shaft to the total mass of the shaft is at least 50%, and the main material of the shaft and the auxiliary material(s) of the shaft are selected from polyolefins and thermoplastic olefin elastomers.

[0272] In one design variant, the main material of the sole covers at least part of the upper, in particular the main material of the upper.

[0273] Preferably, the main material of the sole extends substantially to the forefoot area and / or the rearfoot area and / or the medial area and / or the lateral area of ​​the shaft.

[0274] In one embodiment, the main material of the sole is connected to the upper, particularly to the main material of the upper, without any intermediate connecting elements, such as adhesive or seams. In another embodiment, the mass of the main material of the sole, and optionally the mass of the auxiliary material(s) of the sole, is at least 40%, preferably at least 50%, of the total mass of the sole.

[0275] In one embodiment, the ratio of the mass of the main material of the sole and the mass of the auxiliary material(s) of the sole to the total mass of the sole is at least 50%, and the main material of the sole and the auxiliary material(s) of the sole are selected from polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, thermoplastic polyurethanes (TPU), polyamides, an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer and a polyester.

[0276] In one version, the shoe article, in particular the shoe, in particular the sports shoe, or also the upper and / or the sole of the shoe article, in particular the shoe, (in particular each) - at most 10% of the mass of a contaminating material or several contaminating materials not consisting of polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, thermoplastic polyurethanes (TPU), polyamides, an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer and a polyester, - in particular, a maximum of 10% of the mass of a thermoplastic contaminating material or several thermoplastic contaminating materials and / or a maximum of 5% of the mass of a thermoset contaminating material or several thermoset contaminating materials.

[0277] For example, if the contaminating material(s) consists of thermoplastic contaminant material, the mass fraction of the contaminating materials in the shoe is at most 10%.

[0278] If, for example, the shoe contains 5% of its mass of one or more thermosetting contaminating materials, the shoe may still contain at least 5% of its mass of one or more thermoplastic contaminating materials.

[0279] In one version, the shoe article, in particular the shoe, in particular the sports shoe, or also the upper and / or the sole of the shoe article, in particular the shoe, (in particular each) - one or more contaminating material(s).

[0280] In one version, the shoe article, in particular the shoe, in particular the sports shoe, or also the upper and / or the sole of the shoe article, in particular the shoe, (each) comprises: - at most 10% of the mass containing one or more contaminating materials, - in particular, a maximum of 10% of the mass of one or more thermoplastic contaminating materials and / or a maximum of 5% of the mass of one or more thermally curable contaminating materials.

[0281] In this text, a thermosetting material, and in particular a contaminating thermosetting material, is understood to mean any material that does not have a transformation temperature through a process for shaping plastics, for example by injection molding, extrusion blow molding, hot pressing (thermocompression) or extrusion spinning.

[0282] In this text, thermoplastic material, and in particular thermoplastic contaminating material, refers to any material that has a transformation temperature through a process for shaping plastics, for example by injection molding, blow molding, hot pressing or extrusion.

[0283] The inventors have advantageously determined that the proportion of thermoplastic or thermoset contaminants in shoe articles must not exceed certain proportions so that they can be recycled without separating their various components and the final recycled material exhibits satisfactory mechanical properties in many new applications.

[0284] One non-exhaustive explanation, particularly for thermoset contamination, is that the contaminating material(s) are arranged as nodules in the thermoplastic matrix consisting of the main materials and, where applicable, the auxiliary materials, the upper and the sole.

[0285] Furthermore, the inventors discovered that the properties of the polymer mixture from a shoe article can be surprisingly improved by a contaminating material.

[0286] In particular, the abrasion resistance of the compound is surprisingly improved when the shoe contains one or more contaminating materials made of polyurethane or polyamide, especially when their mass fraction in the shoe is at most 10% (see table in the attached document). Fig. 5) When the proportion exceeds 10%, it was observed that abrasion resistance decreases.

[0287] The mass fraction of contaminating material in the shoe article is then preferably at least 0.5%, more preferably at least 1%.

[0288] In one embodiment, the shoe article, in particular the shoe, in particular the sports shoe, or also the upper and / or the sole of the shoe article, in particular the shoe, (in particular each) comprises a foam made of a contaminating material.

[0289] In one embodiment, the sole or upper comprises a foam made of a contaminating material, which constitutes at least 30 vol.%, preferably at least 40 vol.%, more preferably at least 50 vol.%, preferably at least 60 or 70 vol.% of the sole or upper.

[0290] In one embodiment, the foam made of a contaminating material constitutes at most 10% of the mass of the shoe article, in particular the shoe, if the contaminating material is thermoplastic, and / or at most 5% of the mass of the shoe article, in particular the shoe, if the contaminating material is thermoplastic.

[0291] The foam can be block-foamed or can consist of expanded particles agglomerated together.

[0292] For example, the density of a polyurethane foam is between 0.040 kg / liter and 0.4 kg / liter, for example on the order of 0.055 kg / liter, while the density of a thermoplastic styrene elastomer such as SEBS is greater than or equal to 0.80 kg / liter.

[0293] In a specific embodiment geared towards polyester, the invention relates to a shoe article, in particular a shoe, more precisely a sports shoe, which advantageously comprises, advantageously consists essentially of, or even more advantageously consists of: - a shaft, wherein a large part of the shaft or a large part of the surface of the shaft consists of a main material of the shaft, the shaft optionally comprising one or more auxiliary materials of the shaft; - a sole, wherein a large part of the mass of the sole consists of a main material of the sole, and the sole may optionally include one or more auxiliary materials of the sole; and characterized in that the main material of the shaft and, where applicable, the auxiliary material(s) of the shaft are selected from polyesters and materials chemically compatible with polyesters; and characterized in that the main material of the sole and, where applicable, the auxiliary material(s) of the sole are selected from polyesters and materials that are chemically compatible with polyesters.

[0294] The main material of the shaft may include at least one of the following materials: a thermoplastic copolyester, polyethylene terephthalate.

[0295] The thermoplastic copolyester can be a block copolymer comprising rigid polyester segments and flexible polyether and / or polyester segments, in particular TPEE or TPC-ET.

[0296] The shaft may include a lower part containing a thermoplastic copolyester that is a block copolymer comprising rigid polyester segments and flexible polyether and / or polyester segments, in particular TPEE or TPC-ET.

[0297] The shaft may include an upper part containing polyethylene terephthalate or a thermoplastic copolyester, which is a block copolymer comprising rigid polyester segments and flexible polyether and / or polyester segments, for example TPEE.

[0298] The upper part can consist of an upper layer of polyethylene terephthalate, a lower layer of polyethylene terephthalate, a middle layer of thermoplastic copolymer, and be surrounded on the top and bottom by an adhesive interlayer. An upper interlayer is positioned between the middle layer and the upper layer, and a lower interlayer is positioned between the middle layer and the lower layer. The adhesive interlayers serve to bond the different layers together. The adhesive interlayer can be made of polyethylene terephthalate.

[0299] The upper may include a shoelace made of polyethylene terephthalate.

[0300] The shaft may have eyelets for lacing, for example, in the form of a thread sewn onto the shaft. The eyelets may be made of polyethylene terephthalate.

[0301] The shaft may have an upper reinforcement made of non-woven polyethylene terephthalate.

[0302] The shaft may include a tongue made of non-woven polyethylene terephthalate.

[0303] The shoe may have a reinforcing ring made of thermoplastic copolyester on the back of the shoe and over a midsole.

[0304] The main material of the sole may include at least one of the following materials: a thermoplastic copolyester, a thermoplastic elastomer of the thermoplastic vulcanized poly (TPV) type, comprising a soft phase and a thermoplastic phase made of thermoplastic copolyester.

[0305] The thermoplastic elastomer of the thermoplastic vulcanizate (TPV) type can comprise a soft poly(styrene / butadiene) phase and a thermoplastic phase consisting of a block copolymer with rigid polyester segments and soft polyether and / or polyester segments. The thermoplastic phase can therefore be TPEE.

[0306] The sole may include a midsole comprising a block copolymer with rigid polyester segments and soft polyether and / or polyester segments, in particular TPEE or TPC-ET.

[0307] The sole may include an outsole comprising a thermoplastic vulcanizate (TPV) with a soft poly(styrene / butadiene) phase and a thermoplastic block copolymer phase with rigid polyester segments and soft polyether segments, in particular a thermoplastic TPEE phase.

[0308] Alternatively, the sole can include a rubber outsole. In this case, the outsole is advantageously attached to the midsole using a special adhesive pretreatment, which allows the outsole to be easily removed when heated for recycling the shoe.

[0309] Finally, in this embodiment, which uses polyester as the main material, the shoe article may include an insole containing a block copolymer with rigid polyester segments and flexible polyether and / or polyester segments, in particular TPEE or TPC-ET.

[0310] Sometimes it is necessary to use certain materials to give the shoe item special functions, especially if it is a sports shoe.

[0311] The embodiments and versions according to a first aspect of the invention can be combined independently of one another.

[0312] The injected sole can be an outsole, a midsole, or a combination of both.

[0313] In a first embodiment, the sole is injection-molded directly onto the upper. Preferably, the upper is arranged on a foot-shaped preform, and then the sole is injection-molded onto the lower part of the upper. The lower part of the upper can be an assembly device in conjunction with the lower edges of the upper (e.g., when the upper is three-dimensionally formed by means of welds and / or seams to cover the foot) and / or the textile sole portion of a textile upper component.

[0314] The textile upper component can be a flat textile component that is shaped three-dimensionally to form an inner shoe that accommodates the foot, for example by sewing / welding.

[0315] The textile upper component can be a knitted sock with an integrated knitted sole part, in particular thermally welded or thermally compressed.

[0316] Preferably, the connection between the upper and the sole is made without adhesive.

[0317] The main and / or auxiliary materials for the sole and upper selected in the present invention enable the production of a sole by direct injection molding onto an upper without adhesion problems, thereby simplifying the process and reducing the number of different materials used.

[0318] Preferably, the main material for the sole is selected from polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, thermoplastic polyurethanes (TPU), polyamides, an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer and a polyester.

[0319] The plaintiff has found that this main material of the sole exhibits very good adhesion to the main material of the upper, especially when it is a polyolefin or a thermoplastic olefin elastomer.

[0320] The mixture injected to manufacture the sole may contain, in addition to the main material of the sole, a plasticizer and / or a filler (e.g. calcium carbonate) and / or one or more blowing agents (e.g. in the case of the midsole).

[0321] The plasticizer can be selected from mineral oils and / or naphthenic or paraffinic oils.

[0322] The sole injected onto the upper can be an outsole or a midsole. In the latter case, at least one blowing agent is used in a mixture with the main material of the sole.

[0323] In one variant, the method comprises a step for treating at least a part of the surface of the sole, in particular the outsole and / or the midsole, and / or at least a part of the surface of the upper, in particular the surface of one or more textile components, in order to improve the adhesion of the sole to the upper and / or the outsole to the midsole and / or a functional component (e.g. a lateral reinforcement, a hard toe cap or a heel cap) to the textile component(s) of the upper.

[0324] The treatment step mentioned includes a light abrasion step (in English referred to in particular as "buffing treatment") and / or a plasma treatment step and / or a flame treatment step and / or a corona treatment step.

[0325] This step makes it possible to join two components together, possibly without adhesive. This avoids adding material that could act as a contaminant in subsequent recycling processes.

[0326] In one variant, the main material of the sole and, if applicable, the auxiliary material(s) of the sole are derived at least partially from the recycling of at least one other shoe or at least one boot, in particular from at least one shoe article according to one of the embodiments or configurations according to the first aspect of the invention.

[0327] In one variant, the method comprises a step of foaming a foam component, comprising the main material of the sole or at least an auxiliary material of the sole, onto the sole injected in a softened state in order to bond the foam component at least partially to the sole, in particular without adhesive.

[0328] Two-component injection molding can be carried out as described above.

[0329] The bond between the foam component and the sole is created when the injected sole is in a softened state, i.e., before it has cooled to room temperature.

[0330] In a further aspect, the present invention relates to a method for recycling at least one shoe article, in particular a shoe, comprising collecting at least one shoe article, in particular a shoe, according to any of the variants and embodiments according to a first aspect of the invention or obtained by applying the manufacturing method according to any of the variants and embodiments according to a second aspect of the invention, and converting the at least one shoe article, in particular the shoe, into thermoplastic granules.

[0331] The collected shoe item, especially the shoe itself, is first shredded to obtain fragments with a size of at least 1 mm to 40 mm. These fragments are then conveyed to an extrusion granulation machine to produce thermoplastic granules. They may be pre-washed to remove dust.

[0332] In this text, thermoplastic granules are understood to be all granules that have a hot forming temperature due to a process for shaping plastics, for example by injection molding, blow molding, hot pressing, extrusion, spinning or injection molding with supercritical fluids.

[0333] The thermoplastic granules mentioned above behave like thermoplastic materials when used in a hot processing process, even if they contain one or more thermosetting materials, but in small quantities so as not to impair their processability as thermoplastics.

[0334] Preferably, the extrusion granulation device is a twin-screw extruder or includes one. Advantageously, this type of extruder allows for better mixing of the granulated material.

[0335] Advantageously, it is not necessary to separate the various components of the shoe article, especially the shoe, as they are compatible with each other for use in processes for processing thermoplastic materials.

[0336] In one version, the processing step includes, in particular, the following order: - a step of crushing the shoe article, in particular the at least one shoe (especially a sports shoe), to obtain crushed particles; - a step of compacting the crushed particles to obtain crushed and compacted particles, especially by cold or hot compaction, - an extrusion granulation step of the crushed and compacted particles to obtain granules that can be processed by a hot processing method for plastic(s).

[0337] Advantageously, the compaction step allows the air to be removed from the foamed and / or hollow recycled materials.

[0338] Preferably, the compaction step is carried out by heating the crushed particles, in particular to a temperature of at least 60 °C and at most 110 °C, for example on the order of 70 °C ± 10 °C.

[0339] In one variant, the recycling process includes a step of hot conversion of at least a portion of the thermoplastic granules to produce a plastic part, which in particular forms at least a portion of an object for practicing a sport.

[0340] In this text, a plastic part that at least partially forms an object for the practice of a sport is understood to mean that the part can form only a part or essentially the entirety of a sporting goods item.

[0341] The plastic part contains one or more recycled materials, in particular from recycled thermoplastic granules selected from polyolefins, thermoplastic olefin elastomers, thermoplastic styrene elastomers and vulcanized thermoplastic elastomers, optionally in mixture with one or more other petroleum-based materials and / or from two sources and / or recycled materials and / or materials not derived from the recycling process according to the invention.

[0342] The plastic part is advantageously a fin blade or a fin that includes a fin blade and a receptacle for the foot.

[0343] The plastic part could be a handle, a zipper end, a wheel, a lamp cover, or even a snorkel end.

[0344] The plastic part is not limited to recycling in a sporting goods product, but can be used in any application where the composition of the recycled shoe product exhibits satisfactory mechanical properties.

[0345] In this text, "plastic" means any material based on the use of one or more (Co)(Ter)polymers processed by a hot process such as extrusion injection molding, extrusion forming, extrusion blow molding, thermocompression or an equivalent technique.

[0346] According to a final aspect of the present invention, the subject matter is a plastic part (in particular a molded part, more precisely a one-piece molded part) which in particular forms at least partially an article for the practice of a sport and can be produced by the recycling process according to any embodiment according to a third aspect of the invention, in particular the part is a fin blade or a fin comprising a fin blade and a foot receptacle.

[0347] In one embodiment, the part is a fin blade or a fin comprising a fin blade and a receptacle for the foot, and the part comprises a material that constitutes the largest mass fraction and is made of polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, thermoplastic polyurethanes (TPU), polyamides, an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer and a polyester, preferably selected from thermoplastic styrene elastomers.

[0348] The term "predominant material" means that the mass fraction of this material is the highest among the materials from which the part is made.

[0349] In one embodiment, the part comprises a mass-predominant material selected from polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, thermoplastic polyurethanes (TPU), polyamides, an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer, and a polyester, the mass fraction of the mass-predominant material in the part being greater than or equal to 10%, preferably greater than or equal to 25%, even more preferably greater than or equal to 35%, preferably greater than or equal to 45%, and in particular greater than or equal to 55%.

[0350] In one embodiment, the mass fraction of the recycled thermoplastic granules in the plastic part is at least 10%, preferably at least 25%, more preferably at least 35%, more preferably at least 45%, in particular at least 55%, optionally at least 80% or 90%.

[0351] In a further embodiment, the part comprises a recycled material consisting of polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, thermoplastic polyurethanes (TPU), polyamides, an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer, and a polyester, preferably selected from thermoplastic styrene elastomers. The mass fraction of the recycled material in the part is less than or equal to 25%, preferably less than or equal to 20%, and even more preferably less than or equal to 15%. In another embodiment, the mass fraction of the recycled thermoplastic granules in the plastic part is less than or equal to 25%, preferably less than or equal to 20%, and even more preferably less than or equal to 15%.

[0352] In one aspect, the invention also relates to a shoe article, for example a shoe, and in particular a shoe article for practicing a sport, which is obtained by the method according to one of the embodiments described above.

[0353] According to a further aspect, the invention relates to a device for manufacturing at least one part of a shoe article, wherein the device comprises a mold defining an open cavity, wherein a mold of at least one part of the cavity corresponds to a mold of a sole of the shoe article, wherein the cavity is configured to receive a mixture comprising a molten material and a supercritical fluid via at least one injection channel opening into the cavity, wherein an edge of an opening of the open cavity is configured to be able to come into contact with a contact area of ​​a surface of at least one part of an upper of the shoe article, such that the surface of the at least one part of the upper ensures a closure of the cavity at the contact point between the contact area and the edge, such that the device is configuredthat it carries out the procedure according to one of the embodiments described above.

[0354] According to one embodiment, the device further comprises a lid configured to be placed on the mold to form a closed volume with the mold, comprising the cavity and a complementary part of the cavity within the closed volume, wherein at least one part of the upper of the shoe article is located within the closed volume, and wherein the complementary part and the cavity are located on both sides of the closure of the cavity at the contact point between the contact area and the edge, and wherein the device is configured to implement the method according to one of the embodiments described above.

[0355] According to one embodiment, the device also includes a holder whose shape corresponds to the shape of a foot, wherein an outer surface of the holder is configured to be covered by at least one part of the upper of the shoe article, wherein at least one part of the surface of the upper covers a part of the outer surface of the holder that corresponds to a sole of the foot.

[0356] For better understanding, an embodiment and / or implementation of the invention is described with reference to the accompanying drawings, which, as a non-limiting example, represent an embodiment or implementation of a device and / or a method according to the invention. Identical reference numerals in the drawings denote similar elements or elements with similar functions. [ Fig. 1] is a perspective view of a one-piece mold, the lid belonging to the mold and a shoe upper mounted on a holder before the upper is placed on the edge of the mold cavity according to an embodiment of the invention. [ Fig. 2] is a perspective view of a three-part mold, the lid belonging to the mold and a shoe upper mounted on a holder before the upper is placed on the edge of the mold cavity according to an embodiment of the invention. [ Fig. Figure 3] is a perspective view of a one-piece mold, the lid belonging to the mold and a part of a shoe upper before the step of placing the upper part on the edge of the mold cavity according to an embodiment of the invention. [ Fig. Figure 4] is a perspective view of the shaft part connected with a sole, which was obtained after implementing the method according to an embodiment of the invention, and of the shoe, which was obtained after implementing an additional step to join the shaft part with another part of the shaft. [ Fig. Figure 5] is a sectional view of a shaft with its holder, which is arranged on the mold before the injection step according to an embodiment of the invention; in this figure, the mold lid is shown before it is attached to the mold. [ Fig. Figure 6] is a sectional view of a shaft with its holder, which is arranged on the mold under a cover that forms a closed pressure chamber with the mold on both sides of the edge of the mold cavity, before the injection step according to the embodiment of the invention. Fig. 5. [ Fig. [7] is a perspective view of a shaft with its holder, which, according to the embodiment of the invention, was taken from the following before the injection step: Fig. 5 and Fig. 6 is placed on the mold; in this figure the lid of the mold is shown before it is placed on the mold [ Fig. Figure 8] is a perspective view of the shoe obtained with the shaft holder after an implementation of the method according to the embodiment of the invention. Fig. 5, Fig. 6 and Fig. 7. [ Fig. Figure 9] is a perspective view of a shaft holder with a seal attached to an area of ​​the holder corresponding to a contact area of ​​the surface of the shaft part, according to the embodiment of the invention as shown in the Fig. 5, Fig. 6, Fig. 7 and Fig. 8. [ Fig.

[10] is a perspective view of a shaft with an open surface on the part of the shaft that is intended to engage in the foam material of the sole, according to an embodiment of the invention. [ Fig.

[11] is a perspective view of another shaft with a closed surface on the part of the shaft that is intended to engage in the foamed material of the sole, obtained according to an embodiment of the invention. [ Fig.

[12] is a perspective view of a further shaft with a perforated surface on the part of the shaft that is to be incorporated into the foamed material of the sole obtained according to an embodiment of the invention. [ Fig.

[13] is a perspective view of a further shaft with a perforated or structured surface near the connection area on the part of the shaft that is intended to be received into the foamed material of the sole, which was manufactured according to an embodiment of the invention. [ Fig.

[14] is a sectional view of a shaft with its holder, which is arranged on a mold with multiple injection channels before the injection step according to an embodiment of the invention. [ Fig.

[15] is a sectional view of a shaft with its holder placed on the mold, before the injection step, according to an embodiment of the invention in which an injection channel passes through the holder of the shaft. [ Fig.

[16] is a perspective view of inserts configured to be inserted into the cavity of the mold in order to be connected to the sole obtained after overmolding with the foam, according to an embodiment of the invention. [ Fig.

[17] is a sectional view of a shaft with its holder, which is placed on the mold prior to the injection step, wherein the inserts are placed into the cavity of the mold to be embedded in the foamed material that forms the sole, according to an embodiment of the invention. [ Fig.

[18] is a sectional view of a shaft with its holder, which is placed on the mold after the injection process, wherein the inserts are placed in the cavity of the mold and embedded in the foamed material that forms the sole, according to an embodiment of the invention. [ Fig.

[19] is a diagram showing the sequence of process steps according to one embodiment of the invention. [ Fig. Figure 20 shows schematically in perspective a first example of a shoe that can be manufactured by a method according to the invention. [ Fig. 21] shows the shoe made of Fig. 20 according to the in Fig. 20 longitudinal section II-II shown. [ Fig. Figure 22 shows schematically in perspective a second example of a shoe that can be manufactured by a method according to the invention. [ Fig. Figure 23 shows schematically in perspective a third example of a shoe that can be manufactured by a method according to the invention. [ Fig.

[24] is a detailed sectional view of the shoe made of Fig. 23. [ Fig. 25] is a schematic representation of a contact surface of an insert, wherein the contact surface has a texture with tubular or cylindrical patterns. [ Fig.

[26] is a schematic representation of a contact surface of an insert, wherein the contact surface has a texture with linear patterns. [ Fig. 27] is a schematic representation of a contact surface of an insert, wherein the contact surface has a texture with tubular or cylindrical patterns in the center of the surface and a linear pattern at the edge of the surface. [ Fig.

[28] is a perspective representation of a shape according to an exemplary embodiment. [ Fig. 29] is a sectional view of the shape according to the embodiment shown in Fig. 28. [ Fig. Figure 30] is a sectional view of the steps of closing and opening the mold according to the embodiment shown in Fig. 28. [ Fig.

[31] is a sectional view of the closing and opening phases of a mold variant according to the embodiment in Fig. 28. [ Fig.

[32] is a sectional view of a shaft with its holder, which is arranged on the mold under a cover that, together with the mold, forms a pressure chamber closed on both sides of the edge of the mold cavity, with a pressure channel for the supplementary cavity, according to the Fig. 6 illustrated embodiment of the invention. [ Fig.

[33] is a sectional view of a shaft with its holder, which is arranged on the mold under a cover that forms a closed pressure chamber with the mold on both sides of the edge of the mold cavity, with a pressure channel for the cavity and the complementary cavity, according to the Fig. 6 illustrated embodiment of the invention. [ Fig.

[34] is a sectional view of a shaft with its holder, which is arranged on the mold under a cover that forms a closed pressure chamber with the mold on both sides of the edge of the mold cavity, with several pressure channels for the cavity that correspond to the through-holes of an insert at the level of the outer sole, according to the in Fig. 6 illustrated embodiment of the invention.

[0357] Referring to Fig. 19 The invention relates to a method 100 for manufacturing at least one part of a shoe article, for example a shoe 10, as illustrated in the Fig. 4 or Fig. 8, using an injection step 107 into a cavity 2 of a mold 1 of a supercritical mixture comprising a molten thermoplastic material and a gas in a supercritical state to foam the thermoplastic material to obtain satisfactory properties of a foamed material forming a lightweight and cushioning sole 3 of the shoe 10; in particular, the Fig. 4 or Fig. 8 the part of the shoe 10 obtained according to method 100, wherein part 9 of the upper is embedded in the foamed material of the sole 3. To achieve this result, the cavity 2 has at least a partial shape corresponding to the desired final shape of the foamed sole 3; this is particularly evident in the Fig. 3 and Fig. Figure 5 illustrates this. For example, the dimensions of the cavity shape correspond to the dimensions of the sole of the shoe article on a scale between 1:0.98 and 1:1.02, preferably 1:1.

[0358] To foam the molten thermoplastic material and obtain the foamed material that forms the sole 3, the method consists of pressurizing the cavity 2 of the mold 1, in particular by injecting a gas into the cavity 2 before the supercritical mixture is injected into the cavity 2, and subsequently depressurizing the cavity 2 to trigger an expansion and foaming process of the thermoplastic mixture in the cavity 2 to obtain the foam material of the sole 3.

[0359] In order for part 9 of the upper of the shoe 10 to be embedded in the foamed material of the sole 3, part 9 of the upper is inserted in a suitable manner into the cavity 2 of the mold; for this purpose, the cavity 2 comprises, as shown in the Fig. 3 and Fig. As shown in Figure 5, the cavity 2 includes an opening with an edge 5, on which an area 6, the so-called contact area 6, is placed, a surface 7 of the shaft part 9, so that the surface 7 of the shaft part 9 ensures a closure of the cavity at the contact point between the contact area 6 and the edge 5.

[0360] In order to pressurize the cavity 2 of the form 1, particularly by injecting a gas into the cavity 2, it is essential to ensure sufficient gas tightness of the closure of the cavity 2 at the contact point between the contact area 6 and the edge 5. Since the thickness of the shaft is variable and the shaft can assume complex shapes with significant dimensional tolerances, achieving the desired tightness can be difficult. A particularly advantageous solution can be the use of counter-pressure in the area of ​​the shaft 9 that does not extend into the cavity 2, i.e., in the area of ​​the shaft located on the opposite side of the closure from the cavity 2. This is especially relevant in... Fig. 5, the part of the shaft 9 immersed in the cavity 2 is located in the lower part of the figure, and the part of the shaft 9 not immersed in the cavity is located above the straight line that connects the two with reference numerals 5, 6 in the Fig. 5 and Fig. are labelled 6.

[0361] If, therefore, the pressurization of the cavity 2 is accompanied by the simultaneous generation of a counter-pressure, which is advantageously identical to the pressurization pressure of the cavity 2 in the area of ​​the shaft 9 which is not immersed in the cavity 2, i.e. in the area of ​​the shaft which is on the other side of the closure with respect to the cavity 2, the counter-pressure prevents the pressurized gas from escaping from the cavity at the contact point between the contact area and the edge.

[0362] To generate the back pressure, the method 100 comprises, prior to the step of injecting 107 of the supercritical mixture into the cavity 2 of the mold 1, for example a step of placing 103 a lid 13 on the mold 1 to form a closed volume with the mold 1, which forms the cavity 2 and a complementary part 14 of the cavity 2 in the closed volume, wherein the complementary part 14 and the cavity 2 are located on both sides of the closure of the cavity 2 at the level of the contact between the contact area 6 and the edge 5. Fig. Figure 6 shows in particular the cover 13, which is placed on the mold 1 to form the closed volume that comprises, on the one hand, the cavity 2 and, on the other hand, the complementary volume 14; the surface 7 of the part of the shaft 9 that is to be incorporated into the foamed material of the sole 3 is located within the cavity 2 of the mold 1, and the surface of the other part of the shaft is located within the complementary part 14 of the cavity 2 in the closed volume formed by the cover 1 placed on the mold 1. Fig. Figure 5 shows the lid 13 of form 1 over its corresponding form, but the person skilled in the art will understand that the method works just as well with a form 1 over the lid 13, as exemplified in Figure 5. Fig. 1 is shown in perspective. As in the Fig. 5 and Fig. As shown in Figure 6, seals 15 can also be fitted at a contact point between the lid 13 and the mold 1 to ensure adequate sealing of the enclosed space formed by the lid 13 and the mold 1.

[0363] The complementary part 14 is pressurized, for example by injecting a gas into the complementary part 14 at a pressure similar to the pressure in the cavity 2, so that leaks in region 6 and at edge 5 do not allow pressurized gas to escape between the cavity 2 and the complementary part 14, with the pressure in the complementary part 14 acting as a counter-pressure to the pressure in the cavity 2. The injection 107 of the supercritical mixture into the cavity 2 can then take place, for example, via an injection channel 4 that passes through the shape 1, as shown in Fig. 6 shown.

[0364] The injection of the pressurized gas takes place via one or more pressure channels 119, 119 bis, which differ from the injection channel(s) 4 for the mixture, as shown in the Fig. 32 and Fig. Figure 33 shows that, in particular, a pressure channel 119 can be used to pressurize the cavity 2 and an additional pressure channel 119 can be used to pressurize the additional cavity 14, as shown in Fig. 33 shown.

[0365] According to one embodiment, the cover 13 is configured such that it forms a closed, in particular gas-tight, volume around at least one part of the shaft 9 with the shape 1 in order to enable the generation of the said back pressure within this closed, tight volume, in particular by receiving the pressurized gas of the cavity 2 in this tight volume, in order to prevent the escape of pressurized gas from the cavity at the contact point between the contact area and the edge.

[0366] Advantageously, the area of ​​at least one part of the shaft 9 on the other side of the closure with respect to the cavity 2 can be pressure relieved simultaneously with the pressure relief of the cavity 2 of the shape 1 in order to trigger an expansion of the mixture in the cavity 2 and to form the sole during the inventive method 100.

[0367] For example, the pressure for creating a vacuum in the cavity is between 3 bar and 50 bar, preferably between 10 bar and 30 bar, preferably at 15 bar.

[0368] With reference to Fig. 19 we describe the complete sequence of steps of the process 100 for manufacturing a shoe 10 according to an embodiment which thus comprises the following steps: - Providing a mold 1 that defines an open cavity 2, wherein a mold of at least part of the cavity 2 corresponds to a mold of a sole 3 of the shoe 10, wherein the cavity 2 is configured to receive a mixture of a melt and a supercritical fluid via at least one injection channel 4 opening into the cavity 2; - Attaching 105 an edge 5 of an opening of the open cavity 2 in contact with a contact area 6 of a surface 7 of at least a part of a shaft 9 of the shoe 10, such that the surface 7 of the at least part of the shaft 9 ensures a closure of the cavity at the contact point between the contact area 6 and the edge 5; - Applying negative pressure 105 bis to the cavity 2, in particular by injecting a gas into the cavity 2; - Injecting 107 of the mixture into cavity 2; - Pressure relief 108 of the cavity 2 of the mold, in particular by releasing the gas from the cavity 2, in order to trigger an expansion of the mixture in the cavity 2 and to form the sole 3 from a foamed material resulting from the expansion of the mixture, wherein at least a part of the surface 7 of the at least a part 9 of the shaft is enclosed in the foamed material of the sole 3.

[0369] Through these measures, the process makes it possible to obtain in a single injection step 107 a light and cushioning sole of the shoe 10 which is connected to part of an upper 9 of the shoe 10, wherein the sole 3 and the upper 9 have good peel resistance.

[0370] Pressurization in cavity 2, followed by pressure release in cavity 2, allows the mixture to expand and produces the lightweight and cushioning foam material of the sole. Pressure build-up in the supplementary part 14 of the closed volume ensures the tightness, particularly against gas, of the seal of cavity 2 at the contact point between contact area 6 and edge 5.

[0371] The molten material is, for example, a thermoplastic elastomer polymer.

[0372] According to one application example, the thermoplastic polymer is a thermoplastic polyurethane (TPU), an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), a polyolefin, an ether-ester block copolymer, a styrene-based elastomer, or a mixture of these different components.

[0373] The supercritical fluid is, for example, nitrogen in a supercritical state, carbon dioxide in a supercritical state, or a mixture of nitrogen and carbon dioxide in a supercritical state.

[0374] The density of the finally obtained sole 3 is between 0.1 g / cm³. 3 and 0.4 g / cm² 3 , preferably between 0.15 g / cm³ 3 and 0.25 g / cm² 3 .

[0375] Furthermore, the part of the upper 9 that is embedded in the foamed material of the sole 3 enables a peel strength of more than 2.5 N / mm, measured according to the standard ISO NF EN 1392.

[0376] In particular, step 105 up to the point of applying negative pressure to cavity 2 may, for example, include the following step: - Attaching 103 to a cover 13 on the form 1, so that a closed volume is formed with the form 1, which includes the cavity 2 and a complementary part 14 of the cavity 2 in the closed volume, wherein at least one part of the shaft 9 is located inside the closed volume, wherein the complementary part 14 and the cavity 2 are located on both sides of the closure of the cavity 2 at the level of the contact between the contact area 6 and the edge 5.

[0377] A pressure in the complementary part 14 of the closed volume prevents pressurized gas from escaping from the cavity 2 at the contact point between the contact area 6 and the edge 5.

[0378] According to a Fig. In the application example shown in Figure 3, part 9 of the shaft is placed directly onto the edge 5 of the opening of the cavity 2 of the shape 1, without the use of a holder 8 to hold the shaft.

[0379] In particular, the method may include an additional step for assembling the part of the upper 9 that is connected to the sole 3 and obtained after the pressure relief step with another part 9' of the upper, the assembly forming the shoe 10, as shown in Fig. 4 shown. For example, the assembly step may include sewing the other part 9' of the upper to the part 9 of the upper that is connected to the sole 3.

[0380] According to a further embodiment, which is described in the Fig. 5 and Fig. As shown in Figure 6, the part 9 of the shaft is first placed on a base 8 such that it at least partially covers an outer surface of the base 8, the base 8 having a shape corresponding to a foot shape; a part of the surface 7 of the shaft part 9, which is to be incorporated into the foam material of the sole 3, covers a part of the outer surface of the support 8, which corresponds to a foot sole.During step 105 of placing part of the shaft 9 onto the edge 5 of the recess 2, part of the shaft 9 is thus placed onto the edge 5 of the recess 2 together with the holder 8, so that after placing the cover 13 onto the mold 1 in step 103, the closed volume additionally includes the holder 8 with part of the shaft 9; the surface 7 of part of the shaft 9, which is to engage in the foamed material of the sole 3, is located within the cavity 2 of the mold 1 with a corresponding part of the holder 8, and the surface of the other part of the shaft 9, with another corresponding part of the holder 8, is located within the complementary part 14 of the cavity 2 in the closed volume formed by the cover 13 placed on the mold 1.

[0381] The shaft 9, for example, can be a complete shaft, as in Fig. 7 shown.

[0382] The bracket 8 can be made of, for example, aluminum, steel or plastic.

[0383] Thus, the process 100 makes it possible to obtain a complete shoe 10 in a single injection step 107, comprising a sole 3 of the shoe connected to a complete upper 9 of the shoe 10, as shown in Fig. 8 shown.

[0384] Form 1 consists of a single part, or form 1 comprises several parts 1', 1'', 1''', as in Fig. 2 shown, and the step of providing 103 of the mold 1 includes a step of assembling the various parts 1', 1'', 1'' to form the mold 1. For example, the multi-part mold 1', 1'', 1''' may comprise a mold base 1''' and two halves 1', 1'' of an annular part of the mold, as shown in Fig. 2 shown; the two halves 1', 1'' are configured to form a ring when assembled, the ring being configured to form the edge 5 of the cavity 2 when placed on the base 1''' of the mold 1, the edge 5 then being configured to receive the contact area 6 of the shaft part 9. Furthermore, as shown in the Fig. 5 and Fig. As shown in Figure 6, one or more seals 15' may also be fitted at a contact point between the different parts 1', 1'', 1''' of the mold to ensure adequate sealing of the mold 1.

[0385] According to one embodiment of the form, which is described in the Fig. As shown in Figures 28 to 31, the mold comprises a mold base 1''' and two halves 1', 1'' of an annular part of the mold, similar to the mold in Fig. 2; It should be noted that in Fig. 28 the base of the mold 1''' lies over the two halves 1' and 1'' of the ring-shaped part, while in Fig. 2 the base of the mold is underneath; the person skilled in the art will understand that this difference in the representation is not significant. As in Fig. 2 the two halves 1' and 1'' of the ring-shaped part are configured to form a ring when joined, this ring being configured to form the edge 5 of the cavity 2 when placed on the mold base 1'', the edge 5 then being configured to accommodate the contact area 6 of the shaft part 9.

[0386] According to the specific embodiment in Fig. 28 The mold base 1'' comprises two separate parts, a cover 115 and a bell 114, the bell 114 being configured to enclose all parts, including the cover 115 and the two halves 1', 1'' of the annular part, when the mold is closed. In particular, the two halves 1', 1'' of the annular part of the mold are configured to be mechanically actuated to be displaced relative to each other by sliding in a displacement direction, with a first half 1' moving in a direction D' of the sliding direction and the second half 1'' moving in an opposite direction D'' of the sliding direction, such that the two halves 1', 1'' of the ring move away from each other, as shown in the Fig. 30c or Fig. 31c shown, or approach each other, as in the Fig. 30a or Fig. 31a shown, depending on whether the sliding movement of the two halves is in a first direction, shown in the Fig. 30c or Fig. 31c, or in a second direction, shown in the Fig. 30a or Fig. 31a, occurs; thus the ring of the form closes when the two halves 1', 1'' are actuated to bring them closer together, and conversely, the ring of the form opens when the two halves 1', 1'' are actuated to move away from each other.

[0387] In particular, a contact surface between the bell 114 of the mold base 1''' and each of the two halves 1', 1'' of the ring is configured such that the sliding movement of the two halves in the direction of separation of the two halves 1', 1'' of the ring causes a movement of the bell 114 of the mold base 1''' in a direction D''' transverse to the sliding direction, so that the bell 114, which is initially in contact with the closed ring, which is in contact through its two adjacent halves 1', 1'', moves away from the ring as its two halves 1', 1'' move apart. Conversely, when the bell 114 of the mold base 1''' moves closer together in direction D''' transverse to the sliding direction towards the two halves 1', 1'' of the ring, the pressure P exerted by the bell 114 on the two halves 1', 1'' at the contact point, as described in the Fig. 30b and Fig. Figure 31b shows a sliding movement of the two halves 1', 1'' to close the ring. An elastic element 118 can be provided so that the two halves 1', 1'' of the ring move away from each other when the bell 114 of the mold base 1'' is moved away from the ring in direction D'' transversely to the sliding direction.

[0388] For this purpose, the contact surface between the bell 114 of the mold base 1'' and each of the two halves 1', 1'' of the ring comprises a first contact surface 114' between the bell 114 of the mold base 1'' and the first half 1' of the ring, wherein the first contact surface 114' is inclined at a first angle with respect to the sliding direction, and a second contact surface 114'' between the bell 114 of the mold base 1''' and the second half 1'' of the ring, wherein the second contact surface 114'' is inclined at a second angle with respect to the sliding direction, the second angle having the opposite sign to the first angle.The first contact surface 114' is configured to slide into contact with a corresponding first contact surface 116' of a wall of the first half 1' of the ring, and the second contact surface 114'' is configured to slide into contact with a corresponding second contact surface 116' of a wall of the second half 1'' of the ring.

[0389] According to one variant of the in the Fig. 28 to 30 illustrated embodiment, wherein this variant in Fig. As shown in Figure 31, the contact interface between the bell 114 of the mold base 1''' and each of the two halves 1', 1'' of the ring includes at least one guide 117', 117'' configured to accompany the sliding movement of the two parts 1' and 1'' of the ring when the bell 114 of the mold base 1''' moves transversely to the sliding direction.

[0390] According to these measures, the mold can be alternately actuated to close by a movement of the mold base 1'' in the transverse direction D'' to the sliding direction, and to open by a sliding movement of the two halves 1', 1''' to open the ring. The movement of the mold base 1''' to close can be achieved, for example, by pressure exerted on the mold base 1''' in the direction of the ring; the sliding movement of the two halves 1', 1''' to open can be achieved, for example, by an elastic device.

[0391] In order to enable the execution of injection step 107, the cavity 2 of the mold is configured so that it can receive the mixture of a melt and a supercritical liquid via at least one injection channel 4, 4', 4'', 4''' opening into the cavity 2.

[0392] For example, the shape can include an injection channel 4 that opens into the cavity 2, as in Fig. Figure 6 shows that, in another example, the injection channel 4 opening into the cavity 2 can pass through the holder 8 of the shaft 9, as shown in Figure 6. Fig. 15 shown.

[0393] In another example, the cavity 2 is configured such that it can receive the mixture via at least two injection channels 4', 4'', 4''' opening into the cavity 2, as in Fig. Figure 14 shows three injection channels 4', 4'', 4'''' as examples. In this way, the method 100 enables faster and more uniform filling of the mold cavity and thus the production of a sole 3 of the shoe 10, which is connected to a part of the upper 9 of the shoe 10.

[0394] To improve the strength of the bond between the upper 9 and the sole 3, an additional step for bonding 106 of the surface 7 portion of the upper 9 can be provided, wherein the bonding step 106 is performed before the injection step 107. Alternatively, or in combination with the bonding process 106, the surface 7 portion of the upper 9 can contain hot-melt filaments configured to melt at the injection temperature of the mixture. This enhances the peel strength of the sole and upper.

[0395] According to one embodiment of the method, the part of the surface 7 of the shaft part 9, which is to be incorporated into the foam material of the sole 3, is solid, as shown in Fig. Figure 11 shows that to increase the peel resistance, it is also possible to provide holes in the part of the surface 7 of the shaft part 9 that is to engage with the foamed material of the sole 3, i.e., the part of the surface 7 has holes, as shown in Fig. 12 or in Fig. 3 shown, where, for example, 3 holes penetrate part of surface 7 of part of shaft 9; it is also possible that part of surface 7 is at least partially open, as in Fig. Figure 10 shows, for example, that part of surface 7 is almost completely open, except for a portion of surface 7 near the contact area 6. In the figure shown Fig. In the case shown in Figure 3, where three holes traverse part of surface 7 of part of shaft 9 and where the part of shaft 9 that is to engage with the foamed material of the sole 3 is not mounted on a support 8, the cover 13 must ensure the sealing of the holes or openings of part of surface 7 of part of shaft 9 during steps 105 up to the point of pressurizing the cavity 2 and injecting the mixture into the cavity 107. For this purpose, the cover 13 can, for example, be shaped as shown in Fig. 3 shown, with a substantially flat and level inner surface resting on the said part of the surface 7 of the shaft part 9 in order to close the holes or openings on this part of the surface 7 of the shaft part 9.

[0396] Another way to increase peel resistance is to structure or perforate the part of the surface 7 of the upper part 9 that is intended to engage with the foam material of the sole 3 in contact with or near the contact area 6, as shown in Fig. 13 shown.

[0397] To improve the abrasion resistance or stiffness of the sole 3, the method 100 may include the additional steps of providing 104 and positioning 104 to one or more inserts 12, 12', 12'' configured to be positioned in the cavity 2 of the mold 1.

[0398] For example, the or the in Fig. The 16 illustrated insert(s) 12, 12' are positioned so that they are inserted into an outer surface of the sole, as shown in the Fig. 17 and Fig. Figure 18 shows the mixture being injected into cavity 2 both before and after the injection step 107; In another example, one or more inserts 12'' can be positioned so that they are embedded in the insole 3, as shown in the Fig. 17 and Fig. Figure 18 shows the mixture being injected into cavity 2 both before and after injection.

[0399] These measures increase the abrasion resistance of the sole or improve the stiffness of the sole, depending on whether the inserts 12, 12' are used in the direction of an outer section of the sole 3, for example with inserts 12, 12' made of rubber or thermoplastic material, or whether the insert or inserts 12'' are embedded in the sole 3, for example with inserts 12'' made of carbon plates or thermoplastic material.

[0400] According to one embodiment, a 12-inch insert, positioned to be inserted into an outer surface of the sole 3, comprises one or more through holes 120, wherein the through holes 120 correspond to one or more pressure channels 119, as shown in Fig. 34 is shown, so that a pressurized gas can flow through the insert.

[0401] According to one embodiment, a contact surface 112 between the insert and the sole has a special geometry to enhance the adhesion between the insert and the sole by mechanical locking, without the need for adhesive or surface preparation steps. For example, the special geometry of the insert includes a texture of the contact surface, as shown in the Fig. 25, Fig. 26 or Fig. 27 shown.

[0402] The structure comprises, for example, a plurality of patterns formed on the contact surface 112, wherein the plurality of patterns are distributed over the surface with a certain density, such that the plurality of patterns on a part of the contact surface occupies a part of the contact surface section, wherein this part is between 1% and 15%, preferably 6%, of the contact surface section.

[0403] The patterns are preferably distributed uniformly across the contact surface according to the specified density. The pattern distribution can also be denser in specific areas of the contact surface where the loads are higher. In other words, the density of the pattern distribution in a given area of ​​the contact surface can depend on the loads to which that area is subjected.

[0404] The patterns have a height, measured in a direction perpendicular to the contact surface, wherein this height is between 1 mm and 10 mm, preferably 1.6 mm.

[0405] The patterns have a thickness, measured in a direction perpendicular to the vertical direction, where the thickness is between 1 mm and 2 mm, preferably 1.6 mm. The thickness is a diameter or a width, depending on whether the patterns are tubular or cylindrical, as shown in Fig. 25 shown, or linearly, as in Fig. 26 shown.

[0406] The texture can include tubular or cylindrical patterns in the center of the contact surface and a linear pattern at one edge of the contact surface, as shown in Fig. 27 shown to prevent detachment.

[0407] The linear pattern at the edge may be a burr that forms at a parting line of a closure of a mold for overmolding the insert, thus avoiding the need to remove the burr.

[0408] According to one aspect, the invention also relates to a shoe article, for example a shoe 10, which is manufactured by the method 100 according to one of the embodiments described above.

[0409] According to another aspect, the invention also relates to a device comprising a shape 1 and optionally a lid 13 and optionally a holder 8, configured to perform the method 100 according to one of the embodiments described above.

[0410] According to one embodiment, the device comprises a shape 1 defining an open cavity 2, wherein the shape of at least a part of the cavity 2 corresponds to a shape of a sole 3 of the shoe 10, wherein the cavity 2 is configured to receive a mixture comprising a molten material and a supercritical fluid via at least one channel 4, 4', 4'' 4''' opening into the cavity 2, wherein an edge 5 of an opening of the open cavity 2 is configured to allow it to come into contact with a contact area 6 of a surface 7 of at least a part of a shaft 9 of the shoe 10, such that the surface 7 of the at least part of the shaft 9 ensures a closure of the cavity at the contact point between the contact area 6 and the edge 5, so that the device is thus configured to carry out the manufacturing process 100 according to one of the embodiments described above.

[0411] According to a supplementary embodiment, the device further comprises a lid 13 configured to be placed on the mold 1 to form a closed volume with the mold, which includes the cavity 2, and a complementary part 14 of the cavity in the closed volume, wherein at least one part of the shaft 9 of the shoe is located within the closed volume, wherein the complementary part 14 and the cavity 2 are located on both sides of the closure of the cavity 2 at the level of the contact between the contact area 6 and the edge 5, the device thus being configured to carry out the manufacturing process 100 according to one of the embodiments described above.

[0412] According to a further supplementary embodiment, the device also comprises a holder 8 with a shape corresponding to a foot shape, wherein an outer surface of the holder 8 is configured to be covered by at least one part of the upper 9 of the shoe, wherein at least one part of the surface 7 of the at least one part of the upper 9 covers a part of the outer surface of the holder, which corresponds to a sole of the foot.

[0413] According to one embodiment, the in Fig. 20 The shoe 10 shown has a sole produced by the previously described process 100; a large part of the sole consists of a main material for the sole; in other words, the foamed material resulting from the expansion of the mixture used in process 100 comprises said main material for the sole; The shoe 10 also comprises an upper 30, the mass of which consists mostly of a main material of the upper.

[0414] The main material of the sole can be selected from polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, vulcanized thermoplastic elastomers, thermoplastic polyurethanes (TPU), polyamides, an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer and a polyester.

[0415] The main material of the sole is, for example, a thermoplastic styrene elastomer, in particular selected from SEBS (possibly grafted), SBS, SBC, SIS and SEPS, in this particular example SEBS.

[0416] The main material of the sole is advantageously selected from polyesters, thermoplastic polyurethanes (TPU), polyolefins and block copolymers consisting of rigid polyamide blocks and soft polyether blocks (in particular the material marketed by Arkema under the name Pebax®).

[0417] The sole 20 may include a first auxiliary material for the sole, in particular a polyolefin, more precisely polypropylene, the foamed material resulting from the expansion of the mixture, and the said main material for the sole and the first auxiliary material for the sole.

[0418] The main material of the shaft can be selected from polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, vulcanized thermoplastic elastomers, thermoplastic polyurethanes (TPU), polyamides, an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer, and a polyester; and, for example, a polyolefin, in particular polyethylene or polypropylene, in this specific example, polypropylene.

[0419] The main material of the shaft is advantageously selected from polyesters, thermoplastic polyurethanes (TPU), polyolefins and block copolymers consisting of rigid polyamide blocks and soft polyether blocks (in particular the material marketed by Arkema under the name Pebax®).

[0420] Advantageously, the shaft 30 includes a shoelace 35 made of polypropylene, in particular of braided polypropylene threads.

[0421] Advantageously, the shaft 30 comprises a self-folding component 40, which includes a foam laminated on both sides with a textile selected in particular from polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, vulcanized thermoplastic elastomers, thermoplastic polyurethanes (TPU), polyamides, an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer, and a polyester. The textiles preferably consist of polypropylene and / or polyethylene, in particular a woven or knitted fabric with polypropylene yarns and / or polyethylene yarns, preferably polypropylene yarns.The foam can be selected from polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, thermoplastic polyurethanes (TPU), polyamides, an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer and a polyester; for example, a polyethylene foam.

[0422] The shaft 30 can also include a foam component 50, preferably made of polyethylene, which is housed in the fold of the outer component 40, wherein the foam improves the reception of the rearfoot. The foam can be selected from polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, thermoplastic polyurethanes (TPU), polyamides, an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer, and a polyester.

[0423] The edges of the self-folding component 40 can be joined together using any technique known to a person skilled in the art, for example by one or more seams, preferably using one or more threads of a material made from polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, vulcanized thermoplastic elastomers, thermoplastic polyurethanes (TPU), polyamides, an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer and a polyester, in particular one or more threads of polyolefin, especially polypropylene.

[0424] Preferably, the shaft component 40 is arranged in the rear foot area 12a and partially in the medial 18 and lateral 16 foot area.

[0425] Advantageously, the shaft 30 additionally comprises the shaft component 42, which is arranged in the forefoot region 14a and partially in the lateral 16 and medial 18 foot regions. The shaft component 42 can comprise a knitted or woven fabric. The shaft 30 can comprise further shaft components. The entirety of the shaft components, including components 40 and 42, is preferably three-dimensionally formed using an assembly device. Preferably, the assembly device comprises a material consisting of polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, vulcanized thermoplastic elastomers, thermoplastic polyurethanes (TPU), polyamides, an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer, and a polyester; for example, a nonwoven fabric made of polyolefin, in particular polypropylene.The insole is advantageously thermally fused over all or part of its surface to improve its tear resistance.

[0426] The shaft 30 comprises, as preferably every shaft according to the invention, a rearfoot area 12a, a forefoot area 14a, a lateral area 16, a medial area 18 and an instep area 19 with a tongue.

[0427] The forming of component 40, optionally together with other shaft components, on a foot-shaped preform (so-called lasting process) is carried out, for example, by means of a cord comprising a material selected from polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, vulcanized thermoplastic elastomers, thermoplastic polyurethanes (TPU), polyamides, an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer and a polyester; and in particular a cord made of polypropylene (e.g. a round braid not shown) which puts the lower edges of the textile component 40 and optionally of the other shaft component(s) under tension.

[0428] The shoe 10 may also include lacing eyelets 55 in the molded main material of the upper, for example lacing eyelets 55 made of polypropylene.

[0429] The shoe 10 can also include a non-woven fabric made of polypropylene or polyethylene, which is wholly or partially covered with a coating of poly(ethylene vinyl acetate) (EVA), allowing the eyelets 55 to be bonded to the outer textile component 50 by gluing when the EVA is activated by heating.

[0430] The shoe 10 can comprise textile bands 60 and 61, in particular woven ones, made of polyethylene and / or polypropylene, in particular with polypropylene threads and / or polyethylene threads, in particular polypropylene threads. Each textile band 60 and 61 comprises a lacing area 62 which forms a sleeve for the passage of a shoelace.

[0431] The textile bands 60 and 61 preferably each have a width I1 and I2 of at least 5 mm, in particular of at least 10 mm, in particular of at least 15 mm.

[0432] Preferably, the textile band 60 comprises a first end 64 and a second end 66, which are connected to the component 40. The first and second ends 64, 66 are spaced apart from each other, so that the textile band 60 forms an inverted V.

[0433] Preferably the textile tape 61 comprises a first end 65 and a second end 67 which are essentially superimposed and connected to the component 40.

[0434] Preferably, the lacing area 62 comprises a part of the textile band 60 or 61 folded around itself, which thus forms a sheath for the passage of a shoelace.

[0435] The textile bands 60 and 61 also form lateral reinforcement areas.

[0436] The shaft 30 can include a rear reinforcement 70, which is attached in the region of the rear foot 14 of the component 40. This rear reinforcement 70 is preferably a molded part made of polypropylene.

[0437] The shaft 30 can also comprise a hard front cap 90 made of a molded material, for example from the main material of the shaft, preferably from a polyolefin, a thermoplastic olefin elastomer or a vulcanized thermoplastic elastomer or a thermoplastic styrene elastomer such as SEBS.

[0438] In this particular embodiment, the main material of the shaft 30 is a polyolefin, in particular polypropylene. This is the thermoplastic base material whose mass fraction is the largest compared to the mass fractions of the other materials.

[0439] The shaft 30 also includes a first auxiliary material for the shaft, which differs from the main material of the shaft and in this specific example is polyethylene.

[0440] In this specific example, the mass fraction of polyolefin in the shaft is approximately 55.17%, specifically the mass fraction of polypropylene (main shaft material) is approximately 44.83%, and the mass fraction of polyethylene (first auxiliary material of the shaft) is approximately 10.34%. The mass fraction of thermoplastic olefin elastomer (TPO) in the shaft is approximately 27.59% (second auxiliary material of the shaft), and finally, the mass fraction of adhesive is approximately 17.24%.

[0441] The ratio of the mass of the main material of the shaft 30, in this specific example polypropylene, and the mass of the auxiliary materials of the shaft 30, for example PE and TPO, to the total mass of the shaft 30 is at least 80%, and in particular about 82% or more if the adhesive used is EVA. This ratio preferably tends towards 100%. When the materials are recycled, one or more impurities may remain, but their mass fraction remains small, for example on the order of 5% or less.

[0442] It is possible for the sole 20 to be manufactured and joined to the upper simultaneously. In this case, the sole is injection-molded directly onto the upper, i.e., onto the lower part of the upper 30. Advantageously, the main material of the upper 30 is compatible with the main material of the sole or consists of the same thermoplastic base material, so that the sole preferably adheres to the upper without the use of an external binder.

[0443] Preferably, the mass fraction of the main material of the sole, in particular SEBS, is approximately 65%. The mass fraction of polyolefin, in particular polypropylene mixed with SEBS, is approximately 20%. The mass fraction of filler (e.g., calcium carbonate) in the sole is on the order of 5%. Finally, the mass fraction of plasticizer in the sole is on the order of 10%.

[0444] Shoe 10 consists essentially of a material comprising polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, vulcanized thermoplastic elastomers, thermoplastic polyurethane (TPU), an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer, and a polyester; specifically, polypropylene, polyethylene, TPO, and SEBS, with SEBS predominating in the sole and polypropylene in the upper. Recycling of the shoe is facilitated because the various components do not need to be separated. The shoe is shredded, and the resulting material is processed into thermoplastic granules, which can then be further processed using conventional thermoplastic molding techniques.The thermoplastic granules thus comprise a thermoplastic mixture of the materials selected in the present invention, which are compatible with each other during their hot processing and exhibit good adhesion to each other.

[0445] The thermoplastic granules can therefore be advantageously extruded and injection molded to produce a sole or midsole, either wholly or partially.

[0446] The thermoplastic granules can also be processed to manufacture a hard toe cap or a rear reinforcement, or eyelets, a foam component, or agglomerated or non-agglomerated foam beads.

[0447] Fig. Figure 22 shows a second, non-limiting example of a shoe 200 according to the invention, comprising a sole 220 and an upper 230. The main material of the upper can be selected from polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, vulcanized thermoplastic elastomers, thermoplastic polyurethanes (TPU), polyamides, an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer, and a polyester; in this particular example, preferably a polyolefin, especially polypropylene.

[0448] The upper 230 comprises a textile part 240, which forms a foot-enclosing area with an outer surface 245, and four bands 250, 251, 252 made of a thermoplastic olefin elastomer, which are connected to the outer surface 245 and the sole 220. A portion of each of the bands is arranged between the sole 220 and the outer surface 245 of the textile part 240.

[0449] A strip 250 is arranged along the front edge 205 of the shoe 200 and extends from a lateral side to a medial side of the shoe 200. A strip 251 is arranged along the rear edge 206 of the shoe 200 and extends from a lateral side to a medial side of the shoe 200. A strip 252 is arranged partially along the medial side 207 of the shoe 200 and extends between the front strip 250 and the rear strip 251. A strip that is shown in the photo in Fig. 4 is not visible, is partially arranged along the medial side of the shoe 200 and extends between the front stripe 250 and the rear stripe 251.

[0450] Advantageously, the textile part 240, which forms a receiving area for the foot, comprises a textile component comprising a yarn comprising the main material of the upper, wherein in particular the main material of the upper is a polyolefin or a thermoplastic olefin elastomer.

[0451] Preferably the four strips, including strips 250-252, are strips of the artificial leather type.

[0452] Advantageously, each strip comprises a polymer layer based on a thermoplastic olefin elastomer, the polymer layer being arranged on a textile substrate. The strips are thus advantageously compatible with the polymer material(s) of the textile part 240 and the sole 220, so that they can be bonded to the textile part 240 and the sole 220 by at least partial fusion of their structures. The strips, including strips 250-252, are bonded to the outer surface 245 of the textile part 240 such that the textile substrates are oriented towards the outer surface 245.

[0453] The strip, such as one of the strips 250 to 252, can have a configuration other than a simple strip, depending on the functions it is to fulfill on the shoe. Generally, the strip can be a piece of synthetic leather whose shape is determined according to its final function. In this specific example, the outer surfaces of strips 250 to 252 are essentially smooth, but they can have one or more relief patterns, for example, created by calendering into the polymer layer.

[0454] Fig. Figure 23 shows a third, non-limiting example of a shoe 80 according to the invention. The shoe 80 comprises a sole with a midsole 21 and an outsole 22, wherein the majority of the sole consists of a main material for the sole, and an upper 36, which consists largely of a main material for the upper.

[0455] The main material of the sole is polyester.

[0456] The main material of the midsole 21 can be a thermoplastic copolyester of the TPEE (Thermoplastic Polyether Ester Elastomer) or TPC-ET (Thermoplastic Copolyester Elastomers) type. These are block copolymers comprising rigid polyester segments and flexible polyether and / or polyester segments.

[0457] The main material of the midsole 21 can be a thermoplastic copolyester, referred to as COPE (copolyester thermoplastic elastomer) or TPC (thermoplastic copolyester), of the type TPC-EE (TPC with soft segments with both ether and ester linkages), TPC-ES (“TPC with soft segments with ester linkages”) or TPC-ET (“TPC with soft segments with ether linkages”).

[0458] The midsole 21 can be manufactured by injecting supercritical fluid, as previously described.

[0459] The midsole 21 is advantageously co-molded with the outsole 22.

[0460] The outsole 22 can also be glued to the midsole 21.

[0461] The midsole 21, with or without the outsole 22, can be injection-molded onto the upper. Alternatively, the sole and the upper 36 can be manufactured separately and then joined together.

[0462] The main material of the outsole 22 can be selected from thermoplastic elastomers of the TPV type.

[0463] Thermoplastic vulcanizates (TPVs) belong to the class of thermoplastic elastomers and possess, to a certain extent, the properties of both thermoplastics and elastomers. They are typically two-phase systems: a soft, elastic phase (EPDM) and a hard, thermoplastic phase (PP).

[0464] Preferably, a thermoplastic vulcanizate is used that contains a thermoplastic phase made of thermoplastic copolyester, in particular TPEE. The soft phase can consist of poly(styrene / butadiene), also called SBR rubber (styrene-butadiene rubber), a copolymer of styrene and 1,3-butadiene. The thermoplastic phase can be a thermoplastic block copolymer phase comprising rigid polyester segments and soft polyether and / or polyester segments.

[0465] Alternatively, the outsole 22 can contain rubber. In this case, the outsole 22 is advantageously attached to the midsole 21 with a special adhesive base, allowing the outsole 22 to be removed for recycling the shoe.

[0466] The Shoe 80 may also include an insole made of TPEE or TPC-ET, which can be produced by overfoaming with supercritical fluid as previously described.

[0467] The main material of the shaft is also preferably a polyester.

[0468] Advantageously, the shaft 36 includes a shoelace 23 made of polyethylene terephthalate (PET).

[0469] The shoe 80 may include 24 lacing eyelets made of polyethylene terephthalate (PET).

[0470] The shaft 36 can comprise a lower part 25, which is a protective layer bonded to the shaft. The lower layer 25 advantageously consists of thermoplastic copolyester, in particular of the TPEE or TPC-ET type.

[0471] The shaft 36 can also include an upper part 26 comprising polyethylene terephthalate (PET) and / or a thermoplastic copolyester, for example TPEE.

[0472] Fig.Figure 21 shows an embodiment of the upper part 26. The upper part 26 can comprise an upper layer 26a made of PET, for example, a two-dimensionally woven PET fabric, and a lower layer 26b also made of PET, for example, a three-dimensionally woven PET fabric. A middle layer 26c made of thermoplastic copolymer, for example, TPEE, in particular non-woven TPEE, is surrounded above and below by an adhesive interlayer 26d, 26e. An upper interlayer 26d is arranged between the middle layer 26c and the upper layer 26a, while a lower interlayer 26e is arranged between the middle layer 26c and the lower layer 26b.

[0473] A reinforcing ring 27 is arranged at the rear of the shoe 80, between the upper 36 and the midsole 21. This reinforcing ring is a rigid injection-molded insert, positioned in the mold and optionally connected to the upper. The ring 27 is preferably made of thermoplastic copolyester, particularly of the TPEE or TPC-ET type. The ring 27 can be bonded between the upper 30 and the midsole 21.

[0474] The shaft 36 may also include an upper reinforcement 51 made of foam, which improves the support of the rearfoot. The upper reinforcement 51 may be made of PET, in particular non-woven PET.

[0475] The shaft 36 comprises a rearfoot area 28, a forefoot area 29, a lateral area 31, a medial area 32 and an instep area 33 with a tongue 34.

[0476] The tongue 34 is preferably made of PET, in particular of non-woven PET.

[0477] The upper may include a polyester thread, especially TPEE, which gives the shoe flexibility.

[0478] The outsole 22 is preferably manufactured and joined to the upper simultaneously. In this case, the outsole is injection-molded directly onto the upper, i.e., onto the lower part of the upper 36, preferably using the method described above.

[0479] Advantageously, the main material of the upper 36 is compatible with the main material of the sole or consists of the same thermoplastic base material as it, so that the outsole preferably adheres to the upper without the use of an external binder.

[0480] Alternatively, shoe 80 can also be manufactured using a classic Strobel construction. The outsole 22 can be bonded to the upper 36 by gluing. The outsole 22 and the upper 36 are therefore manufactured separately and then joined together.

[0481] The adhesives that can be used to join the various parts of the shoe 80, and in particular to join the upper to the sole, can be polyurethane- or polyester-based adhesives.

[0482] The table below summarizes the mechanical properties measured on examples of polymer mixtures obtained from the recycling of shoes according to the inventive method.

[0483] The mixture from Example 1 is derived from the recycling of a shoe that does not contain any contaminating materials as defined in this text. The shoe recycled to produce the mixture from Example 1 therefore contains 50 g of polypropylene (PP), 12 g of polyethylene (PE), 250 g of styrene-ethylene-butadiene-styrene (SEBS), and 25 g of a vulcanized thermoplastic elastomer (TPV, in this specific example EPDM (ethylene-propylene-diene) / PP (polypropylene)).

[0484] The recycled shoe used to produce the mixture from Example 2 is identical to the shoe from Example 1, except that the sole of the recycled shoe in Example 2 contains thermoplastic polyurethane with a mass fraction of 2%.

[0485] The recycled shoe made from the mixture in Example 3 is identical to the shoe in Example 2, except that the mass fraction of thermoplastic polyurethane in the shoe is 5%.

[0486] The recycled shoe made from the mixture in Example 4 is identical to the shoe from Example 2, with the difference that the mass fraction of thermoplastic polyurethane in the shoe is 10%.

[0487] The shoe made from the mixture in Example 5 is identical to the shoe from Example 1, with the difference that the shoe from Example 5 contains 2% of the mass of thermoplastic polyamide from a polyamide hook and loop fastener system of the recycled shoe.

[0488] It has been observed that the presence of polyurethane and polyamide in an amount of no more than 10% of the shoe's mass not only improves its breaking strength but, surprisingly, also its abrasion resistance. With a polyurethane content exceeding 10% of the mass, a reduction in abrasion resistance is observed.

[0489] Furthermore, the recycled mixtures obtained can be perfectly processed thermally (extrusion injection molding or blow molding or hot pressing, extrusion forming, etc.), retaining their final properties, making them suitable for numerous new applications.

Claims

[1] Footwear article produced by a process (100) comprising the following steps: - Providing (103) a mold (1) defining an open cavity (2), wherein the shape of at least part of the cavity (2) corresponds to the shape of a sole (3) of the shoe article (10), wherein the cavity (2) is configured to open into the cavity (2) via at least one injection channel (4, 4', 4'', 4''') to receive a mixture comprising a molten material and a supercritical fluid; - Arranging (105) an edge (5) of an opening of the cavity (2) which is in contact with a contact area (6) of a surface (7) of at least one part of a shaft (9) of the shoe article (10), such that the surface (7) of the at least one part of the shaft (9) ensures a closure of the cavity at the contact point between the contact area (6) and the edge (5); - Applying negative pressure (105 bis) to the cavity (2); - Injecting (107) the mixture into the cavity (2); - Pressure relief (108) of the cavity (2) of the mold to trigger an expansion of the mixture in the cavity (2) and to form the sole (3) from a foamed material resulting from the expansion of the mixture, wherein at least a part of the surface (7) of the at least a part (9) of the shaft is enclosed in the foamed material of the sole (3). [2] Footwear article according to claim 1, wherein at least one part of the surface (7) of at least one part of the upper (9) is at least partially perforated or open. [3] Footwear article according to claim 1 or 2, wherein the at least one part of the surface (7) of the at least one part of the upper (9) in contact with the contact area (6) is structured or perforated. [4] Footwear articles according to any one of claims 1 to 3, characterized by , that: - a large part of the mass of the shaft (9, 30, 36, 230) consists of a main material of the shaft and, if applicable, of one or more auxiliary materials of the shaft; - a large part of the sole (3, 20, 21, 22, 220) consists of a main sole material and optionally one or more auxiliary sole material(s), wherein the foamed material resulting from the expansion of the mixture comprises the main sole material and the auxiliary sole material(s); - The main material of the shaft and, if applicable, the additional material(s) of the shaft are selected from the following materials: polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, vulcanized thermoplastic elastomers, a thermoplastic polyurethane (TPU), polyamides, an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer, and a polyester. - that the main material of the sole and, where applicable, the auxiliary material(s) of the sole belong to the same chemical family as the main material of the upper and, where applicable, to the same chemical family as the auxiliary material(s) of the upper, or that the main material of the sole and, where applicable, the auxiliary material(s) of the sole are chemically compatible with the main material of the upper and, where applicable, with the auxiliary material(s) of the upper. [5] Footwear articles according to claim 4, characterized by that the main material of the sole and, where applicable, the auxiliary material(s) of the sole are identical to the main material of the upper and, where applicable, identical to the auxiliary material(s) of the upper. [6] Footwear articles according to claim 4 or 5, characterized by, that the main material of the shaft is selected from polyesters, thermoplastic polyurethanes (TPU), polyolefins and block copolymers consisting of rigid polyamide blocks and soft polyether blocks. [7] Footwear articles according to any one of claims 4 to 6, characterized by , that the main material of the sole is selected from polyesters, thermoplastic polyurethanes (TPU), polyolefins and block copolymers consisting of rigid polyamide blocks and soft polyether blocks. [8] Footwear articles according to any one of claims 4 to 7, characterized by , that the shaft comprises a yarn comprising a material selected from: polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, vulcanized thermoplastic elastomers, thermoplastic polyurethane (TPU), an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer and a polyester. [9] Footwear articles according to any one of claims 4 to 8, characterized by that the shaft includes a textile component and that the textile component includes a yarn that comprises the main material of the shaft. [10] Footwear articles according to any one of claims 4 to 9, characterized by , that the shaft comprises a textile part forming a foot receiving area with an outer surface, and at least one part, in particular a band (250, 251, 252) comprising a thermoplastic olefin elastomer, wherein the band (250, 251, 252) is connected to the outer surface of the textile part and to the sole. [11] Footwear articles according to any one of claims 4 to 10, characterized by , that the shaft comprises a textile part forming a foot receiving area with an outer surface, and at least one part, in particular a band (250, 251, 252) comprising a thermoplastic olefin elastomer, wherein the band (250, 251, 252) is connected to the outer surface of the textile part and to the sole. [12] Footwear articles according to any one of claims 4 to 11, characterized by , that the sole comprises a cellular component and / or foam beads comprising a material selected from: polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, thermoplastic polyurethane (TPU), an ether amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether ester block copolymer, a styrene-based elastomer and a polyester. [13] Footwear articles according to any one of claims 4 to 12, characterized by , that the shaft (30) comprises a front hard tip (90) comprising the main material of the shaft or an auxiliary material of the shaft, and / or a rear reinforcement (70) comprising the main material of the shaft or an auxiliary material of the shaft. [14] Footwear articles according to any one of claims 4 to 13, characterized by, that the shaft (30) comprises at least one through-hole for at least one lacing element, wherein the at least one through-hole comprises a textile band comprising at least one yarn comprising the main material of the shaft, in particular the main material of the shaft is a polyolefin. [15] Footwear articles according to any one of claims 4 to 14, characterized by , that the shaft (30) comprises a foam component which comprises the main material of the shaft, in particular the main material of the shaft is a polyolefin. [16] Footwear articles according to any one of claims 4 to 15, characterized by , that the upper (30; 130) and / or the sole (20; 120) each comprise a recycled material from a sole and / or upper of another shoe and / or a recycled material from a sole and / or upper of a boot. [17] Footwear articles according to any one of claims 4 to 16, characterized bythat the ratio of the mass of the main material of the shaft and, where applicable, the mass of the auxiliary material(s) of the shaft to the total mass of the shaft is greater than or equal to 40%. [18] Footwear articles according to any one of claims 4 to 17, characterized by that the ratio of the mass of the main material of the shaft and the mass of the auxiliary material(s) of the shaft to the total mass of the shaft is greater than or equal to 50%. [19] Footwear articles according to any one of claims 4 to 18, characterized by that the ratio of the mass of the main material of the sole and, where applicable, the mass of the auxiliary material or materials of the sole to the total mass of the sole is greater than or equal to 40%. [20] Footwear articles according to any one of claims 4 to 19, characterized by that the ratio of the mass of the main material of the sole and the mass of the auxiliary material or materials of the sole to the total mass of the sole is greater than or equal to 50%. [21] Footwear articles according to any one of claims 4 to 20, characterized by , that the footwear article (10) contains at most 10% by mass of one or more contaminating materials that are not made of polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, vulcanized thermoplastic elastomers, thermoplastic polyurethane (TPU), an ether-amide block copolymer (PEBA), ethylene vinyl acetate (EVA), an ether-ester block copolymer, a styrene-based elastomer and a polyester, in particular at most 10% by mass of one or more thermoplastic contaminating materials and / or at most 5% by mass of one or more thermoset contaminating materials. [22] Footwear articles according to any one of claims 4 to 21, characterized by that the main material of the sole and, where applicable, the auxiliary material(s) of the sole are at least partly derived from the recycling of at least one other footwear article (10). [23] Footwear articles with an upper and a sole directly injected onto the upper, characterized by , that the directly injected sole contains a foamed material resulting from the expansion of a mixture containing a supercritical fluid. [24] Footwear articles according to claim 23, characterized by that the foamed material is a plastic material, in particular TPU or PEBA. [25] Footwear articles according to claim 23 or 24, characterized by that the directly injected sole is a single piece. [26] Device for manufacturing at least one part of a shoe article (10), the device comprising a mold (1) defining an open cavity (2), the shape of at least one part of the cavity (2) corresponding to the shape of a sole (3) of the shoe article (10), the cavity (2) being configured to receive a mixture comprising a molten material and a supercritical fluid via at least one injection channel (4, 4', 4'', 4''') opening into the cavity (2), an edge (5) of an opening of the open cavity (2) being configured to be brought into contact with a contact area (6) of a surface (7) of at least one part of an upper (9) of the shoe article (10), such that the surface (7) of the at least one part of the upper (9) ensures a closure of the cavity at the contact point between the contact area (6) and the edge (5), the device thus being configuredthat it carries out a procedure (100) in the company which includes the following steps: , - Providing (103) a mold (1) defining an open cavity (2), wherein the shape of at least part of the cavity (2) corresponds to the shape of a sole (3) of the shoe article (10), wherein the cavity (2) is configured to open into the cavity (2) via at least one injection channel (4, 4', 4'', 4''') to receive a mixture comprising a molten material and a supercritical fluid; - Arranging (105) an edge (5) of an opening of the cavity (2) which is in contact with a contact area (6) of a surface (7) of at least one part of a shaft (9) of the shoe article (10), such that the surface (7) of the at least one part of the shaft (9) ensures a closure of the cavity at the contact point between the contact area (6) and the edge (5); - Applying negative pressure (105 bis) to the cavity (2); - Injecting (107) the mixture into the cavity (2); - Pressure relief (108) of the cavity (2) of the mold to trigger an expansion of the mixture in the cavity (2) and to form the sole (3) from a foamed material resulting from the expansion of the mixture, wherein at least a part of the surface (7) of the at least a part (9) of the shaft is enclosed in the foamed material of the sole (3).

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