Article of footwear, and method for manufacturing such an article of footwear

Abstract

The present invention relates to an article of footwear (100) comprising an upper (110, 145, 155) and an outsole (130) connected via at least one heat-fused portion. The upper (110, 145, 155) comprises at least one textile portion that is at least partially heat-fused. The outsole (130) comprises one or more slits (132, 132i, 132t, 132l) leading to and opening onto the outer face (130a) of the outsole (130), each of the slits (132, 132i, 132t, 132l) having a bottom (133, 133i), and the distance between a bottom (133, 133i) and the inner face (130b) of the outsole (130) is less than or equal to 0.50 times the depth (p) of the slit (132i) corresponding to the bottom (133i). The present invention further relates to a method for manufacturing such an article of footwear.

Description

[0001] FOOTWEAR AND METHOD FOR MANUFACTURING SUCH A FOOTWEAR

[0002] Technical Field

[0003] The present invention relates to the field of footwear, in particular sports shoes.

[0004] The present invention also relates to the field of methods for manufacturing such footwear.

[0005] Prior art

[0006] Conventional footwear articles generally include an upper and a sole structure. The upper is secured to the sole structure and forms a void within the footwear article to comfortably receive and secure a foot. The sole structure is secured to a lower area of ​​the upper, and operatively disposed between the ground, and the upper. In athletic footwear articles, the sole structure may include an outsole and a midsole. The midsole often includes a polymeric foam material that absorbs shock from the ground upon impact to lessen the effects on the foot and leg during walking, running, or other ambulatory activities. The sole structure may also include a liner positioned proximate the underside of the foot to enhance the comfort of the footwear article.

[0007] Soles are traditionally joined to the uppers using a process called Strobel, in which the various sole elements (inner sole, midsole, and outsole in particular) are assembled. The manufacturing process for a traditional shoe requires dozens of steps and produces a lot of waste from material cuts.

[0008] The goal is to simplify the manufacturing processes for footwear, particularly by reducing the number of steps and / or energy and material consumption. This issue is also part of the search for a manufacturing process that can be implemented as close as possible to the place of use of the footwear in order to reduce its carbon impact, facilitate stock management, and allow the personalization of the footwear.

[0009] One solution is to eliminate the sewing steps required to shape the initially flat upper in three dimensions. The upper is obtained by assembling one or a few pieces, rather than by sewing multiple pieces together.

[0010] WO 2019 / 234374 A1 thus proposes a first textile liner formed in three dimensions directly at the output of a textile loom (for example a knitting loom), partially heat-meltable, used in the construction of the upper, then to secure this first liner to a wear sole. The first textile liner is reinforced by placing a second textile liner, in three dimensions, partially heat-meltable, around the first liner by wrapping the junction between the first liner and the wear sole in order to improve resistance to delamination. The assembly comprising the first and second textile liners and the wear sole undergoes a heat treatment to melt the heat-meltable threads and fix the shape of an upper. The manufacturing process is simplified by significantly reducing the number of manufacturing steps.

[0011] However, there is a need to further improve these footwear articles, in order to make them lighter, improve their resistance to abrasion and tearing, and improve their breathability. Indeed, the thermofused textile portions are not breathable. In addition, they stiffen the footwear article. They are necessary to provide abrasion resistance, tear resistance and fix the shape of the article, but they must not limit the flexibility and conformability of the footwear article.

[0012] Furthermore, limiting the number of stages in the manufacture of a footwear item restricts the range of technical functions and aesthetic results available.

[0013] It is indeed sought that the simplified construction stages (knitting of a tubular element, or even thermocompression / thermoforming for example) allow both to functionalize the footwear article (in particular by ensuring the following property(ies): cushioning, recovery, comfort, proprioception, breathability, possibly impermeability, resistance to wear / abrasion / tearing, etc.) while offering varied visual aspects.

[0014] Furthermore, footwear manufactured using a thermocompression process has rather rigid outsoles due to the compaction of the thermomelted material. It is not possible to reliably use foam, which is actually crushed during the thermocompression process. The outsoles of such articles therefore lack flexibility and cushioning.

[0015] This problem can be partially overcome by selecting very flexible hot melt materials. However, it is difficult to find flexible hot melt materials with a melting or softening temperature suitable for thermocompression processing, and which also have good abrasion resistance if they are to be used as outsoles.

[0016] Indeed, the melting temperature(s) used must be lower than the melting or degradation temperature of the textile elements of the footwear article which are not intended to be at least partially thermofused. In addition, if one seeks to use thermofusible recycled materials at least in part for the manufacture of the outsole by thermocompression, it is difficult to control the resulting hardness and therefore flexibility because the precise composition of said recycled materials is not known precisely.

[0017] There is thus a need for a footwear article comprising one or more thermo-fused textile portion(s), or at least partially thermo-fused textile portion(s), which is light, flexible, and breathable, while offering satisfactory resistance to abrasion and tearing, and comfortably conforming to the shape of the foot.

[0018] There is a need for a comfortable footwear article which can be manufactured by thermocompression and whose outsole is flexible, and which can use recycled waste which is at least partly thermofusible.

[0019] There is also a need for a method of manufacturing such an article of footwear that is simplified while offering numerous possibilities with regard to the technical and aesthetic functions that can be imparted to the article of footwear.

[0020] Statement of the invention

[0021] The present invention relates, according to a first aspect, to an article of footwear, in particular a sports shoe, comprising an upper, a wear sole and a foot-receiving volume, the wear sole extending between an internal face opening into the foot-receiving volume of the article of footwear and an external face, in particular at least a part of said external face or said entire external face is a face for engagement with the ground, the upper and the wear sole are connected by means of at least one thermofused portion, and said upper comprises at least one textile portion thermofused at least partially.

[0022] Advantageously, said outsole comprises one or more slot(s) opening out and open on the external face of said outsole, each slot having a bottom, and in particular a top opposite said bottom, and

[0023] - the distance (d) between a bottom (in particular said bottom or a bottom chosen from said bottoms) and the inner face of the outsole is less than or equal to 0.50 times, or 0.45 times or 0.40 times or 0.35 times or 0.30 times or 0.25 times or 0.20 times, the depth (p) of the slot corresponding to said bottom (or d < 0.50 or 0.45 or 0.40 or 0.35 or 0.30 or 0.25 or 0.20 * p) (in particular designated in this text by ratio A); and / or

[0024] - the distance (d) between a bottom (in particular said bottom or a bottom chosen from said bottoms) and the internal face of the outsole is less than or equal to 0.50 times or 0.45 times or 0.40 times or 0.35 times or 0.30 times or 0.25 times or 0.20 times, the distance (D) between the internal face of the outsole and the top of the slot corresponding to said bottom (in particular designated in this text by ratio B).

[0025] Advantageously, the arrangement of several slots opening out and open on the external face of the outsole which are particularly deep in relation to the total thickness of the outsole makes it possible to provide flexibility to said outsole manufactured entirely or partly by thermocompression.

[0026] Preferably, a slot comprises a bottom, in particular a proximal end, and a top, in particular a distal end opposite said proximal end.

[0027] Advantageously, the distance (d) between a bottom (in particular said bottom or a bottom chosen from said bottoms) and the internal face of the outsole corresponds to the distance (d) between the bottom of a given slot and the portion of the internal face of the outsole opposite said bottom and passing through a vertical plane of the footwear article substantially perpendicular to the support plane P of the footwear article at rest.

[0028] The use of an inflatable bladder in the thermocompression molding process, particularly described below, advantageously makes it possible to mold complex shapes and slots of significant depth.

[0029] Indeed, the configuration of a molding impression is generally limited by the clearance between the draft and the undercut. Since the bladder is deflated during demolding, this arrangement facilitates the demolding of the part, including undercut shapes.

[0030] In one embodiment, all or part of the inner face of the outsole is substantially flat, in particular does not include a recess or hollow opposite a protrusion projecting from the outer face of the outsole.

[0031] In effect, the hot melt material is pushed and pressed by the inflatable bladder against the molding assembly so that the inner face of the outsole is in contact with the inflatable bladder and therefore adopts the outer shape of the bladder in an inflated state.

[0032] Preferably, the outsole comprises a plurality of slots, in particular at least 5 or 10 or 15 or 20 or 25 or 30 or 35 slots, more preferably satisfying ratio A and / or ratio B.

[0033] The outsole may comprise one or more slots not satisfying ratio A and / or ratio B set out above combined with one or more slots satisfying ratio A and / or ratio B set out above.

[0034] The inventors have determined that the presence of slot(s) satisfying ratio A and / or ratio B stated above makes it possible to attribute flexibility, and therefore good flexibility to the outsole, thus compensating for the rigidity conferred on the outsole intrinsically by its thermocompression manufacturing process, and also because of the rigid and various materials used (such as waste soles and / or shoes and / or textiles).

[0035] Advantageously, the formation of slit(s) in the outsole opening onto its external face, in particular on the external face of engagement with the ground of the footwear article, provides flexibility.

[0036] Advantageously, the slot(s), in particular satisfying ratio A and / or ratio B, do not open onto the internal face of the outsole.

[0037] Advantageously, said outsole comprises a slot or slots each having: a first end and a second end,

[0038] - a first end which may be opposite, or open onto, a medial edge, respectively lateral edge, or a front edge, respectively rear edge, of the outsole or of the footwear article, and

[0039] - a second end which may be opposite, or open onto, a lateral edge, respectively medial, or a rear edge, respectively front, of the outsole or of the footwear article.

[0040] The slot(s) according to the invention may be substantially straight, or curved or comprise several curves, preferably is / are substantially straight.

[0041] For example, a slot according to the invention is substantially parallel to the vertical axis (V) of the footwear item.

[0042] For example, a slot according to the invention is inclined relative to the vertical axis (V) of the footwear item.

[0043] In this text, the vertical axis (V) of the footwear article is understood to mean any straight line extending from the upper towards the outsole, and substantially perpendicular to the support plane (P) on which said footwear article rests, at least part of the external engagement face of said footwear article being in contact with said support plane.

[0044] Preferably, the outsole comprises one or more slots having (each) a substantially constant width.

[0045] For example, the outsole comprises one or more slits having (each) a variable width, for example increasing from the bottom of said slit towards the top of said slit. In this case, the width of the measured slit is the smallest width that can be measured on the slit. In one embodiment, at least one slit according to the invention, or each slit according to the invention, has a depth (p) which is greater than its width (I), in particular has a depth (p) which is greater than two times or three times or four times or five times or six times or seven times or eight times or nine times or ten times or even 20 times or 30 times its width. In one embodiment, at least one slit according to the invention, or each slit according to the invention has a depth (p) which is less than or equal to 30 times the width (I) of said slit, in particular less than or equal to 20 times the width (I) of said slit.

[0046] In one embodiment, the width (I) of said slot ranges from 1 mm to 10 mm, in particular from 1 mm to 8 mm or from 1 mm to 6 mm or from 1 mm to 4 mm.

[0047] In one embodiment, the depth (p) of the slot ranges from 5 mm to 45 mm, in particular ranges from 5 mm to 40 mm, more particularly ranges from 5 mm to 35 mm, for example ranges from 5 mm to 30 mm or 25 mm.

[0048] In one embodiment, the length (L) of said slot ranges from 5 mm to 350 mm.

[0049] In one embodiment, the outsole comprises one or more slots having a length (L) ranging from 5 mm to 60 mm.

[0050] Advantageously, one or more outsole element(s) intended to form all or part of the outsole being thermocompressed with part or all of the upper, the outsole is connected to the upper, and its internal face opens, in particular directly, into the volume for receiving the foot of the footwear article.

[0051] Preferably, the upper and the outsole are connected by means of at least one thermofused textile portion of the upper and / or at least one thermofused textile portion of the outsole (for example originating from a textile part of the sole) and / or at least one thermofused portion (in particular non-textile) of the outsole (for example originating from thermoplastic granules).

[0052] In conventional footwear manufacturing processes, a midsole is placed between the upper and the outsole. A midsole typically comprises a foaming material to trap air. However, due to the thermocompression process of compacting the molten material, the reliable implementation of such a midsole is complex since it must be placed between the upper and an outsole without being crushed / compacted and remaining correctly positioned.

[0053] Advantageously, in the invention, the outsole, at least partly or entirely thermocompressed, is thus directly connected to the upper. Preferably, the midsole and / or a sockliner is / are added after the thermocompression step to the footwear article.

[0054] Footwear item

[0055] The footwear article comprises a volume for receiving or accommodating the foot as well as an opening for introducing the foot for placing the foot in said volume for accommodating the foot. Advantageously, the footwear article comprises a medial side and a lateral side, in particular said footwear article comprises a forefoot region arranged between the medial and lateral sides, a forefoot region arranged on the lateral side, a forefoot region arranged on the medial side, a midfoot region arranged on the medial side, a midfoot region arranged on the lateral side, a rearfoot region arranged between the medial and lateral sides, a rearfoot region arranged on the medial side, and a rearfoot region arranged on the lateral side, and optionally an instep area.

[0056] Advantageously, the article of footwear comprises a medial edge, extending on the medial side, and a lateral edge extending on the lateral side.

[0057] Advantageously, the article of footwear comprises a front edge and a rear edge, in particular extending between the medial and lateral sides.

[0058] Advantageously, the footwear article comprises a central longitudinal axis L extending between its front and rear edges.

[0059] Advantageously, the footwear article comprises a transverse axis T extending between its medial and lateral sides, in particular substantially perpendicular to the longitudinal axis L.

[0060] In this text, the medial side of the footwear article, and of any element it comprises (upper, outsole, midsole, sole element, internal / external textile tubular element, internal / external (textile) foot covering part, etc.), is understood to mean any element or part of the footwear article arranged between the central longitudinal axis L of the footwear article and the natural internal side of the foot.

[0061] In this text, the lateral side of the footwear article, and of any element it comprises (upper, outsole, midsole, sole element, internal / external textile tubular element, internal / external (textile) foot covering part, etc.), is understood to mean any element or part of the footwear article arranged between the central longitudinal axis L of the footwear article and the natural external side of the foot.

[0062] Preferably, the footwear article comprises a textile tubular element, in particular an internal one, comprising a textile part, in particular an internal one, covering at least in part the top of the foot, and optionally an external textile tubular element comprising an external textile part covering at least in part the top of the foot.

[0063] Preferably, the outer textile tubular element comprises an interior volume receiving at least in part the inner textile tubular element.

[0064] Preferably, the inner textile tubular element and the outer textile tubular element are at least partially superimposed. Preferably, the inner upper covering portion and the outer upper covering portion are at least partially superimposed.

[0065] Stem

[0066] Advantageously, the upper comprises, in particular is essentially made up of, a textile part, in particular an internal part covering at least part of the top of the foot, possibly superimposed at least in part with an external textile part covering at least part of the foot.

[0067] Preferably, the upper extends, in particular at least in part, in one or more regions of the top of a foot chosen from: the forefoot region arranged on the lateral side and / or the forefoot region arranged on the medial side; and / or the forefoot region extending between the lateral side and the medial side; and / or the instep area; and / or the midfoot region arranged on the lateral side and / or the midfoot region arranged on the medial side; and / or the rearfoot region arranged on the lateral side and / or the rearfoot region arranged on the medial side; and / or the rearfoot region extending between the lateral side and the medial side; and optionally at least in part the leg region.

[0068] Preferably, the upper extends, in particular at least in part, in the following regions: the forefoot region on the lateral side, the forefoot region on the medial side, the forefoot region extending between the lateral side and the medial side; the midfoot region on the lateral side, the midfoot region on the medial side, the rearfoot region on the lateral side, the rearfoot region on the medial side, the rearfoot region extending between the lateral side and the medial side, and optionally at least in part the leg region and / or in the instep area.

[0069] Preferably, the upper extends between a lateral side and a medial side of the article of footwear, and between a front edge and a rear edge of the article of footwear.

[0070] The upper may include other upper element(s), for example a logo, one or more functional element(s), and / or one or more aesthetic element(s) secured to the external textile covering part and / or to the upper (in particular internal) covering part.

[0071] Advantageously, the functional element may be a rear buttress, a front hard toe, or a lateral or medial reinforcement.

[0072] Advantageously, the textile covering part (in particular external) comprises one or more regions in which threads are glued together or a thread is glued to itself. Sole structure / Outsole

[0073] The footwear article advantageously comprises a sole structure comprising said outsole.

[0074] The sole structure may include, in addition to the outsole, a midsole and / or a sockliner.

[0075] Naturally, the sole structure extends between the foot and the ground.

[0076] Advantageously, the footwear article comprises an external face for engagement with the ground.

[0077] In a preferred example, the outer face of the outsole is the outer ground-engaging face of the footwear article.

[0078] The sole structure may comprise a midsole and / or a sockliner, in particular arranged removably in the foot-receiving volume of the footwear item. In particular, the outer face of the midsole or the outer face of the sockliner is arranged directly opposite the inner face of the outsole.

[0079] The outsole advantageously comprises the textile sole part of the textile tubular element, in particular internal, and / or the textile sole part of the external textile tubular element, and possibly a textile pocket receiving one or more thermofusible element(s) at least in part and / or one or more sole element(s) (for example an insert, a cushioning element, etc.) in particular non-thermofusible.

[0080] A sole element may be a heat-fusible film, for example made of polyurethane, covering all or part of the external face of the sole part of the textile tubular element, in particular the external one.

[0081] The outsole can be thermocompressed in whole or in part.

[0082] Advantageously, the outsole includes an internal face opening directly into the foot-receiving volume of the footwear item.

[0083] Advantageously, the outsole is secured to the upper by at least one thermofused textile portion:

[0084] - which comprises the upper, in particular by at least one thermofused textile portion of the textile part, in particular internal, of covering and / or at least one thermofused textile portion of the external textile part of covering, and / or

[0085] - which comprises the sole structure, in particular by at least one thermofused textile portion of the sole part of the tubular element, in particular internal, and / or at least one thermofused textile portion of the sole part of the external tubular element. The outsole may be additionally secured to the upper by one or more stitching(s) or another means other than a thermofused textile portion.

[0086] In one example, the outsole may be differentiated in height, in particular may comprise a portion of its height in a composition A, in particular comprising one or more thermofused polymer material(s), and a portion of its height in a composition B different from composition A, in particular not comprising thermofused material. In particular, the portion in composition A may be derived from a mixture of one or more thermofused polymer(s) which has / have been thermofused, and the portion in composition B may be derived from a non-thermofused or non-thermofused mixture, for example rubber.It may be one or more element(s) in a non-thermofusible and abrasion-resistant material placed in the bottom of the part(s) of the mold intended to form one or more parts of the external face of the outsole, in particular the external face for engaging the footwear article, or even joined together after the thermocompression step during a step of finishing the outsole.

[0087] In one embodiment, the outsole or sole structure is in a mixture of material(s) having a Shore A hardness ranging from about 45 to about 80.

[0088] Textile tubular element, particularly external

[0089] Advantageously, the tubular textile element, in particular external, is woven or knitted (in particular with weft or warp stitches), preferably knitted (in particular with weft stitches).

[0090] The textile tubular element, in particular the external one, is preferably a knitted tube, in particular a tube knitted on a circular knitting machine of small diameter (i.e. the diameter of which is between 5 cm and 20 cm, in particular between 5 cm and 15 cm).

[0091] The textile tubular element, in particular the external one, is preferably a tube comprising a bent part, in particular intended to receive the heel.

[0092] The tubular textile element, particularly the external one, is advantageously a knitted sock.

[0093] The textile tubular element, in particular the external one, preferably comprises an open front end, in particular one which is closed, more particularly closed by sewing. Preferably, the open front end which is closed by sewing is a toe receiving area.

[0094] Advantageously, the textile tubular element, in particular external, comprises a volume for receiving or accommodating the foot and an opening for introducing the foot for accommodating the foot in said accommodating volume. Advantageously, the textile tubular element, in particular external, comprises a textile part, in particular external, for covering at least part of the foot, and a textile sole part (in particular external) in textile connection (in particular in knitted connection) with the textile part, in particular external, for covering at least part of the foot.

[0095] Advantageously, the textile tubular element, particularly the external one, is of unitary knitted construction.

[0096] The textile part, particularly the external part, covering the foot may cover the whole or one or more regions of the top of the foot.

[0097] Advantageously, the external textile part covering the foot is an external textile part covering the top of the foot, in particular covering all or part of the top of the foot.

[0098] The textile part of the sole of the textile tubular element, in particular the external part, may cover all or one or more regions of the underside of the foot.

[0099] The textile part, in particular the external part, of the covering and / or the textile part, in particular the external part, of the sole is / are arranged according to the configuration of the desired footwear item.

[0100] Preferably, the textile part, in particular the external covering part, extends into one or more regions of the top of the foot chosen from: the forefoot region arranged on the lateral side and / or the forefoot region arranged on the medial side; and / or the forefoot region extending between the lateral side and the medial side; and / or the instep area; and / or the midfoot region arranged on the lateral side and / or the midfoot region arranged on the medial side; and / or the rearfoot region arranged on the lateral side and / or the rearfoot region arranged on the medial side; and / or the rearfoot region extending between the lateral side and the medial side; and optionally a region arranged in at least part of the leg region.

[0101] The region(s) of the underside of the foot in which the textile part of the sole extends, in particular the external part, is / are chosen from: the forefoot region extending between the lateral and medial sides of the footwear article; the midfoot region extending between the lateral and medial sides of the footwear article; and the rearfoot region extending between the lateral and medial sides of the footwear article.

[0102] Preferably, the external textile tubular element comprises an external face and an internal face, in particular substantially opposite.

[0103] Preferably, the outer face of the outer textile tubular element is oriented facing the exterior of the footwear item. Advantageously, the textile tubular element, in particular the outer one, comprises one or more thread(s), and in particular one or more non-thermofused thread(s), and / or one or more thermofused thread(s) at least in part, in particular entirely or in part.

[0104] Preferably, the tubular textile element, in particular the external one, comprises one or more monofilament yarn(s) and / or one or more multifilament yarn(s) and / or one or more spun yarn(s) of fibers. Said yarn(s) may be those described in the present text below.

[0105] In one embodiment, the external face of the outsole, or possibly the external face of engagement with the ground of the footwear article, comprises, in particular is essentially constituted, at least in part of the textile sole part of the external textile tubular element.

[0106] In particular, the textile sole part of the external textile tubular element fits, in particular forms a covering fitting, the contour of one or more slot(s) opening out and open on the external face of said outsole as well as the contour of said bottom(s) corresponding to said slot(s).

[0107] Internal textile tubular element

[0108] Advantageously, the internal textile tubular element is woven or knitted (in particular with weft or warp stitches), preferably knitted (in particular with weft).

[0109] The internal textile tubular element is preferably a knitted tube, in particular a tube knitted on a small diameter circular knitting machine (i.e. with a diameter between 5 cm and 20 cm, in particular between 5 cm and 15 cm).

[0110] The internal textile tubular element is preferably a tube comprising a bent part, in particular intended to receive the heel.

[0111] The internal textile tubular element is advantageously a knitted sock.

[0112] The inner textile tubular element preferably comprises an open front end, in particular which is closed, more particularly closed by sewing. Preferably, the open front end is a toe receiving area.

[0113] Advantageously, the internal textile tubular element comprises a volume for receiving or accommodating the foot and an opening for introducing the foot for accommodating the foot in said accommodating volume.

[0114] Advantageously, the internal textile tubular element comprises an internal textile part, covering at least part of the foot, and an internal textile sole part in textile connection (in particular in knitted connection) with the internal textile part covering at least part of the foot. Advantageously, the internal textile tubular element is of unitary knitted construction.

[0115] The internal textile part covering at least part of the foot may cover all or one or more regions of the top of the foot.

[0116] Advantageously, the internal textile part covering the foot is an external textile part covering the top of the foot, in particular covering all or part of the top of the foot.

[0117] The textile sole portion of the internal textile tubular element, also referred to in this text as the internal sole textile portion, may cover all or one or more regions of the underside of the foot.

[0118] The internal textile covering part and / or the internal sole textile part is / are arranged according to the configuration of the desired footwear item.

[0119] Preferably, the inner textile covering portion extends into one or more regions of the top of the foot selected from: the forefoot region arranged on the lateral side and / or the forefoot region arranged on the medial side; and / or the forefoot region extending between the lateral side and the medial side; and / or the instep area; and / or the midfoot region arranged on the lateral side and / or the midfoot region arranged on the medial side; and / or the rearfoot region arranged on the lateral side and / or the rearfoot region arranged on the medial side; and / or the rearfoot region extending between the lateral side and the medial side; and optionally a region arranged in at least part of the leg region.

[0120] The region(s) of the underside of the foot in which the textile part of the sole extends, in particular the internal part, is / are chosen from: the forefoot region extending between the lateral and medial sides of the footwear article; the midfoot region extending between the lateral and medial sides of the footwear article; and the rearfoot region extending between the lateral and medial sides of the footwear article.

[0121] Advantageously, the internal textile tubular element comprises one or more thread(s), and in particular one or more non-thermal-melt thread(s), and / or one or more thermo-melt thread(s) at least in part or totally.

[0122] Preferably, the internal textile tubular element comprises one or more monofilament yarn(s) and / or one or more multifilament yarn(s) and / or one or more spun yarn(s) of fibers. Said yarn(s) may be those described in the present text below.

[0123] Preferably, the internal textile tubular element comprises an external face and an internal face, in particular substantially opposite. Preferably, the internal face of the external textile tubular element is oriented opposite the external face of the internal textile tubular element.

[0124] Preferably, the external face of the external textile tubular element is oriented opposite the exterior of the footwear article.

[0125] In one embodiment, the inner textile tubular element and the outer textile tubular element are two distinct and separate knitted pieces.

[0126] In this case, when the internal and external textile tubular elements are at least partially superimposed, the internal textile tubular element being arranged in an interior volume for receiving the foot of the external textile tubular element, the internal mounting face of the external textile tubular element is oriented opposite the external mounting face of the internal textile tubular element.

[0127] The internal mounting face of the internal textile tubular element is then oriented opposite the volume of the foot of the footwear item.

[0128] In one embodiment, the internal textile tubular element and the external textile tubular element are in the same textile piece (in particular knitted), in particular are in textile connection (in particular knitted) at their openings for introducing the foot into their respective foot receiving volumes or at their respective open foot tips. In this case, the internal textile tubular element being arranged in the foot receiving volume of the external textile tubular element by turning over, said internal and external textile tubular elements being superimposed at least in part, the internal mounting face of the external textile tubular element is oriented opposite the internal mounting face of the internal textile tubular element.

[0129] The external mounting face of the internal textile tubular element is then oriented opposite the volume of the foot of the footwear item.

[0130] Advantageously, on the footwear item corresponding to the finished item, in practice, the external face of the internal textile tubular element is oriented directly opposite the internal face of the external textile tubular element.

[0131] Textile portion at least partially heat-melted

[0132] Advantageously, an at least partially heat-melted textile portion is:

[0133] - a portion of one or more thread(s) which is partially heat-melted so that said portion retains a recognizable textile structure, the thread(s) being glued to each other, and / or to one or more other thread(s), and / or is / are stiffened (in particular without being glued to each other); or

[0134] - a portion of one or more thread(s) which is heat-melted so that said portion forms a film or coating or a polymeric melt such as a binder (in particular the textile structure is no longer recognizable).

[0135] Advantageously, in all cases, a change in state of the thermofusible textile portion is observed, in particular making it possible to bond threads together, and / or to form a film or a coating or a binder or a matrix, and / or to stiffen the thread(s), in order to retain the shape given during thermocompression and to form differentiated technical zones. The tubular textile element, in particular internal or external, may comprise one or more textile portion(s) at least partially thermofusible, in particular one or more thermofusible textile portion(s) or one or more partially thermofusible textile portion(s).

[0136] The textile tubular element, in particular internal or external, may comprise one or more textile portion(s) at least partially thermofused, in particular one or more thermofused or partially thermofused textile portion(s).

[0137] A thermofused or partially thermofused textile portion may be a portion:

[0138] - a single-component monofilament yarn that is at least partially heat-melted (and therefore in particular heat-meltable before its transformation), or

[0139] - a two-component monofilament yarn comprising at least one first component which is at least partially heat-melted (and therefore in particular heat-meltable before its transformation) and at least one second component which is not heat-melted (and therefore in particular not heat-meltable before its transformation) as defined in the context of the present invention,

[0140] - a multifilament yarn comprising one or more single-component thermofused filament(s) at least partially (and therefore in particular thermofusible before transformation) or two-component filament(s), each filament comprising at least one first thermofused component at least partially (and therefore in particular thermofusible) and at least one second non-thermofused component (and therefore in particular non-thermofused before transformation) as defined in the context of the present invention, optionally mixed with one or more single-component non-thermofused filament(s) (and therefore in particular non-thermofusible) in the context of the present invention.

[0141] For example, a monocomponent yarn is a polyurethane monofilament yarn, for example having a melting temperature ranging from approximately 80°C to 120°C.

[0142] For example, a bi-component yarn comprises filaments each of which is of the core-coat type, i.e. comprising a coat comprising said first component having a melting temperature ranging from about 80°C to about 120°C and a core comprising said second component, in particular having a melting or softening temperature higher than that of the first component, for example ranging from 150°C to 190°C.

[0143] Said at least partially thermofused (or thermofusible) single-component or two-component yarn(s) preferably has / have (each) a linear density ranging from 300 dtex to 1200 dtex, in particular ranging from approximately 400 dtex to 800 dtex, in particular ranging from approximately 600 dtex to 700 dtex.

[0144] At least partially melted yarn(s) means: one or more fully melted yarn(s), and one or more partially melted yarn(s). Preferably, said at least partially melted yarn(s) is / are one or more single-component multifilament yarn(s).

[0145] Preferably, said single-component or two-component thermofusible multifilament yarn(s) each has / have an elongation at break greater than or equal to 80% or 100%, more preferably greater than or equal to 115, preferably less than or equal to 200%.

[0146] The monofilament yarn(s) and / or the spun fiber yarn(s) and / or the multifilament yarn(s) according to the invention may be made of one or more materials chosen from:

[0147] - a list I comprising: polyesters, in particular chosen from polyethylene terephthalate (PET) and polybutylene terephthalate (PBT) or a combination thereof; polyamides, in particular chosen from PA 6, PA 6-6, and a combination thereof; polyolefins, in particular polyethylene, polypropylene, and a combination thereof; elastanes; and a combination thereof; and / or

[0148] - a list II comprising: cotton, regenerated cellulose, for example viscose, linen, sisal, wool, jute, silk, hemp, and a combination of these;

[0149] - a list III comprising: para-aramids, meta-aramids and carbon; and / or

[0150] - a list IV including: recycled textiles, in particular recycled clothing, for example thermal protective clothing such as that for firefighters.

[0151] The material(s) listed in List I, and / or List II, and / or List III and / or List IV, can be recycled and / or bio-sourced at least in part.

[0152] The monofilament yarn(s) preferably has / have a diameter greater than or equal to 0.01 mm and less than or equal to 5 mm, more preferably greater than or equal to 0.1 mm and less than or equal to 2 mm. The multifilament yarn(s) and / or spun yarn(s) of fibers preferably has / have a linear density greater than or equal to 10 dtex and less than or equal to 1000 dtex, more preferably greater than or equal to 30 dtex and less than or equal to 500 dtex.

[0153] Advantageously, the non-thermofused thread(s) comprises / comprise, in particular is / are essentially made up of, one or more polymer material(s) whose melting or degradation temperature is higher than the maximum temperature used in the manufacturing process of the footwear article.

[0154] The thread(s), in particular non-thermal melted thread(s), may also be one or more elastic thread(s).

[0155] Elastic thread is understood to mean any thread whose elongation at break is greater than or equal to 100% or 200%, in particular greater than or equal to 300%, in particular greater than or equal to 400%. The elastic thread preferably comprises an elastic core, in particular made of elastane, and possibly one or more cover threads. The elongation can be measured using the ASTM D 1578-93 (2016) standard. By definition, the elastic thread is not heat-melted.

[0156] Definitions

[0157] In this text, the term "hot-melt" or "first hot-melt component" means any material or first component which is hot-melted or partially hot-melted during the manufacture of the footwear article according to the invention.

[0158] In this text, the term non-hot-melt is understood to mean any material / component which is not hot-melted during the manufacture of the footwear article according to the invention.

[0159] This material or component may be a thermoplastic material or not, but which has a melting or softening temperature or even a degradation temperature which is higher than the highest heating temperature used in the manufacturing process of the footwear article according to the invention.

[0160] In this text, the term “at least partially thermofusible thread(s)” is understood to mean that said thread(s) is / are totally thermofusible or comprises / comprises only a portion of its structure which is thermofusible.

[0161] In a first embodiment, the footwear article comprises an internal textile tubular element, in particular an internal sock, an external textile tubular element, in particular an external sock, and one or more at least partially thermofused sole element(s).

[0162] For example, the at least partially thermofused sole element(s) is / are arranged between the inner and outer sole textile portions of said inner and outer textile tubular elements. This arrangement is preferred when one or more sole elements comprise / comprise one or more thermofused material(s) not compatible by hot bonding with one of the sole textile portions of an inner / outer textile tubular element. In addition, the delamination resistance of the sole structure is improved.

[0163] Preferably, the sole portion of the external textile tubular element fully or partially matches the geometry of the external engagement face of the footwear item.

[0164] The textile sole part of the external textile tubular element is therefore visible from the outside of the footwear item.

[0165] For example, the sole portion of the external textile tubular element comprises one or more patterns, for example one or more colored or transparent / translucent threads, at least partially thermo-fused or non-thermo-fused, visible on the external engagement face of the footwear article.

[0166] For example, the at least partially thermofused sole element(s) is / are arranged between the outer sole textile part and the ground engagement face of the footwear article (in particular the inner face of the molding assembly described in the method below).

[0167] For example, each of the inner and outer sole textile parts of the inner and outer textile tubular elements comprises at least partly thermofused yarn(s), in particular made of polyurethane, possibly mixed with one or more non-thermofused yarn(s), for example made of high-tenacity polyester (PET for example).

[0168] For example, the internal textile part covering at least in part the foot comprises one or more non-thermal melted thread(s) (for example one or more multifilament thread(s), in particular made of polyester (PET for example)), possibly mixed with one or more thermomelted thread(s) at least in part.

[0169] The non-thermal melted yarn(s) has / have a linear mass ranging from 200 denier to 1000 denier, in particular from 400 denier to 950 denier.

[0170] For example, the external textile part covering at least in part the foot comprises one or more thermofused thread(s) at least in part, possibly mixed with one or more non-thermofused thread(s).

[0171] In one variant, the outer face of the internal textile part covering the foot comprises an internal main textile region, and the inner face of the external textile part covering the foot comprises an external main textile region comprising at least one textile portion that is at least partially heat-melted, and the external and internal main regions are at least partially superimposed and are not glued together.

[0172] Advantageously, the main outer and inner regions of the upper are not glued together, which improves breathability and flexibility of the upper, and allows for different aesthetic results.

[0173] Furthermore, this arrangement is advantageously obtained by a manufacturing method allowing energy savings, as described below, in particular with reference to a second aspect of the invention.

[0174] Preferably, the outer main textile region extends between the inner and outer faces of the inner textile foot covering portion, in particular forms a part of the latter.

[0175] Preferably, the outer main textile region comprises a partially heat-fused or heat-fused textile portion.

[0176] In an alternative embodiment, the external textile part covering the foot comprises one or more additional external textile region(s), and the internal textile part covering the foot comprises one or more additional internal textile region(s). In particular, an external additional textile region is at least partially superimposed with a corresponding internal additional textile region, said external and internal additional textile regions are not glued together.

[0177] Advantageously, the outer main textile region is distinct from the outer additional textile region.

[0178] Advantageously, the additional internal region(s) each comprises a textile portion that is at least partially heat-melted.

[0179] Advantageously, the additional external region(s) does not comprise / (each comprises) a thermofused textile portion.

[0180] Advantageously, the internal main textile region is distinct from the internal additional main region.

[0181] In an alternative embodiment, the external, respectively internal, textile part covering at least a portion of the top of the foot comprises a medial, respectively lateral, upper edge, substantially free over at least a portion of its length, in particular substantially free over at least a portion of its length from the medial, respectively lateral, upper edge of the internal, respectively external, textile part covering at least a portion of the top of the foot. Advantageously, the external, respectively internal, main textile region extends substantially between said medial or lateral upper edge, and the sole textile part of the external, respectively internal, textile tubular element.

[0182] In an alternative embodiment, the external main textile region extends between a medial or lateral upper edge of the external textile part covering at least a portion of the top of the foot, and the sole textile part of the external tubular element, and optionally the internal main textile region extends between a medial or lateral upper edge of the internal textile part covering at least a portion of the top of the foot, and the sole textile part of the internal tubular element.

[0183] In one variant, the inner and outer main regions are substantially superimposed.

[0184] In an alternative embodiment, the external textile covering portion comprises a medial or lateral upper edge of which at least a portion of the length is not glued to the internal textile covering portion, in particular to the corresponding medial or lateral upper edge. In an alternative embodiment, the external textile covering portion of the foot comprises a medial or lateral upper edge comprising one or more external lacing zones, and optionally the internal textile covering portion of the foot comprises a medial or lateral upper edge comprising one or more internal lacing zones, possibly cooperating with said external lacing zone(s) for the passage of at least one common elongate element through at least one internal lacing zone and one external lacing zone.

[0185] Preferably, the external or internal lacing zone is a through opening.

[0186] In an alternative embodiment, the inner main textile region does not include a thermofused textile portion.

[0187] In one variant, the internal main textile region comprises sections of yarn(s) which are movable (in particular sliding) relative to each other, in particular knitted stitches which are movable relative to each other.

[0188] Advantageously, each of these arrangements allows flexibility to be given to the main internal textile region, and to maintain good breathability because the sections of mobile thread(s) promote the evacuation of heat and perspiration.

[0189] In an alternative embodiment, the inner textile tubular element comprises a sole textile portion comprising one or more thermofused textile portion(s), and the outer textile tubular element comprises a sole textile portion comprising one or more thermofused textile portion(s). In an alternative embodiment, at least 50% or 60% or 70% or 80% or 90% of the total mass of each of the sole textile portions of the inner and outer textile tubular elements consists essentially of thermofused textile portion(s).

[0190] In a variant, at least 50% or 60% or 70% or 80% of the total mass of the external textile tubular element consists essentially of at least partially thermofused textile portion(s), in particular thermofused textile portion(s).

[0191] In one variant, at least a portion of the upper, and said at least one sole, are of unitary molded construction.

[0192] Advantageously, at least a portion of the upper and said at least one outsole are manufactured during the same molding step, in particular a thermocompression step. In a variant, at least 20% or 30% or 40% or 50% or 60% or 65% or 70% or 75% or 80% or 85% or 90% or 95% or approximately 100% of the external face of the internal textile part covering at least part of the foot is not glued, in particular is not secured, with the internal face of the internal textile part covering at least part of the foot.

[0193] In a variant, the internal textile part covering at least part of the foot and the external textile part covering at least part of the foot are secured to each other essentially at their respective lower peripheral edges, in particular by means of one or more thermo-fused textile portion(s).

[0194] Advantageously, the lower peripheral edges are those respectively connecting the external textile covering part with said at least one outsole and connecting the internal textile covering part with said at least one outsole.

[0195] In one variant, the outsole comprises several slots arranged so as to delimit at least one protrusion between at least two adjacent slots, in particular said at least one protrusion comprises at least two free side walls.

[0196] Advantageously, the protrusions each comprise a free external wall, in particular forming a portion of the external face of the outsole, more particularly forming a portion of the external face of engagement with the ground of the footwear article.

[0197] Advantageously, each of the protrusions comprises a posterior portion connecting the latter to the body of the outsole.

[0198] Advantageously, the outsole thus comprises a outsole body and protrusions projecting from the outsole body.

[0199] Advantageously, each of the protrusions comprises at least two free side walls. Advantageously, protrusions comprise protrusions comprising three, or four or five or more, free side walls.

[0200] The above arrangements allow for the formation of freely deforming protrusions which improve the cushioning and flexibility of the outsole in several directions.

[0201] In particular, the sole part of the external textile tubular element fits the free side walls, and possibly the free external wall(s) (notably defined below), of one or more protrusions.

[0202] In one embodiment, the footwear article comprises a medial edge and a lateral edge, the outsole extends between said medial and lateral edges, and the outsole comprises one or more transverse slits extending at least in part between said lateral and medial edges of the footwear article, and optionally opening onto at least one of said lateral and medial edges of the footwear article.

[0203] One or more transverse slits may extend across a portion of the width of the outsole or across substantially the entire width of the outsole, particularly in the rearfoot region and / or in the midfoot region and / or in the forefoot region.

[0204] Advantageously, the transverse slits of the outsole form zones of flexibility improving the rolling of the foot, and providing flexibility to said outsole manufactured from material(s) considered rigid and resistant to deformation for this type of application. Indeed, this type of thermocompressed material(s) is considered to limit the natural movement of the foot when walking or running.

[0205] Advantageously, the outsole comprises one or more transverse slit(s) in the midfoot region, in particular at the crease of the foot.

[0206] Advantageously, the resistance / flexibility constraint being the strongest in this region, this arrangement makes it possible to improve the rolling of the foot.

[0207] In this text, the term "transverse slit" means any slit whose front and rear ends are opposite the medial and lateral edges of the footwear item, respectively. In a variant, the outsole comprises one or more slits, each of which has a length (L) greater than its width (I), in particular each of which has a length (L) which is greater than or equal to 4 times or 5 times or 6 times or 7 times or 8 times or 9 times or 10 times or 15 times or 20 times or 25 times or 30 times or 40 times its width (I).

[0208] For example, a transverse slit has a width (I) of 1 mm to 5 mm, and a length of 5 mm to 50 mm.

[0209] In one embodiment, the article of footwear comprises a medial edge and a lateral edge, the outsole extends between said medial and lateral edges, and the outsole comprises one or more transverse slits extending between and opening onto said lateral and medial edges of the article of footwear.

[0210] Advantageously, the longer the transverse slit(s), the greater the flexibility provided to the outsole in general and targeted in the area of ​​the outsole comprising said slit(s).

[0211] In one embodiment, the article of footwear comprises a front edge and a rear edge, the outsole extends between said front and rear edges, and the outsole comprises one or more longitudinal slits extending:

[0212] - at least partly between said front and rear edges of the footwear; and / or

[0213] - extending at least partially into at least two regions of the footwear article chosen from: a rearfoot region, a midfoot region, and a forefoot region.

[0214] One or more longitudinal slits may extend over a portion of the length of the outsole or over substantially the entire length of the outsole, particularly in the rearfoot region and / or in the midfoot region and / or in the forefoot region.

[0215] One or more longitudinal slits may open onto at least one of the front and rear edges of the outsole, possibly opening onto the front and rear edges.

[0216] In this text, a longitudinal slit is understood to mean any slit whose front and rear ends are respectively:

[0217] - opposite the front and rear edges of the footwear article, in particular opening onto one of the front and rear edges of said article or opening onto the front and rear edges of said footwear article, and / or

[0218] - extending at least partially into at least two regions of the footwear article chosen from: the rearfoot region, the midfoot region, and the forefoot region.

[0219] In the latter case, a longitudinal slit may open onto one of the lateral and medial edges or onto both the lateral and medial edges.

[0220] In one variant, the outsole comprises one or more transverse slot(s) intersecting with one or more longitudinal slot(s).

[0221] In a variant, said at least one protrusion comprises a free external wall, or each of said protrusions comprises a free external wall, and the surface (cm 2) of said free external wall of said at least one protrusion is less than or equal to 0.20 times, or 0.15 times or 0.10 or 0.08 times, or 0.05 times, the total surface area of ​​the external face of the outsole. In a variant, the outsole comprises several protrusions, the total sum of the surfaces of the free external walls of the protrusions represents at least 50%, or at least 60% or at least 70% or at least 80%, of the total surface area of ​​the external face of the outsole.

[0222] The above provisions further improve the flexibility and conformability of the outsole when the foot rolls.

[0223] In a variant, said slot or each of said slots has a depth (p) greater than or equal to 3 mm, in particular greater than or equal to 5 mm.

[0224] In one variation, the outsole is of unitary molded construction.

[0225] Advantageously, the inner and outer sole textile portions respectively of the inner and outer textile tubular elements and one or more sole element(s), are molded together by thermocompression to form the outsole in one piece.

[0226] In one variant, a medial edge and a lateral edge of the outsole are directly connected respectively to a lateral edge and a medial edge of the upper, in particular are connected via at least one thermofused textile portion.

[0227] In one variant, the footwear article comprises a sole element arranged in the foot receiving volume, in particular in a removable manner, and having an external face arranged opposite the internal face of the outsole, in particular the sole element is an intermediate sole.

[0228] In one variant, the footwear article comprises a foot support zone arranged in the bottom of the foot receiving volume of the footwear article, the outsole comprises a lateral edge, respectively medial, comprising a lateral edge, respectively medial, projecting substantially above the foot support zone towards the upper.

[0229] In a variant, said outsole comprises one or more thermofused recycled material(s), optionally one or more thermofused recycled textile material(s).

[0230] In one variant, said article comprises:

[0231] - an internal textile tubular element comprising an internal textile part covering at least part of the foot, and

[0232] - an external textile tubular element comprising an external textile part covering at least part of the foot, said external textile tubular element receiving in an interior volume at least part of said internal textile tubular element, and the upper comprises said external and internal textile parts covering at least part of the foot.

[0233] In one variant, the inner textile tubular element comprises a sole textile portion comprising one or more thermofused textile portion(s), and the outer textile tubular element comprises a sole textile portion comprising one or more thermofused textile portion(s).

[0234] In one variant, at least 50% of the total mass of each of the textile sole parts of the internal and external textile tubular elements consists essentially of thermofused textile portion(s).

[0235] In one variant, at least part of the upper, and the outsole, are in a molded part, in particular in a thermocompressed part.

[0236] Advantageously, the thermocompressed part comprises a wear sole and the internal and external textile tubular elements.

[0237] This arrangement promotes the integrity of the footwear item, its different components are therefore less likely to delaminate and separate than if they had been glued using an exogenous glue or sewn.

[0238] In one variant, at least one textile portion of the internal textile tubular element, in particular of the internal textile part covering the top of the foot, is embossed in at least one thermofused textile portion of the external textile tubular element, in particular of the external textile part covering the top of the foot.

[0239] Advantageously, the textile portion embossed in the thermofused textile portion is not thermofused so that its textile imprint (for example the knitting / weaving pattern) is printed in the thickness of the thermofused textile portion during the step of thermocompression of the upper and is thus visible from the outer face of the thermofused textile portion.

[0240] In one variant, the footwear article comprises an upper, and the upper comprises at least one non-thermally melted textile portion embossed in a thermomelted textile portion, in particular the embossed textile portion is visible from the outer face of the upper. In one variant, the inner face of the sole structure forms a foot support zone configured to be arranged under the foot when the footwear article is worn, and the support zone is vertically set back from the upper edge of the main edge of the sole structure along all or part of said main edge.

[0241] More particularly, the foot support zone of the sole structure is set back vertically from the upper edge of the main edge of the sole structure in the rearfoot region of the footwear article along all or part of said rearfoot region, by at least 5 mm or at least 10 mm.

[0242] This arrangement advantageously makes it possible to reduce the weight of the sole structure. In one variant, the sole structure comprises a main edge comprising a front edge, a rear edge, a medial edge and a lateral edge, in particular corresponding to the front, rear, medial and lateral edges of the footwear article.

[0243] An edge of the sole structure preferably extends vertically between the inner face of the sole structure and the upper edge of said edge.

[0244] In a variant, the internal covering textile part and / or the external covering textile part each comprises one or more textile loops for lacing, in particular knitted, not comprising a thermofused textile portion, and optionally the footwear article comprises one or more lace(s) not comprising a thermofused textile portion.

[0245] In one variant, at least a portion of the outsole, or essentially the entire outsole, comprises particles that are at least partially thermofused and agglomerated together or thermocompressed together.

[0246] Advantageously, at least 30% by mass, preferably at least 50% by mass, more preferably at least 80% by mass of the outsole is formed of particles which are at least partly thermofused and agglomerated together.

[0247] Advantageously, particles are bonded to other particles via thermofused portions of said particles.

[0248] In examples, at least a portion of the outsole, or substantially all of the outsole, comprises at least partially thermally fused particles, and at least partially non-thermally fused particles, which are agglomerated together or thermally compressed together.

[0249] The particles have advantageously undergone a thermocompression step (for example a preliminary thermocompression step for the formation of a wear sole element / insert, and / or a thermocompression step i) described below) so that they are thermocompressed and therefore agglomerated together into a block.

[0250] Advantageously, said particles (in particular whether they are at least partly heat-melted and / or whether they are at least partly non-heat-melted) comprise (in particular are) particles originating from waste chosen from shoe waste, textile waste, and sole waste or a combination thereof.

[0251] Advantageously, said particles (in particular whether they are at least partly heat-melted and / or whether they are at least partly non-heat-melted) comprise (in particular are) particles comprising (in) materials selected from polyolefins (e.g. EVA, polypropylene, polyethylene), olefinic thermoplastic elastomer(s), polyesters (e.g. PBT and PET), polyamides (PA 66), and a combination thereof. Advantageously, the at least partly heat-melted particles have at least one dimension, in particular an average size, greater than or equal to 0.5 mm, in particular less than or equal to 10 mm, more particularly less than or equal to 6 mm, in particular greater than or equal to 1 mm.

[0252] Advantageously, the at least partly non-thermally melted particles have at least one dimension, in particular an average size, greater than or equal to 0.5 mm, in particular less than or equal to 10 mm, more particularly less than or equal to 6 mm, in particular greater than or equal to 1 mm.

[0253] In one embodiment, at least a portion of the outsole, or substantially all of the outsole, comprises at least partially thermally fused particles, and / or at least partially non-thermally fused particles, and agglomerated together, having different optical properties.

[0254] For example, at least a portion of the outsole, or substantially all of the outsole, comprises substantially opaque or transparent particles and particles in a particular color or particles in at least two different colors.

[0255] The subject of the present invention, according to a second aspect, is a method for manufacturing an article of footwear, in particular a shoe, in particular according to any one of the variant embodiments with reference to the first aspect of the invention, comprising the steps: (i) molding by thermocompression:

[0256] - at least one textile tubular element, in particular external, comprising a textile part, in particular external, covering at least part of the foot,

[0257] - and optionally at least one internal textile tubular element received at least in part in an interior volume of said external textile tubular element,

[0258] - said textile part, in particular external, covering at least one part of the foot comprising one or more thermofusible textile portion(s),

[0259] - optionally said internal textile tubular element comprises an internal textile part covering at least one part of the foot, said internal textile part covering at least one part of the foot comprising one or more thermofusible textile portion(s),

[0260] - as well as a wear sole assembly comprising one or more wear sole element(s), at least partly thermofusible or at least partly thermofused,

[0261] - with a molding assembly comprising a wear sole impression comprising one or more notches, each of said notch(s) having a bottom and a top opposite said bottom,

[0262] - so as to melt or soften the thermofusible textile portion(s) of said textile part, in particular external, covering at least in part the foot, and optionally the thermofusible textile portion(s) of said internal textile part covering at least in part the foot, and said thermofusible outsole element(s) at least in part;ii) a footwear article is removed from the mold comprising an upper comprising at least one textile portion at least partly heat-melted, and a wear sole connected to said upper by means of at least one heat-melted portion, said wear sole extends between an internal face opening into a volume for receiving the foot of the footwear article and an external face, the wear sole comprises one or more slot(s) opening and open on the external face of said wear sole, each of said slot(s) having a bottom, and in particular a top opposite said bottom, and;

[0263] - the distance between a bottom (in particular said bottom or a bottom chosen from said bottoms) and the inner face of the outsole is less than or equal to 0.50 times, or 0.45 times or 0.40 times or 0.35 times or 0.30 times or 0.25 times or 0.20 times, the depth (p) of said slot corresponding to said bottom (or d<0.50 or 0.45 or 0.40 or 0.35 or 0.30 or 0.25 or 0.20 * p) (in particular designated in this text by ratio A); and / or

[0264] - the distance (d) between a bottom (in particular said bottom or a bottom chosen from said bottoms) and the internal face of the outsole is less than or equal to 0.50 times or 0.45 times or 0.40 times or 0.35 times or 0.30 times or 0.25 times or 0.20 times, the distance (D) between the internal face of the outsole and the top of the slot corresponding to said bottom (in particular designated in this text by ratio B).

[0265] Advantageously, the mold assembly comprises an upper mold part and a lower mold part cooperating together and forming between them an empty molding space having substantially the external shape of the footwear article.

[0266] Advantageously, the method comprises the arrangement of an inflatable bladder having substantially a foot shape, in particular corresponding substantially to the internal shape of the footwear article, in said empty molding space, in particular at least partly in the volume for receiving the foot of the tubular textile element, in particular internal.

[0267] Advantageously, the bladder is hollow, and is connected in its upper part to a handle facilitating its grip, in particular said handle comprises at least one means for admitting an inflation fluid (e.g. air) for inflation and a means for discharging the inflation fluid (which may be said air inlet means).

[0268] The inflatable bladder is preferably made of a flexible material, for example silicone, which is temperature-resistant, in particular resistant to a temperature greater than or equal to 150°C or 180°C or 200°C or 250°C (in particular depending on the melting temperature(s) of the hot-melt material(s) used), and which can undergo several inflation and deflation cycles. When the inflatable bladder is deflated, it preferably substantially recovers its initial shape. Preferably, the inflatable bladder is reusable.

[0269] Preferably, the inflation pressure ranges from 3 bars to 5 bars.

[0270] In an exemplary embodiment, the inflatable bladder is inflated to an inflation pressure ranging from 3 bars to 5 bars, for example of the order of 4 bars.

[0271] In one embodiment, a sole element, in particular a wear element, is a sole element (or insert), in particular a wear element, thermocompressed in a preliminary thermocompression step and carried out before the thermocompression step (i). This preliminary thermocompression step comprises the thermocompression of one or more thermofusible material(s) at least in part, optionally with one or more non-thermofusible material(s) (for example textile waste made of polyacrylic, or wool or cotton).

[0272] This preliminary thermocompression step may be carried out using the mold assembly used in step (i). The at least partly thermofusible material(s) may be thermofusible particles, in particular having an average size ranging from 1 mm to 6 mm, for example from 3 mm to 5 mm.

[0273] For example, hot melt particles have a Shore A hardness ranging from 45 to 80.

[0274] Advantageously, this at least partially thermocompressed sole element is arranged in a sandwich between the internal and external sole textile parts of the internal and external textile tubular elements.

[0275] The thermo-melted material(s) comprising this thermo-compressed sole element is / are thermo-melted again at least in part during the thermo-compression step (i).

[0276] For example, the hot-melt / thermo-melted material(s) is / are chosen from polyurethanes, polyolefins (e.g. PP, PE), polyesters (PET, PBT).

[0277] For example, the heating temperature during the preliminary thermocompression stage ranges from 110°C to 170°C, especially from 120°C to 160°C.

[0278] For example, the duration of the preliminary or final thermocompression step (iii) ranges from 5 minutes to 30 minutes, particularly from 10 minutes to 25 minutes, more particularly from 15 minutes to 20 minutes.

[0279] For example, the heating temperature of the lower mold part during the thermocompression step i) ranges from 160°C to 220°C, in particular from 170°C to 210°C. In one embodiment, the outsole assembly comprises one or more outsole elements, at least partly thermofusible or at least partly thermomelt, which is / are particles at least partly thermofusible, and optionally in admixture with particles at least partly non-thermofusible. The at least partly thermofusible particles, and / or the at least partly non-thermofusible particles, may be (or comprise) particles originating from sole(s) and / or upper(s) and / or shoe(s) and / or textile(s) waste, in particular ground.

[0280] In this case, the particles are thermocompressed during the thermocompression step i) of the process according to the invention.

[0281] Advantageously, the at least partly thermofusible particles have at least one dimension, in particular an average size, greater than or equal to 0.5 mm, in particular less than or equal to 10 mm, more particularly less than or equal to 6 mm, in particular greater than or equal to 1 mm.

[0282] Advantageously, the at least partly non-heat-melting particles have at least one dimension, in particular an average size, greater than or equal to 0.5 mm, in particular less than or equal to 10 mm, more particularly less than or equal to 6 mm, in particular greater than or equal to 1 mm.

[0283] For example, at least partly hot-melt particles, and / or at least partly non-hot-melt particles, have a Shore A hardness ranging from 45 to 80.

[0284] For example, the particles comprise one or more hot-melt / thermofused materials selected from polyurethanes, polyolefins (e.g., PP, PE), and polyesters (PET, PBT).

[0285] In examples, during the thermocompression step i), the sole assembly comprises at least partly thermofusible particles, and optionally at least partly non-thermofusible particles.

[0286] Advantageously, during the thermocompression step i), the outsole assembly comprising the particles is heated to a temperature allowing the melting of the thermofusible portions of the particles, and an inflation pressure, for example at least of the order of 3 bars, is applied to the inflatable bladder so that the thermofused mixture comprising the particles is compressed against the molding imprint of the outsole. The heating temperature during the thermocompression step is determined so as to melt the targeted thermofusible portions of the particles.

[0287] Preferably, during the demolding step, the inflatable bladder is deflated, and the outsole and upper are demolded before the outsole and upper reach room temperature. This arrangement, combined with the deflation of the bladder, facilitates the demolding of undercut shapes.

[0288] Definitions

[0289] A thermofusible textile portion is understood to mean any textile portion before it becomes a partially thermofused, or thermofused, textile portion once transformed by the process according to the invention.

[0290] A partially heat-melted textile portion is as defined above in this text.

[0291] One or more outsole elements of said outsole assembly is understood to mean any element in a material capable of forming an outsole according to the invention. Thus, textile waste from clothing can form outsole elements capable of being thermocompressed if they have intrinsic properties or possibly in a mixture with other waste making it possible to form an outsole by thermocompression.

[0292] At least partially heat-meltable particles may be fully heat-meltable or only partially heat-meltable, and thus comprise a non-heat-meltable portion.

[0293] At least partially non-heat-meltable particles may be completely non-heat-meltable or only partially non-heat-meltable, and thus comprise a heat-meltable portion.

[0294] In a first embodiment, step (i) comprises the thermocompression of an internal textile tubular element, in particular an internal sock, of an external textile tubular element, in particular an external sock, and of one or more at least partially thermofusible sole element(s), in particular at least one of which has been thermocompressed during a preliminary thermocompression step to form a sole insert.

[0295] For example, the thermofusible sole element(s) or sole insert is / are disposed between the inner and outer sole textile portions of said inner and outer textile tubular elements.

[0296] This arrangement promotes the attachment of the sole element(s) to the textile tubular elements, in particular making it possible to compensate for any lack of compatibility between the sole element(s) and the textile tubular elements.

[0297] For example, the hot-melt sole element(s) is / are arranged between the outer sole textile portion and the inner face of the molding assembly.

[0298] For example, each of the inner and outer sole textile parts of the inner and outer textile tubular elements comprises at least partly hot-melt yarns, in particular made of polyurethane, possibly mixed with one or more high-tenacity polyester yarns (PET for example).

[0299] In one variant, the upper mold portion is heated solely by heat transmitted from the heated lower mold portion.

[0300] Advantageously, the heating heat of the lower part of the mold dissipates towards the upper part of the mold, the heat provided by the lower part of the mold is sufficient to bond together and / or stiffen the at least partly heat-fusible thread(s) of the textile part, in particular external, of the covering.

[0301] In one embodiment, the molding assembly comprises an inflatable bladder and a mold assembly, and the inflatable bladder is disposed within an interior volume of the inner textile tubular member, said inner textile tubular member and said sole assembly being thermocompressed between an inner face of the mold assembly and the inflatable bladder in an inflated state.

[0302] In a variant, said outsole assembly comprises at least 80 g, in particular between 80 g and 210 g, of one or more at least partially thermofusible outsole element(s), in particular comprising one or more thermofusible recycled material(s), in particular derived from textile waste and / or footwear waste.

[0303] In one embodiment, the thermofusible outsole elements comprise (or are) at least partly thermofusible particles, optionally mixed with at least partly non-thermofusible particles, in particular derived from textile waste and / or footwear waste, in particular ground.

[0304] In a variant, said outsole assembly comprises at least 80g, in particular between 80g and 210g, of at least partly heat-meltable particles, optionally mixed with at least partly non-heat-meltable particles, in particular derived from textile waste and / or footwear waste, in particular ground.

[0305] Said particles may have been thermocompressed in a preliminary step to form a sole element which undergoes step i) of thermocompression, or be thermocompressed directly during step i) of thermocompression.

[0306] In a variant, during steps (ii) and (iii), the internal covering textile part and / or the external covering textile part each comprises one or more textile loops for lacing, in particular knitted, not comprising a thermofusible textile portion, and at least one lace (in particular at least partly textile) is passed through one or more loops and does not comprise a thermofusible textile portion. This arrangement makes it possible to improve the productivity of the method for manufacturing the footwear article by avoiding lacing operations carried out after thermocompression (iii).

[0307] The alternative embodiments, definitions and embodiments with reference to the first aspect of the invention apply independently of one another to the manufacturing method according to a second aspect of the invention.

[0308] Description of the drawings

[0309] The invention will be better understood on reading the following description of the embodiments of the invention given as non-limiting examples, with reference to the appended drawings, in which:

[0310] [Fig. 1] Figure 1 schematically illustrates a shoe of the state of the art on which the different upper regions defined in the present text are represented with reference to the article of footwear according to the invention;

[0311] [Fig. 2] Figure 2 schematically illustrates the different regions of the sole structure shown in Figure 1;

[0312] [Fig. 3] Figure 3 schematically illustrates a first example of an internal textile tubular element arranged in the receiving volume of a foot of a first example of an external textile tubular element;

[0313] [Fig. 4] Figure 4 schematically represents a second example of an internal textile tubular element and a second example of an external textile tubular element of unitary textile construction, in particular integral at the level of their foot introduction openings;

[0314] [Fig. 5] Figure 5 schematically represents the internal textile tubular element of Figure 4 arranged in the receiving volume of the foot of the external textile tubular element of Figure 4;

[0315] [Fig. 6] Figure 6 schematically represents a lateral view of a first example of an article of footwear according to the invention;

[0316] [Fig. 7] Figure 7 schematically represents a part of the footwear article 100 according to the section plane VII-VII shown in Figure 6;

[0317] [Fig. 8] Figure 8 schematically represents, seen from the medial side, the article of footwear shown in Figure 6;

[0318] [Fig. 9] Figure 9 schematically represents a view from below of the footwear article of Figure 6;

[0319] [Fig. 10] Figure 10 schematically represents, seen from the lateral side, the internal textile tubular element before thermocompression used in the manufacture of the footwear article shown in Figures 6 to 9; [Fig. 11] Figure 11 schematically represents, seen from the lateral side, the external textile tubular element before thermocompression used in the manufacture of the footwear article shown in Figures 6 to 9;

[0320] [Fig. 12] Figure 12 schematically represents a side view of the internal and external textile tubular elements arranged in the upper and lower parts of the mold before their thermocompression;

[0321] Description of the embodiments

[0322] For the purpose of reference of the terminology used in this text and associated with an article of footwear, the article of footwear 10 shown in Figure 1, in particular a sports shoe, can be divided into three general regions: a forefoot region 12, a midfoot region 14 or also called midfoot 14; a heel (or rearfoot) region 16. The forefoot region 12 generally includes portions of the article of footwear 10 corresponding to the toes and the joints connecting the metatarsals to the phalanges. The midfoot region 14 generally includes portions of the shoe 10 corresponding to the arch of the foot. The heel region 16 generally corresponds to the rear portions of the foot, and notably includes the calcaneus bone.The footwear article 10 also includes a lateral side 17 and a medial side 18, which extend through each of the forefoot 12, midfoot 14, and heel 16 regions and correspond to opposite sides of the footwear article 10. More particularly, the lateral side 17 corresponds to an outer area of ​​the foot, and the medial side 18 corresponds to an inner area of ​​the foot. The footwear article 10 includes a foot insertion opening 5 for accessing the foot receiving (or receiving) volume 6.

[0323] The footwear article 10 comprises an instep area 11 extending substantially centrally between the lateral side 17 and the medial side 18 in the midfoot region and optionally partially in the forefoot region 12.

[0324] The shoe 10 also comprises a longitudinal axis L and a transverse axis T, in particular substantially perpendicular to the axis L. The shoe 10 also comprises a front side 19a and a rear side 19b.

[0325] The footwear article 10 comprises an upper 15 and a sole structure, in particular an outsole 20.

[0326] In addition to the footwear article 10, the forefoot region 12, the midfoot region 14, the heel region 16, the lateral side 17, the medial side 18, the front side 19a, the rear side 19b, the instep area 11, the foot insertion opening 5, and the foot receiving or accommodating volume 6, may apply to the sole structure or outsole 20, to the upper 15, and to their individual elements, such as for example, in a non-limiting manner, to a textile tubular element alone, or to superimposed internal and external textile tubular elements, to their respective textile foot covering parts and to their respective textile sole parts.

[0327] Figure 2 schematically represents for reference purposes, the different regions that a sole structure can comprise, corresponding to the regions defined in Figure 1. Figure 3 schematically represents a first example of an internal textile tubular element 50 and a first example of a separate external textile tubular element 60, each in a knitted textile piece, in particular each in a knitted sock. The internal textile tubular element 50 has an external face 53 and an internal face 54, in particular substantially opposite the external face 53. The external textile tubular element 60 has an external face 63 and an internal face 64, in particular substantially opposite the external face 63. The internal textile tubular element 50 comprises an internal textile covering part 52 of the foot and an internal textile sole part 55, as well as a bent portion 56 making it possible to form a heel region.In this specific example, the internal textile foot covering portion 52 extends in the forefoot, midfoot, and heel regions, from the lateral side to the medial side. In this specific example, the internal textile sole portion 55 extends between a front edge and a rear edge in the forefoot, midfoot, and heel regions, from the lateral side to the medial side.

[0328] The outer textile tubular element 60 comprises an outer textile foot covering portion 62 and an outer textile sole portion 65, as well as an angled portion 66 for forming a heel region. In this specific example, the outer textile foot covering portion 62 extends in the forefoot, midfoot, and heel regions, and this between the lateral and medial sides. In this specific example, the outer textile sole portion 65 extends between a front edge and a rear edge in the forefoot, midfoot, and heel regions, and this between the lateral and medial sides.

[0329] Advantageously, the internal textile tubular element 50 is arranged in the receiving volume 61 of the foot of the external textile tubular element 60, the tubular elements 50, 60 are thus substantially superimposed at least in part, the internal face 64 of the external tubular element 60 being opposite the external face 53 of the internal tubular element 50. The internal 50 and external 60 textile tubular elements are preferably placed on a foot-shaped preform (in particular the preform is arranged in the receiving volume of the foot of the internal textile tubular element 50), then undergo a thermocompression step during which the thermofusible textile portions of said internal 50 and external 60 textile tubular elements are thermomelted so as to secure the internal textile tubular element 50 to the external textile tubular element 60, and shape the assembly to the shape of the preform.The inner 50 and outer 60 textile tubular elements are then cooled on the preform preferably in order to freeze said shape.

[0330] During the thermocompression step, the preform is an inflatable bladder (in particular in a silicone or polyurethane material which can be inflated and deflated, and is therefore reusable). The heating temperature applied during the thermocompression step is determined so as to melt more or less the targeted hot-melt material(s). Thus, depending on the desired effects, threads can be glued together and / or stiffened and / or threads can form a film or a coating, for example coating the internal textile tubular element 50, or the external textile tubular element 60.

[0331] One or more sole elements (not shown in FIG. 3), for example a wear sole or a flexible element made of a material having a Shore A hardness of between 40 and 70, is / are arranged between the internal textile sole part 55 and the external textile sole part 65.

[0332] For example, the outsole is a part obtained by thermocompression of one or more sole element(s) which are at least partly thermofusible in a thermocompression step prior to the thermocompression step of the textile tubular elements 50,60.

[0333] For example, a sole element is / comprises particles and / or fibers that are at least partly heat-meltable, in particular entirely heat-meltable, possibly in association with non-heat-meltable particles and / or fibers within the meaning of the invention.

[0334] For example, particles are particles with an average size of 3 mm to 5 mm, and are made of polyurethane. Polyurethane can be virgin or recycled.

[0335] For example, the particles to be thermocompressed can be placed in a partially or completely thermofusible textile pocket.

[0336] The Shore A hardness of the particles is, for example, 40 to 80.

[0337] Preferably, the inner 55 and outer 65 textile sole parts consist essentially of thermofusible thread(s) or each comprise at least 80% by mass of their total mass of thermofusible thread(s).

[0338] Preferably, the outer textile covering portion 60 comprises at least 30%, in particular at least 60% by mass, of at least partially hot-melt yarn(s).

[0339] For example, the outer textile covering part 60 and the inner textile covering part 50 each comprise at least 30% by mass of non-thermal-fusible yarn(s), for example multifilament yarn(s) made of polyester (e.g. PET) having a linear mass of 450 dtex or 900 dtex.

[0340] For example, hot melt yarn is a 600 denier multifilament yarn, with a tenacity of around 2g / denier, an elongation at break of 130%, and a melting temperature of 100°C.

[0341] For example, the temperature during the preliminary step of thermocompression of the outsole ranges from 100°C to 140°C, for at least about 5 minutes and an inflation pressure of the inflatable bladder is in the order of 3 bars to 5 bars.

[0342] For example, the temperature during the thermocompression step of the tubular elements 50, 60, and the outsole, ranges from 140°C to 180°C, for example for 15 to 20 minutes, under a bladder inflation pressure of approximately 4 bars.

[0343] Preferably, during the thermocompression step, the at least partially thermofusible or entirely thermofusible threads of the internal and external textile sole parts (55, 65) are thermofused.

[0344] The inner and outer textile tubular elements 50 and 60 being preferably separate knitted pieces, they may have different configurations. For example, as shown in Figure 3, the outer textile covering portion of the foot 62 covers less of the foot than the inner textile covering portion of the foot 52, in particular the outer textile covering portion of the foot 62 does not include an instep area and covers less of the ankle than the inner textile covering portion 52.

[0345] Figure 4 schematically represents a second example of an inner textile tubular element 70 and a second example of an outer textile tubular element 80 which are of unitary textile construction, in particular in a single U-shaped knitted piece. The inner textile tubular element 70 has an outer face 73 and an inner face 74. The outer textile tubular element 80 has an outer face 83 and an inner face 84. The inner and outer textile tubular elements 70 and 80 are textileally connected at their foot insertion openings corresponding to the fold line 75 from which the inner tubular element 70 is returned into the foot receiving volume 85 of the outer textile tubular element 80. The inner 70 and outer 80 textile tubular elements are advantageously knitted socks, and each have a bent portion 72, 82.The textile tubular elements 70, 80 could alternatively be knitted together at their toes, the folding of the tubular element 70 then being carried out from the toe of the latter. In the superimposed position, the internal face 74 of the internal tubular element 70 is arranged opposite the internal face 84 of the external tubular element 80.

[0346] The internal and external textile tubular elements 70, 80 are arranged on a foot-shaped preform (not shown), in particular the preform is arranged in the receiving volume of the foot of the internal textile tubular element 70. The internal 70 and external 80 textile tubular elements then undergo a thermocompression step during which thermofusible textile portions are thermomelted to secure said internal and external textile tubular elements 70, 80 together and form them to form the preform.

[0347] The thermocompression step can take place as described with reference to the first examples of internal and external textile tubular elements (50,60).

[0348] Figures 6 to 12 show a first example of an article of footwear 100, in particular a sports shoe. The article of footwear 100 comprises an upper 110, and a sole structure 120 comprising a wear sole 130. In this specific example, the sole structure 120 consists essentially of the wear sole 130.

[0349] The upper 110 and the outsole 130 are connected by means of at least one portion, in particular textile, which is thermofused.

[0350] Advantageously, the footwear article 100 comprises an internal textile tubular element 140 comprising an internal textile covering part 145 of at least a part of the foot and an external textile tubular element 150 comprising an external textile covering part 155 of at least a part of the foot.

[0351] Advantageously, said external textile tubular element 150 is substantially a knitted sock and the internal textile tubular element 140 is also a knitted sock distinct from the knitted sock of the element 150. Alternatively, these tubular elements 140, 150 could be in knitted connection at their foot insertion openings as shown in FIG. 4 or at their toes.

[0352] Advantageously, the external textile tubular element 150 receives in its internal volume 151, that is to say the foot-receiving volume, at least in part said internal textile tubular element 140.

[0353] In one example, the internal textile covering portion 145 comprises an external face 145a, and the external textile covering portion 155 of at least a portion of the foot comprises an internal face 155b.

[0354] In one example, the outer face 145a of the inner textile covering portion 145 comprises an outer main region 148, and the inner face 155b of the outer textile covering portion 155 comprises an inner main region 158 comprising at least one textile portion that is at least partially heat-fused. In particular, the inner and outer main regions 148 and 155 are at least partially superimposed and are not glued together, in particular are not secured to each other.

[0355] In one example, the outer main region 148 extends into the forefoot region on the lateral side 102 and the medial side 104 and partially therebetween, into the midfoot region on the medial side 104 and the lateral side 102, and into the rearfoot region on the lateral side 102 and the medial side 104 and therebetween. For example, the outer main region 148 does not extend into the instep area disposed partly in the midfoot region, and partly in the forefoot region, between the lateral 102 and medial 104 sides. In particular, the outer main region 148 occupies approximately 50%, in particular at least 80%, of the outer face 145a of the inner textile covering portion 145. In particular, the outer main region 148 extends between the inner 145b and outer 145a surfaces of said inner textile covering portion 145.

[0356] In one example, the outer main region 148 does not include a heat-fused or partially heat-fused textile portion.

[0357] In the particular example of footwear article 100 shown in Figures 6-8, the inner main region 158 and the outer main region 148 are substantially continuous.

[0358] The outer main region 148 could extend along the outer face 145a at a ratio less than 80%, and comprise one or more additional outer region(s), in particular distinct from one another, distinct and separate from the outer main region 148. This arrangement varies according to the number and location of the partially heat-melted or heat-melted textile portions on the inner covering textile part 145.

[0359] In this example, the inner main region 158 extends in the forefoot region on the lateral side 102 and on the medial side 104 and between them, in the midfoot region on the medial side 104 and the lateral side 102 and between them (in particular includes an instep area), and in the rearfoot region on the lateral side 102 and on the medial side 104 and between them. In particular, the inner main region 158 occupies approximately at least 50%, in particular at least 80%, of the inner face 155b of the inner textile covering portion 155. In particular, the inner main region 158 extends between the inner 155b and outer 155a faces of said outer textile covering portion 155.

[0360] The outer main region 148 comprises in one example one or more thermofused or partially thermofused textile portions, more preferably still comprises one or more threads glued to itself and / or to each other. The inner main region 158 could extend along the inner face 155b according to a ratio less than 80%, and comprise one or more additional internal regions, in particular distinct from each other, distinct and separated from the inner main region 158. This arrangement varies according to the number and location of the partially thermofused, or thermofused, textile portions on the outer covering textile part 155.

[0361] In this example, approximately at least 50%, in particular at least 80%, of the external face 145a of the internal textile covering part 145 is not glued, in particular is not secured, to the internal face 155b of the internal textile covering part 155.

[0362] Advantageously, the internal textile covering part 145 and the external textile covering part 155 are secured to each other essentially at their respective lower peripheral edges 146, 156 extending on the lateral side 102, the medial side 104 and the front and rear edges, in particular by means of one or more thermofused textile portion(s).

[0363] Advantageously, the internal textile covering part 145 comprises a free medial upper edge 145m and a free lateral upper edge 1451.

[0364] Advantageously, the internal textile covering part 155 comprises a free medial upper edge 155m and a free lateral upper edge 1551.

[0365] In particular, the medial upper edges 145m and 155m are not integral with each other, and the lateral upper edges 1451 and 1551 are also not integral with each other. The covering parts 145 and 155 thus delimit between them a space E accessible from the outside of the footwear article 100. This space can advantageously be closed by means of a lace (not shown), for example passed through the lacing openings 112 provided near the edges 145m, 1451, 155m and 1551.

[0366] Advantageously, the inner textile tubular element 140 comprises a sole textile portion 142, in particular consisting essentially of thermofused textile portions, and the outer textile tubular element 150 comprises a sole textile portion 152, in particular consisting essentially of thermofused textile portions. The sole portions 142 and 152 thus enter the sole structure 120, in particular the outsole 130, and are arranged under the foot.

[0367] In this particular example, the upper 110 and the outsole 130 are of unitary molded construction, in particular by thermocompression as described below.

[0368] For example, thermofused materials in whole or in part, in particular recycled, form a thermocompressed sole insert 170 and arranged between the sole parts 142 and 152. Advantageously, the outsole 130 extends between an internal face 130b and an external face 130a, in particular said external face 130a is a face of engagement with the ground of the footwear article 100.

[0369] Advantageously, the outsole 130 comprises several slots 132 opening out and open on the external face 130a, each of said slots 132 having a bottom 133 and a top 135 opposite said bottom 133. The distance d between a bottom 133 and the internal face 130b of the outsole 130 is less than or equal to 0.50 times the depth (p) of the slot corresponding to said bottom (ratio A). Thus, the depth (pi) shown in Figure 7 is of the order of 20 mm for the slot 132i and the distance (di) is of the order of 3 mm between the bottom 133i corresponding to the slot 132i and the internal face 130b. The ratio A applies to all of the slots 132.

[0370] Advantageously, the distance (d) between a bottom 133 and the inner face 130b of the outsole 130 is less than or equal to 0.50 times the distance (D) between the inner face 130b of the outsole 130 and the top 135 of the slot corresponding to said bottom (ratio B). Advantageously, the ratio B applies to all of the slots 132.

[0371] The outsole 130 may further comprise slots not satisfying ratio A, and possibly not satisfying ratio B. It is however necessary for the outsole 130 to comprise slots 132 satisfying ratio A, and possibly ratio B, in order to provide sufficient flexibility to the outsole, and facilitate the rolling of the foot. Advantageously, the footwear article 100 comprises a foot receiving volume 105, and the internal face 130b of the outsole 130 opens directly into the foot receiving volume 105. In particular, the outsole 130 extends between the medial 104 and lateral 102 edges, and the front 106 and rear 108 edges of the footwear article 100. In particular, the slots 132 are arranged so as to delimit protrusions 134, in particular having free side walls, more particularly four free side walls 134a, 134b, 134c and 134d.

[0372] Advantageously, the slots 132 comprise transverse slots 132t extending between and opening onto said lateral 102 and medial 104 edges of the footwear article 100.

[0373] Advantageously, the slots 132 comprise longitudinal slots 1321 extending at least in part between said front 106 and rear 108 edges of the footwear article 100, or extending at least in part in two regions chosen from the forefoot region, the midfoot region, and the heel region, and possibly opening onto at least one of said lateral 102 and medial 104 edges.

[0374] Advantageously, the protrusions 134 each comprise a free external wall 134e, and the surface (cm 2 ) of a free external wall 134e is less than or equal to 0.20 times the total surface area of ​​the external face 130a of the outsole 130 corresponding to the external face of engagement with the ground of the footwear article.

[0375] In this embodiment, the total sum of the surfaces of the free external walls 134e represents approximately 80% of the total surface area of ​​the external face 130a of the outsole 130. Advantageously, the sole textile portion 152 of the external textile tubular element 150 perfectly matches the free side walls, for example the walls 134a, 134b, 134c and 134d, and the free external walls, for example the wall 134e, of the protrusions 134 delimited by the slots 132 as well as the bottoms 133 corresponding to said slots 132. The sole portion 152 thus forms all or part of the external engagement face 130a of the shoe 7 but also covers the periphery of the protrusions 134.

[0376] In this example, the transverse slots 132t extend across the entire width of the outsole 130, and thus have lengths ranging from 40 mm to 80 mm.

[0377] For example, the slot 132ti has a length Li of about 55 mm, and a width li of about 5 mm. The width li of the slot 132ti is the distance between the respective side walls of the two adjacent protrusions delimiting said slot 132ti, said side walls facing each other.

[0378] The 132 slots can have different widths and lengths depending on the technical effects sought.

[0379] The width of the slots 132 is preferably greater than or equal to 1 mm, more preferably ranging from 3 mm to 8 mm.

[0380] In one example, the footwear article 100 comprises a sole element, in particular an intermediate sole (not shown), arranged in the foot receiving volume 105 in a removable manner, and having an external face arranged opposite the internal face 130b of the outsole 130.

[0381] In this non-limiting example, the dotted line A represents the inner face 130b of the sole structure 130, said inner face 130b forms a foot support zone configured to receive the bottom of the foot. The inner face 130b is thus set back vertically along all or part of the upper edge 131 of the main edge 138 of the sole structure 130, for example set back 10 mm from the upper edge 131 of the rear edge, in the rear foot region. The sole structure 130 is thus hollowed out. This hollowed-out arrangement is possible due to the thermocompression method described below. It makes it possible to lighten the sole structure and to form vertical edges over all or part of the periphery of the sole structure 130, in particular the front, rear, lateral and medial edges.The numerous slots 132, transverse 132t and longitudinal 1321, delimit between them protrusions 134 having free side walls, and make it possible to provide flexibility to the outsole 130, in particular the rolling lines of the foot, thus improving comfort and proprioception.

[0382] In an exemplary embodiment not illustrated in the figures, the external 155 and internal 145 textile parts covering the foot at least in part are substantially secured to each other, in particular glued to each other, along their internal 155b and external 145a faces. In particular, said parts 145 and 155 are glued to each other by means of several partially heat-melted and / or heat-melted textile portions.

[0383] Figures 10 to 12 describe an example of a thermocompression manufacturing method according to the invention, cited without limitation, for obtaining the footwear article 100.

[0384] Figure 10 schematically represents the internal textile tubular element 140' before its thermocompression comprising an internal textile foot covering portion 145' and an internal sole textile portion 142', the element 140' preferably being a knitted sock. Advantageously, the internal textile foot covering portion 145' may comprise thermofusible textile portions, or does not comprise thermofusible textile portions. Advantageously, the internal sole textile portion 142' consists essentially of thermofusible yarn(s), in particular single-component polyurethane monofilament yarns, for example of approximately 600 denier.

[0385] Figure 11 schematically represents the external textile tubular element 150' before its thermocompression comprising an external textile foot covering part 155' and an external sole textile part 152', the element 150' preferably being a knitted sock.

[0386] Advantageously, the outer sole textile portion 152' is essentially made up of thermofusible threads, possibly in association with a high-tenacity non-thermofusible synthetic thread. The outer foot covering textile portion 155' comprises in this example one or more thermofusible threads, mixed with one or more non-thermofusible threads.

[0387] As can be seen in Figures 10 and 11, in this specific non-limiting example, the textile parts of the inner sole 142' and outer sole 152' cover substantially the entire underside of the foot but also partially envelop the foot in order to form a rim for the sole structure once thermocompressed.

[0388] During the thermocompression step, the internal textile tubular element 140' is placed in the receiving volume of the foot 151' of the external tubular element 150' and then said elements 140' and 150' are placed in a mold assembly 160 comprising an upper mold part 164 and a lower mold part 166.

[0389] Preferably, the textile covering parts of the inner 145' and outer 155' foot are arranged partly in the upper mold part 164 and the textile parts of the inner 142' and outer 152' sole are arranged in the lower mold part 166. Line B represents the joint plane between the upper and lower mold parts 162 and 164, forming the separation line after demolding between the upper 110 and the outsole 130. Advantageously, a sole assembly comprising at least partially or fully heat-meltable materials (recycled or not), possibly comprising textile materials, is arranged between the inner and outer sole parts 142', 152' and / or between the outer face 152'a of the outer sole part 152' and the lower mold part 166. Said sole assembly is therefore arranged in the lower mold part 166.Preferably, the mass of said sole assembly is greater than or equal to 100 g and less than or equal to 220 g, in particular of the order of 180 g.

[0390] Advantageously, the upper and lower mold parts 162 and 164 each comprise an internal cavity, and once assembled form a molding volume, in particular corresponding substantially to the external shape of the footwear article 100, receiving the nested internal and external tubular elements 140' and 150', and possibly said thermofusible materials.

[0391] During the thermocompression step, the mold assembly is sealed, then the lower mold part 160 is heated, in particular to a temperature between 160°C and 180°C, the inflatable bladder (not shown) is inflated, for example with an inflation pressure of the order of 4 bars to 6 bars, and thus presses the internal 140' and external 150' textile tubular elements, as well as possibly the sole assembly, against the internal cavities (not shown) of the upper 164 and lower 166 mold parts. The heat applied to the lower mold part 166 makes it possible to obtain the fusion of the thermofusible textile portions and all or part of the thermofusible material(s) of the sole assembly, which molten material flows and fills the internal cavity of the lower mold part 166.

[0392] For example, the duration of thermocompression is approximately 15-20 minutes.

[0393] Advantageously, the upper mold part 164 has a temperature much lower than the heating temperature of the lower mold part, in particular the upper mold part is not heated to a temperature between 160°C and 180°C since it is heated indirectly by the heat provided by the lower mold part. The heating temperature applied to the upper mold part 164 is therefore significantly lower than the heating temperature applied to the lower mold part 166.

[0394] The thermofusible textile portions arranged in the upper mold part 164 are thus advantageously partially thermofused, in particular the threads are glued together and / or the mesh structures are stiffened and / or glued together. The management of the heating difference between the lower mold part 166 and the upper mold part allows the internal main region 148 not to be glued with the external main region 158. This arrangement makes it possible to offer varied functionalization possibilities for the footwear article 100, for example to keep a breathable and flexible internal foot covering textile part 145, in whole or in part, with an external foot covering textile part 155 more rigid than the part 145, thus making it possible to freeze the final shape of the upper 110 using a simplified manufacturing process, and consuming little energy.

Claims

DEMANDS 1. Footwear article (100), in particular sports shoe (100), comprising an upper (110, 52, 145, 62, 155), an outsole (130) and a foot pocket (105), characterized in that the outsole (130) extends between an inner face (130b) opening into the foot pocket (105) of the footwear article (100) and an outer face (130a), the upper (110, 52, 145, 62, 155) and the outsole (130) are connected by means of at least one heat-fused portion, and said upper (110, 52, 145, 62, 155) comprises at least one textile portion that is at least partially heat-fused, in that said outsole (130) comprises one or more slot(s) (132, 132i, 132t, 1321) opening onto the outer face (130a) of said outsole (130), said slot or each of said slots (132, 132i, 132t, 1321) having a bottom (133, 133i), and the distance between a bottom (133, 133i) and the inner face (130b) of the outsole (130) is less than or equal to 0,50 times the depth (p) of the slot (132, 132i, 132t, 1321) corresponding to said bottom (133, 133i).

2. Footwear article (100) according to claim 1, characterized in that the outsole (130) comprises several slots (132, 132i, 132t, 1321) arranged so as to delimit at least one protrusion (134) between at least two adjacent slots (132, 132i, 132t, 1321), in particular said at least one protrusion (134) comprises at least two free lateral walls (134a, 134b, 134c, 134d).

3. Footwear article (100) according to claim 2, characterized in that said at least one protrusion (134) comprises a free external wall (134e), and in that the surface (cm 2 ) of said free outer wall (134e) of said at least one protrusion (134) is less than or equal to 0.20 times the total area of ​​the outer face (134a) of the outsole (130).

4. Footwear article (100) according to claim 3, characterized in that the outsole (130) comprises several protrusions (134) and in that the total sum of the areas of the free external walls (134e) of the protrusions (134) represents at least 50% of the total area of ​​the external face (130a) of the outsole (130).

5. Footwear article according to any one of claims 1 to 4, characterized in that said slit or each of said slits (132, 132i, 132t, 1321) has a depth (p) greater than or equal to 10 mm, in particular greater than or equal to 15 mm.

6. Footwear article (100) according to any one of claims 1 to 5, characterized in that the footwear article (100) comprises a medial edge (104) and a lateral edge (102), in that the outsole (130) extends between said medial (104) and lateral (102) edges and comprises one or more transverse slots (132t) extending at least in part between said lateral (102) and medial (104) edges of the footwear article (100), and optionally opening onto at least one of said lateral (102) and medial (104) edges of the footwear article (100).

7. Footwear article (100) according to any one of claims 1 to 6, characterized in that the footwear article (100) comprises a front edge (106) and a rear edge (108), in that the outsole (130) extends between said front (106) and rear (108) edges and comprises one or more longitudinal slots (1321) extending: - at least partly between said front edge (106) and rear edge (108) of the footwear article (100) and / or; - extending at least in part into at least two regions of the footwear article (100) chosen from: a rearfoot region (16), a midfoot region (14), and a forefoot region (12).

8. Footwear article (100) according to claim 7, characterized in that the outsole (130) comprises one or more transverse slot(s) (132t) intersecting one or more longitudinal slot(s) (1321).

9. Footwear article (100) according to any one of claims 1 to 8, characterized in that the outsole (130) is of unit molded construction.

10. Footwear article (100) according to any one of claims 1 to 9, characterized in that a medial edge and a lateral edge of the outsole (130) are directly connected respectively with a lateral edge and a medial edge of the upper (110, 52, 145, 62, 155), in particular are connected via at least one thermofused textile portion.

11. Footwear article (100) according to any one of claims 1 to 10, characterized in that the footwear article (100) comprises a sole element disposed within the foot compartment (105), in particular in a removable manner, and in that said element of the sole has an external face arranged opposite the internal face (130b) of the outsole (130), in particular the sole element is an intermediate sole.

12. Footwear article (100) according to any one of claims 1 to 11, characterized in that the footwear article (100) comprises a foot support area (130b) disposed in the bottom of the foot reception volume (105) of said footwear article (100), and in that the outsole (130) comprises a lateral, respectively medial, edge comprising a lateral, respectively medial rim projecting substantially over the foot support area (130b) towards the upper (110).

13. Footwear article (100) according to any one of claims 1 to 12, characterized in that said outsole (130) comprises one or more thermally melted recycled material(s) u(s), optionally one or more thermally melted recycled textile material(s).

14. Footwear article (100) according to any one of claims 1 to 13, characterized in that said article comprises: - an internal tubular textile element (50, 70, 140) comprising an internal textile part covering at least part of the foot (52, 145), and - an external textile tubular element (60,80,150) comprising an external textile part covering at least part of the foot (62,155), said external textile tubular element (60,80,150) receiving in an internal volume (61,85,151) at least in part said internal textile tubular element (50,70,140), and in that the upper (110,52,145,62,155) comprises said external (62,155) and internal (52,145) textile parts covering at least part of the foot.

15. Footwear article (100) according to claim 14, characterized in that the internal textile tubular element (50,70,140) comprises a sole part (55,142) comprising one or more thermofused textile portion(s), and in that the external textile tubular element (60,80,150) comprises a sole part (65,152) comprising one or more thermofused textile portion(s).

16. Footwear article (100) according to any one of claims 1 to 15, characterized in that at least a part of the upper (110,52,145,62,155), and at least a part of the outsole (130), are in a molded piece, in particular in a thermo-compressed piece.

17. Footwear article (100) according to any one of claims 1 to 16, characterized in that at least a part of the outsole comprises thermofused particles at least in part, and agglomerated together.

18. A method for manufacturing a footwear item (100), in particular according to any one of claims 1 to 17, characterized in that it comprises the steps: (i) molding by thermocompression: - at least one tubular textile element (140', ISO 7 ), in particular external, including a textile part covering at least part of the foot (145', 155'), - said textile part, in particular external, covering (145', 155') comprising one or more heat-fusible textile portion(s), - and an outsole assembly comprising one or more thermofusible outsole element(s) at least in part or thermomelted u(s) at least in part, with a molding assembly comprising an outsole impression comprising one or more notches, each or all of said notches having a bottom, so as to melt or soften said thermofusible textile portion(s) of said textile part, in particular external, covering at least in part of the foot (145', 155'), and said thermofusible outsole element(s) at least in part or thermomelted u(s) at least in part of the outsole assembly;(ii) a footwear article (100) is demolded, comprising an upper (110, 52, 145, 66, 155) including at least one textile portion at least partially thermofused, and an outsole (130) connected to said upper (110, 52, 145, 66, 155) by means of at least one thermofused portion, said outsole (130) extending between an inner face (130b) opening into a foot pocket (105) of the footwear article (100) and an outer face (130a), the outsole (130) comprising one or more slots (132, 132i, 132t, 1321) opening onto the outer face (130a) of said outsole (130), each or all of said slot(s) (132, 132i, 132t, 1321) having a bottom (133, 133i), and the distance from a bottom (133, 133i) and the inner face (130b) of the outsole (130) is less than or equal to 0.50 times the depth of the slot (132, 132i, 132t, 1321) corresponding to said bottom (133, 133i).; 19. A manufacturing method according to claim 18, characterized in that the molding assembly comprises an inflatable bladder and a mold, and in that the inflatable bladder is arranged within an internal volume of the textile tubular element (140', ISO 7 ), said tubular textile element (140', 150 7 ) and said sole assembly being thermo-compressed between an inner face of the mold and the inflatable bladder in an inflated state.

20. Manufacturing method according to either of claims 18 and 19, characterized in that said sole assembly comprises at least 80 g of one or more thermo-fusible outsole element(s) at least in part or thermo-melted u(s) at least in part, in particular comprising one or more recycled thermo-fusible or thermo-melted u(s) material(s), in particular derived from textile waste and / or footwear waste.

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