Liquid thermoplastic polymer application patterns for high traction applications

Abstract

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

Description

FIELD OF THE INVENTION

[0001] The present invention relates to a sole structure, preferably for a sports shoe, comprising a base layer and a polymer layer arranged on a ground-facing side of the base layer in a pattern, wherein the pattern comprises one or more first areas and one or more second areas having a lower thickness than the one or more first areas and wherein the pattern comprises an alternating arrangement of first areas and second areas such that a longitudinal extension of the first areas and of the second areas is essentially perpendicular to a longitudinal axis of the sole structure, and / or wherein the surface area of the first areas is at least two times the surface area of the second areas for providing grip when in contact to a surface, preferably a wet surface. Furthermore, the present invention relates to a shoe comprising the sole structure and a method of manufacturing the sole structure.BACKGROUND

[0002] Sufficient traction on soles, in particular for sport shoes is essential for improving performance and safety during the course of a workout. Reducing the slipperiness of sport soles on smooth surfaces is necessary and desirable for enhancing athletic performance and preventing injuries. For doing so, advanced materials as well as surface design and coatings are used in the manufacture of sport soles. Specialized rubber compounds are used as they offer high friction on smooth surfaces. Modern sport soles use blends of synthetic and natural rubbers to enhance grip. For instance, one approach is to design compounds that soften at higher temperatures which leads to increasing traction when the sole warms up during activity.

[0003] A different approach for enhancing the traction of soles is incorporating nanoparticles, such as silica or carbon black, into rubber matrices, which can improve both durability and grip. These materials enhance the microstructure of the rubber, which provides a better interaction with the surface. Furthermore, advanced designs include micro-textures on the sole that increase the contact area, which improves the grip on smooth surfaces. Another approach to prevent slipping comprises sole coatings that repel water or absorb it depending on the application. This approach is primarily used to maintain traction in wet conditions.

[0004] EP 1 784 095 B1 concerns a sports shoe with an upper and a sole, which provides on the bottom a pattern of traction which aids to grip into the surface of a grass court or hard court, in which the running sole is moulded on directly inside the upper and only the traction aids protrude out through the upper in order to reduce weight and at the same time retain mechanical strength and flexibility.

[0005] Furthermore, US 8 800 174 B2 concerns shoe soles with and without removable / replaceable gripping pods for athletic or sport shoes with enhanced traction. The sole portions or gripping pods may be provided with a supply of a substance that exhibits a tackiness for enhancing friction between the shoe sole and hard floor.

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

[0007] DE 10 2021 107 373 A1 relates to a sole of a shoe which comprises a sole body and a plurality of lower projections and a plurality of upper projections, each arranged at least at a location corresponding to a forefoot in the sole body.

[0008] DE 10 2014 219 918 A1 relates to soles for shoes, in which the sole includes a porous mesh and a continuous first layer arranged at least partially on a first side of the porous mesh, wherein the first layer penetrates the porous mesh at least partially to form a tread structure on a second side of the porous mesh opposite the first side, and wherein the first layer and the porous mesh are bonded at least in an area where the tread structure is formed.

[0009] However, a common disadvantage of these soles is that the final sole may provide great traction in dry conditions, however struggle to maintain the high levels of grip on surfaces that are smooth. This is even more disadvantageous for wet surfaces for outdoor sport activities when performed during wet weather conditions.SUMMARY OF THE INVENTION

[0010] Therefore, the object of the present invention is to provide an improved sole structure and a method for manufacturing the same, as well as a sports shoe comprising the sole structure in order to at least partly overcome the above-mentioned deficiencies of the prior art.

[0011] The above-outlined problems are addressed by the aspects of the present invention.

[0012] In a first aspect, the present invention relates to a sole structure, preferably for a sports shoe, comprising: a. a base layer; and b. a polymer layer arranged on a ground-facing side of the base layer in a pattern; wherein the pattern comprises one or more first areas and one or more second areas; wherein the one or more second areas have a lower thickness than the one or more first areas; and wherein the pattern comprises an alternating arrangement of first areas and second areas such that a longitudinal extension of the first areas and of the second areas is essentially perpendicular to a longitudinal axis of the sole structure, and / or wherein the surface area of the first areas is at least two times the surface area of the second areas.

[0013] The sole structure of the present invention has shown to enhance traction on smooth and wet surfaces while reducing the probability of slipping. When using the sole structure according to the invention, the running performance of the wearer, e.g. an athlete is substantially improved. Due to the reduced risk of slipping, e.g on wet and smooth surfaces, the sole structure provides for an improved overall workout experience and result. In particular, and when comparing to conventional sole structures, the sole structure of the present invention exhibits a drastic improvement in friction. Moreover, the sole structure has the advantage that it can be individually designed based on the friction force, which acts on the sole structure. Specifically, individual gait patterns and leading force vectors can be used to tailor the specific application of the sole structure to e.g. the individual running style of an athlete. Furthermore, the sole structure is considerably lighter and thinner, due to the inventive materials and manufacturing method, making the overall sole structure more desirable.

[0014] A "sole structure" according to present disclosure is but not limited to the bottom part of a shoe or footwear that provides cushioning, support, and traction for the wearer.

[0015] A "polymer layer" according to present disclosure is but not limited to, a layer comprising one or more polymers. The polymer layer is preferably made from durable and long-lasting materials. In particular, the polymer material will provide for the contacting zone, which is in contact with the ground during e.g. the course of a gait. Furthermore, the polymer layer provides flexibility, durability, cushioning, and support in the sole structure.

[0016] A "base layer" according to present disclosure is but not limited to, a foundational part of the sole structure and helps to maintain the structural integrity of the sole structure. The base layer may include materials that absorb shock and reduce the impact on the joints. The base layer is made from durable materials to withstand the wear and tear of regular use. The base layer works in conjunction with other layers of the sole structure and the sports shoe, and in particular with the polymer layer.

[0017] In some embodiments, the polymer layer in the one or more first areas may have a thickness of 0.1 mm - 0.9 mm, preferably 0.2 mm - 0.8 mm, more preferably 0.3 mm - 0.7 mm, even more preferred 0.4 mm- 0.6 mm, most preferred 0.5 mm.

[0018] This specific thickness of the polymer layer provides for an overall thin sole structure. This has the advantage that a more natural movement of the foot is enabled, which allows for a better flexion of the foot and e.g. toe splay. In this manner, a more natural gait is encouraged which reduces strain on certain parts of the foot and leg.

[0019] Moreover, by using the polymer layer with the specific thickness, the proprioception of the feet on the ground for the wearer is enhanced. This is especially important in sports like running, barefoot-style training, and agility drills, where precise foot placement and balance are important. Furthermore, by using the polymer layer of the present invention, less material between the foot and the ground is provided than compared to conventional soles which leads to quicker response times for the wearer. This is advantageous in sports requiring rapid changes in direction, acceleration, or deceleration. In addition, the specific thickness of the polymer layer keeps the foot closer to the ground which reduces the "stack height" of e.g. the sports shoe. This improves stability and balance when using the polymer layer of the present invention.

[0020] In some embodiments, the polymer layer in the one or more second areas may have a thickness of 0 mm. In this manner, the second areas are free from polymer and only comprise the base layer. This leads to an enlarged surface area of the sole structure, which enhances the grip on the ground and the traction of the sole structure.

[0021] In some embodiments, the pattern may be a grid, lattice, line, spiral, honeycomb, dots, wave, sine wave pattern or any combination thereof. Alternatively, or in addition, the pattern may be an outlined and / or filled pattern. In some embodiments, the polymer layer in the one or more second areas may have the same thickness as in the one or more first areas.

[0022] These specific patterns improve the traction of the sole structure, which helps the wearer to maintain a secure footing on a variety of surfaces. Due to this improved traction, the wearer experiences greater stability, which reduces the chances of slipping or losing balance. This is especially important in sports requiring sudden stops, lateral movements, and quick turns, such as e.g. running, football, basketball, and tennis. In particular, using the patterns of the present invention allows for faster turns, cuts, and lateral movements.

[0023] In some embodiments, each of the one or more first areas may comprises a higher amount of polymer than each of the one or more second areas.

[0024] This difference in amount of the polymer on the first and second areas provides for a varying height which offer better grip across multiple surface types, such as for example wet, dry, muddy, or uneven terrain. The first areas can dig into softer surfaces like grass or dirt, while the second areas maintain contact on harder surfaces. In this manner, the grip of the sole structure is improved.

[0025] In some embodiments, the surface area of the one or more first areas may be at least 2.5 times the surface area of the one or more second areas, preferably at least 3 times.

[0026] These specific ratios of first and second areas allow for the enhanced grip and traction of the sole structure.

[0027] In some embodiments, the pattern may comprise an alternating arrangement of first areas and second areas such that a longitudinal extension of the first areas and of the second areas may be essentially perpendicular to a longitudinal axis of the outsole, wherein the first areas may have a length, depth and / or width in a direction essentially perpendicular to the longitudinal extension of at least 1.0 mm, preferably at least 2.0 mm, more preferably at least 2.5 mm, most preferred at least 3.0 mm; and / or of at most 9.0 mm, preferably at most 7.0 mm, more preferably at most 5.0 mm, most preferred at most 3.5 mm, and / or wherein the second areas may have a length, depth and / or width in a direction essentially perpendicular to the longitudinal extension of at least 0.2 mm, preferably at least 0.3 mm, more preferably at least 0.4 mm, most preferred at least 0.5 mm; and / or of at most 3.0 mm, preferably at most 2.5 mm, more preferably at most 2.0 mm, most preferred at most 1.5 mm.

[0028] This specific length, depth and / or width have shown improved traction characteristic. In particular, the essentially perpendicular first and second areas provide for a superior grip of the sole structure on wet and / or smooth surfaces.

[0029] In some embodiments, the polymer in the polymer layer may be from the group of polyurethanes (PU), thermoplastic polyamides (TPE-A or TPA), thermoplastic polyesters (TPE-E or TPE), thermoplastic styrenic block copolymers (TPE-S or TPS), thermoplastic polyurethanes (TPE-U or TPU), thermoplastic vulcanizates (TPE-V or TPV), rubber or ethylene-vinyl copolymer (EVA), preferably thermoplastic polyurethanes (TPE-U or TPU), and / or combinations thereof.

[0030] These polymers allow for an enhanced traction while reducing the probability of slipping. Moreover, the use of these specific polymers has shown that a time efficient and sustainable process in the production of the sole structure is achieved while providing for a more durable and long-lasting sole structure. Suitable polymer materials may be elastic foam materials, such as thermoplastic elastomers and / or elastomers. Preferred materials used in present disclosure are thermoplastic elastomers. More preferred materials used in present disclosure are urethane-based thermoplastic elastomers (TPU), polyester-based thermoplastic elastomers (TPE) and / or polyamide-based thermoplastic elastomers (TPA).

[0031] The polymer may be characterized by a Shore A value and / or Shore D value, wherein the Shore A value may be in the range of 20 to 120, preferably, 40 to 100, more preferably, 60 to 80; and the Shore D value may be in the range of 2 to 80, preferably 5 to 75, more preferably 8 to 70. The use of a polymer comprising these Shore A and / or Shore D values provide for the durable properties of the polymer layer and the overall sole structure.

[0032] In some embodiments, the one or more first areas and the one or more second areas may have an undulating shape.

[0033] The undulating shape allows for an enlarged surface area of the sole structure while the longitudinal extension of the first and second areas are essentially perpendicular to the longitudinal axis of the sole structure. In this manner, the sole structure provides for an enhanced traction and grip.

[0034] In some embodiments, the undulating shape may have an amplitude of at least 1 mm, preferably at least 2 mm, more preferably at least 3 mm, most preferred at least 3.5 mm; and / or at most 9 mm, preferably at most 8 mm, more preferably at most 7 mm, even more preferably at most 6 mm, even more preferably at most 5 mm, most preferred at most 4.5 mm.

[0035] It has been shown that these specific amplitude values of the undulating shape enhance the traction properties of the sole structure.

[0036] In some embodiments, the undulating shape may essentially correspond to a sine wave. In some embodiments, the undulating shape may have a wavelength of at least 2 mm, preferably at least 4 mm, more preferably at least 6 mm, most preferred at least 7 mm; and / or at most 14 mm, preferably at most 12 mm, more preferably at most 10 mm, most preferred at most 9 mm.

[0037] It has been shown that the specific wavelength exhibits superior traction properties for the sole structure on wet surfaces.

[0038] In some embodiments, the ratio between amplitude and wavelength may be of at least 0.1:4, preferably at least 0.2:3, more preferably at least 0.3:2, most preferred at least 0.8:3.5 and / or at most 3:0.5; preferably at most 2:1, more preferably at most 1:1, most preferred at most 1:2.

[0039] These specific ratios between wavelength and amplitude provide for beneficial grip properties of the sole structure.

[0040] In some embodiments, the pattern may be a line-shaped pattern and the width of the first area of the one or more first areas may be of at least 1 mm, preferably at least 1.5 mm, more preferably at least 2 mm, most preferred at least 3 mm and / or wherein the second area of the one or more second areas may have a width of at least 0.3 mm, preferably at least 0.7 mm, most preferred at least 1 mm.

[0041] In some embodiments, the shoe may be a running shoe. By using the sole structure of the present invention, an improved sports shoe is provided which shows superior traction on wet and smooth surfaces.

[0042] In some embodiments, the base layer may be a midsole of the sports shoe or a portion thereof.

[0043] In this manner, the sole structure of the present invention is directly integrated into the midsole. This reduces the overall weight of the sports shoe, making it more desirable and material efficient. It is conceivable that the base layer may comprise cushioning elements.

[0044] In some embodiments, the polymer layer may be arranged in one or more sections corresponding to sections of the sports shoe, including a toe section, a forefoot section, a heel section, a midfoot section, a sidewall section and / or an upper section.

[0045] By doing so, the sole structure can be designed based on individual needs of the wearer. For example, the polymer layer may be arranged in sidewall sections for providing more grip when quickly turning and cutting when e.g. playing basketball.

[0046] In a second aspect, the present invention relates to a sports shoe comprising the sole structure according to the present invention. The sports shoe of the present invention exhibits improved traction and grip properties, in particular on wet and / or smooth surfaces. Moreover, the grip and traction during workouts is improved when using the sports shoe of the present invention. In some embodiments, the sports shoe may be a running shoe. The running shoe of the present invention shows an improved traction when used during running. In particular, when using the running shoe of the present invention e.g. during wet weather conditions, the sole structure provides for a reduced risk of slipping of the wearer.

[0047] In a third aspect, the present invention relates to a method for manufacturing a sole structure, preferably for a sports shoe, comprising the steps of: a. providing a polymer, b. providing a solvent, c. mixing the polymer with the solvent, thereby forming a liquified polymer, d. arranging the liquified polymer of step c) onto a base layer, e. curing the arranged liquified polymer on the base layer, and f. thereby providing the sole structure with a pattern comprising one or more first areas and one or more second areas, wherein in step d) the liquified polymer is arranged on the base layer in the pattern and / or wherein after step e) the pattern is obtained by post-processing the cured polymer, and wherein arranging the liquified polymer provides for an alternating arrangement of first areas and second areas such that a longitudinal extension of the first areas and of the second areas is essentially perpendicular to a longitudinal axis of the sole structure, and / or wherein the surface area of the first areas is at least two times the surface area of the second areas.

[0048] A "solvent" according to present disclosure is but not limited to, a compound capable of dissolving, dispersing, or extracting the polymer.

[0049] "Curing" according to present disclosure is to be understood but not limited to, as a the chemical and / or physical process of hardening, setting and / or solidification of the polymer. Curing may be carried out using radiation.

[0050] "Mixing" according to present disclosure is to be understood but not limited to, as a process of combining to or more substances resulting in a mixture of the individual substances, preferably in a liquid form.

[0051] "Arranging" according to present disclosure is to be understood but not limited to, as a process of applying and depositing for example the liquified polymer onto the base layer.

[0052] The "liquified polymer" is to be understood but not limited to, as the polymer having semi-solid or liquid physical properties.

[0053] "Post-processing", "texturing" or "post-treating" according to present disclosure is to be understood but not limited to, as a process of manipulating physical properties of the sole structure that enhances the traction of the sole structure. In particular, this may be done by external influence, e.g. mechanical force, laser and / or addition of additives. By doing so, a texture is provided by the sole structure which can considerably improve the traction characteristic of the sole structure.

[0054] The advantages of the method for manufacturing a sole structure are avoiding e.g. glue- and injection molding-based deposition while providing a sole structure with enhanced traction and friction performance. While the sole structure can be specifically used to create a lighter and thinner e.g. outsole, the sole structure can be further used to enhance the grip of the sports shoe for particular workouts, e.g. when arranging the liquified polymer in particular zones of the sports shoe.

[0055] A conventional sole structure, for example an outsole for a sports shoe usually is manufactured by e.g. injection molding. The method according to the invention is based on a different approach, namely, the production of a liquified polymer by mixing the polymer and the solvent and which is applied and cured on the base layer. In this manner, the sole structure is manufactured more efficiently while the liquified polymer can be arranged more precisely and effectively. By doing so, no material waste is produced e.g. by cutting excess material. In this manner, the method according to present invention provides for an improved method for producing the inventive sole structure for e.g., a sports shoe, by only consuming as much material as needed and avoiding any waste production.

[0056] It has been shown that using a liquified polymer is advantageous for the overall manufacturing process, as the properties of the liquified polymer can be finetuned based on specific process requirements. Specifically, the liquified polymer can exhibit a different dynamic viscosity by increasing or decreasing the amount of solvent. In this manner, the deposition of the polymer can be significantly affected i.e. the polymer can be deposited onto the base layer in a more efficient manner.

[0057] Furthermore, no manual assembly is required as well as a glue-less application is possible, providing for an efficient process with reduced material consumption and consequently reduced overall costs, that is applicable to automated processes. Gluing may require complex pretreatment of the components and additionally adhesives used for the gluing of plastic components are often harmful or environmentally hazardous.

[0058] The liquified polymer may be deposited on predetermined portions of the sports shoe. For example, the liquified polymer may be arranged only in the heel section or the toe section. Moreover, the liquified polymer may comprise different physical properties on each of the predetermined portions. In this manner, the sports shoe may be conceptually adapted to individual needs while allowing for a lighter total weight of the sports shoe as well as enhancing its durability and traction.

[0059] In some embodiments, the method may further comprise the step of texturing, wherein the step of texturing may occur prior to the step of curing the liquified polymer. The step of texturing may comprise adding additives. For example, rubber particles may be added to the liquified polymer. The rubber particles may have a grain size of 0.3 - 0.4 mm. After curing the liquified polymer, the sole structure obtains a grainy design with an uneven surface structure. Another example for texturing comprises the addition of e.g. silica, preferably 2 wt.-% (e.g. Evonik Acematt TS100 or Evonik Acematt 790) to the polymer before mixing with the solvent. In this manner, the produced sole structure has a matte appearance. It has been shown that the step of post-treating according to the invention provides for a sole structure which exhibits 30 % better traction as compared to conventional sole structures.

[0060] Texturing the polymer precedes the curing step. It is also possible that the polymer is textured after curing the polymer. In this manner, the pattern is obtained by post-treating, e.g. mechanically roughing the polymer.

[0061] In some embodiments, the method may further comprise post-treating mechanically the cured polymer.

[0062] For example, the sole structure can be treated in an abrasive manner by using a rotary brush. In this manner a texture is added to the sole structure. By doing so, the surface area of the sole structure is enlarged, which leads to better traction. Moreover, the surface of the sole structure is manipulated in this manner and individual designs are provided which may be desirable for e.g. the wearer. The choice of the post-treating device depends on the desired pattern and / or the physical characteristic of the cured polymer.

[0063] In some embodiments, post-processing the cured polymer may comprise laser treatment.

[0064] The laser treatment may be performed by manipulating the thickness of the polymer layer, i.e. cutting out specific areas on the polymer layer which thereby provides for the second areas of the sole structure. For example, the surface of the sole structure may be engraved via laser energy. In this manner, the top surface is treated by the laser and e.g. burnt away. Preferably, this will affect about 0.3 mm of the thickness of the cured polymer. By doing so, an improved look of the sole structure is crafted while providing for second areas.

[0065] In some embodiments, the solvent may be a mixture selected from the group of solvent-borne and / or water-borne solvents, preferably from the group of solvent-borne solvents, more preferably from the group of (C1-C6) ethers, (C1-C10) esters, (C1-C8) ketones, (C1-C8) alkanes, and / or combinations thereof.

[0066] The solvent may be a mixture of one or more of tetrahydrofuran (THF), methyl ethyl ketone (MEK), cyclohexane (CYC), ethyl acetate, butyl acetate, preferably THF and / or CYC. These solvents have the advantage that they provide for a homogenous mixture when mixed with the polymer. Moreover, the solvents have the advantage that they can be removed in a time efficient manner during the curing process and allow for a production process that is capable of adapting to various physical properties of the liquid polymer.

[0067] In some embodiments, in step e) curing may take place at a temperature of between 20°C to 150°C, preferably 30°C to 100°C, more preferably 40°C to 50°C, and the curing time may be between 2 min to 750 min, preferably, 5 min to 390 min, more preferably 10 min to 30 min.

[0068] These specific curing temperatures have the advantages to provide for a quick curing time.

[0069] In some embodiments, during step c) the ratio of the polymer to solvent in the mixture may be in the range of 10 to 90 wt.%., preferably 20 to 80 wt. %, more preferably 30 to 70 wt. %.

[0070] It has been shown that the specific ratios provide for a desirable viscosity of the liquified polymer.

[0071] In some embodiments, arranging the liquified polymer of step c) onto a base layer may be performed with a dynamic viscosity of 10000 to 50000 mPa·s, preferably of 20000 to 40000 mPa·s.

[0072] These specific viscosities provide for a quick arranging process of the liquified polymer onto the base layer. In this manner, the overall process is performed in a time- and energy-efficient manner.

[0073] The dynamic viscosity is measured via rotational viscometry. The viscosity is determined by applying rotational shear stress and observing the resistance to rotation. In particular, the viscosity is determined by measuring the fluid's resistance of the liquified polymer by rotating a probe in a sample of the liquified polymer and measuring the torque needed to turn the probe.

[0074] In some embodiments, the outsole may be the sole structure according to the first aspect of the invention. In addition or alternatively, the sole structure may be a sole. Using the inventive sole structure as an outsole and / or sole has shown to improve the traction of the sports shoe.

[0075] In a fourth aspect, the present invention relates to an outsole which is obtained by the method according to the third aspect of the invention.

[0076] The many advantages discussed in the context of the other aspects of the present invention apply also to the outsole obtained by the method according to the third aspect, i.e. the method of the present invention.

[0077] We emphasize that all aspects, features, and options discussed and disclosed above within the context of the first aspect may be applied to, or combined with, the discussion and disclosure of the second aspect, and vice versa, unless physically or technically ruled out, even if not every possible combination or sub-combination of features is explicitly spelled out in the following. The technical advantages of such options and features that have already been discussed above are therefore not repeated, at least not to the same degree of detail, and reference is instead made to the corresponding explanations above, for conciseness.SHORT DESCRIPTION OF THE FIGURES

[0078] Possible embodiments of the present invention are further described in the following detailed description with reference to the following figures: Fig. 1: shows an embodiment of a sole structure comprising a line-shaped pattern. Fig. 2: shows an embodiment of a sole structure comprising an undulating pattern. Fig. 3: shows an embodiment of a sole structure comprising a grid-shaped pattern which has been post-processed. Fig. 4: shows an embodiment of a sole structure comprising a wave-shaped pattern which has been post-processed. Fig. 5: shows three embodiments of textured and post-treated sole structures. Fig. 6: is a diagram showing the friction properties of sole structures according to the invention in a comparative manner. Figs. 7a-7c: show preferred embodiments of sport shoes comprising the sole structures according to the invention. Fig. 8: shows a flow diagram of the method for manufacturing the sole structure. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0079] Possible embodiments of the different aspects of the present invention and disclosure are described below, predominately with respect to sport shoes. It is, however, once again emphasized that the different aspects may also be practiced in different kinds of soles and shoes and are not limited to the specific embodiments set forth below.

[0080] Reference is further made to the fact that in the following only individual embodiments can be described in more detail. The skilled person will understand that the features and possible modifications described with reference to these specific embodiments may also be further modified and / or combined with one another in a different manner or in different sub-combinations, without departing from the scope of the present invention and disclosure. Individual features or sub-features may also be omitted if they are dispensable to obtain the desired result. In order to avoid redundancies, reference is therefore made to the explanations in the preceding sections, which also apply to the following detailed description.

[0081] Fig. 1 shows an embodiment of the sole structure 10. The sole structure 10 comprises a base layer 40 on which a polymer layer 30 is arranged in a line-shaped pattern 50.

[0082] The pattern 50 comprises first areas 35 and second areas 45. The first and second areas 35, 45 are arranged in an alternating manner in the pattern 50. As can be seen in Fig. 1, the first and second areas 35, 45 are essentially perpendicular to a longitudinal axis (shown as a dashed line) of the sole structure 10.

[0083] However, the pattern 50 can be also a grid, lattice, line, spiral, honeycomb, dots, wave, sine wave pattern or any combination thereof.

[0084] The first areas 35 comprise a higher amount of polymer than the second areas 45. As can be seen, the second areas 45 are free from the polymer layer 30. In other words, the polymer layer 30 in these second areas 45 has a thickness of 0 mm. The polymer layer 30 in the first areas 35 has a thickness of 0.5 mm. However, the thickness of the polymer layer in the first areas 35 may vary depending on the individual requirements of application. The sole structure 10 thus can have a thickness which is in between 0.1 - 0.9 mm. The surface area of the first areas 35 is significantly higher than the surface area of the second areas 45. Preferably, the surface area of the first areas 35 is at least 3 times higher.

[0085] The first areas 35 in Fig. 1 have a depth in a direction essentially perpendicular to the longitudinal extension. The depth of the first areas 35 is of at least 1.0 mm, preferably at least 2.0 mm, more preferably at least 2.5 mm, most preferred at least 3.0 mm. The width of the second areas 45 are of at most 9.0 mm, preferably at most 7.0 mm, more preferably at most 5.0 mm, most preferred at most 3.5 mm. The second areas 45 have also a depth in a direction essentially perpendicular to the longitudinal extension of the sole structure. The depth of the second areas 45 is of at least 0.2 mm, preferably at least 0.3 mm, more preferably at least 0.4 mm, most preferred at least 0.5 mm; and / or of at most 3.0 mm, preferably at most 2.5 mm, more preferably at most 2.0 mm, most preferred at most 1.5 mm.

[0086] In particular, the first areas 35 have a width which is of at least 1 mm. The width of the first areas 35 is preferably at least 1.5 mm, more preferably at least 2 mm, most preferred at least 3 mm. The second areas 45 have a width which is of at least 0.3 mm. Preferably, the width of the second areas 45 is of at least 0.7 mm, most preferred at least 1 mm.

[0087] The polymer layer 30 comprises a TPU-based polymer. However, the polymer in the polymer layer 30 can be also from polyurethanes (PU), thermoplastic polyamides (TPE-A or TPA), thermoplastic polyesters (TPE-E or TPE), thermoplastic styrenic block copolymers (TPE-S or TPS), thermoplastic polyurethanes (TPE-U or TPU), thermoplastic vulcanizates (TPE-V or TPV), rubber or ethylene-vinyl copolymer (EVA).

[0088] It is conceivable that the base layer 40 is partly or completely integrated into a midsole of the sports shoe. Preferably, the polymer layer 30 is the outsole of the sports shoe. The sports shoe comprising the sole structure 10 is in particular a running shoe. In this case, the running shoe comprises superior traction properties due to the sole structure 10. This is advantageous in particular when running on wet and / or smooth ground e.g. outside during wet weather conditions.

[0089] To avoid redundancies, only additional features and / or differences will be described in the following with respect to the embodiments shown in the Figs. 2 to 7.

[0090] As can be seen in Fig. 2, the first and second areas 35, 45 of the sole structure 10 have an undulating shape which corresponds to a sine wave. In particular the second areas 45 have a lower thickness and width than the first areas 35. In this manner, the surface area of the first areas 35 ins enlarged. In particular, the surface area of the first areas 35 is at least 2.5 times the surface area of the second areas 45. Preferably, the ratio of surface area between the first and second areas 35, 45 can be at least 3 times.

[0091] The undulating shape of the first and second areas 35, 45 has a wavelength of at least 2 mm. It is conceivable, that the wavelength can be at least 4 mm, more preferably at least 6 mm, most preferred at least 7 mm. Furthermore, the wavelength of the undulating shape of the first and second areas 35, 45 is at most 14 mm. Preferably this wavelength can be at most 12 mm, more preferably at most 10 mm, most preferred at most 9 mm.

[0092] Specifically, the undulating shape of the first and second areas 35, 45 has an amplitude which is of at least 1 mm and at most 9 mm. It is conceivable that the amplitude can be of at least 2 mm, more preferably at least 3 mm, most preferred at least 3.5 mm. Furthermore, this amplitude of the undulating shape can be of at most 8 mm, more preferably at most 7 mm, even more preferably at most 6 mm, even more preferably at most 5 mm, most preferred at most 4.5 mm.

[0093] When putting the wavelength and the amplitude of the undulating shape in relation to each other, the ratio between amplitude and wavelength is of at least 0.1:4. However, the ratio can be of preferably at least 0.2:3, more preferably at least 0.3:2, most preferred at least 0.8:3.5.

[0094] The ratio between the wavelength and the amplitude is furthermore of at most 3:0.5. Preferably, the ratio can be of at most 2:1, more preferably at most 1:1, most preferred at most 1:2.

[0095] In Fig. 3, the pattern 50 has a grid-shaped pattern. The sole structure 10 comprises an alternating arrangement of first areas and second areas 35, 45. The arrangement is in a longitudinal extension of the first and second areas 35, 45 is essentially perpendicular to a longitudinal axis of the sole structure (shown in dashed line). The surface area of the first areas 35 is two times the surface area of the second areas 45.

[0096] The second areas 45 have lower thickness than the first areas 35. As can be seen in Fig. 3, the second areas 45 are not free from the polymer layer 30 but comprise the polymer layer 30 with a specific thickness. This thickness is preferably of 0.2 mm. The second areas are crafted by using laser treatment. In this manner, the polymer layer 30 in the second areas 35 are cut out using laser with a depth of 0.3 mm.

[0097] Furthermore, the sole structure 10 in Fig. 3 comprises a texture. This texture is provided by using additives, in particular silica- or rubber-based additives. In this manner, the surface of the sole structure 10 is further enlarged, leading to improved traction and grip while maintain a glossy and shiny appearance. It is conceivable that the textured sole structure is further post-treated using brushes or roller devices.

[0098] Coming now to Fig. 4, the first and second areas 35, 45 have an undulating shape and both comprise polymer layer 30. The polymer layer 30 in the first areas 35 have a different thickness and width as compared to the polymer layer 30 in the second areas 45.

[0099] As can be seen in Fig. 4, the width of the second areas 45 is lower than the width of the first areas 35. In particular, the surface area of the first areas 35 is three times the surface area of the second areas 45. Just as explained in the context of the embodiment shown in Fig. 3, the sole structure 10 shown in Fig. 4 has also a texture. The texture is provided by adding silica- or rubber-based materials before curing the polymer. Moreover, the surface of the polymer layer 30 has been roughened mechanically using devices such as pattern brushes. As can be seen in Fig. 4, the sole structure 10 maintains a shiny appearance and a glossy design.

[0100] In Fig. 5, a detailed view of three different sole structures 10 are shown that comprises different textures. The sole structures 10 each comprises additives, which leads to an unlevelling of the surface of the sole structure 10. In addition, the sole structures 10 have been mechanically roughened, as a result of which a matt and rough appearance of the sole structures 10 is obtained.

[0101] The resulting appearance of the sole structure 10 depends on the mechanical treatment which has been applied. For example, a mechanical treatment comprising the application of pattern brushes or rollers can be used during post-treatment.

[0102] In Fig. 6, various embodiments of the sole structure 10 according to the invention have been tested compared to simple sole structures based on TPU and rubber material.

[0103] As can be taken from Fig. 6, the sole structures according to the invention exhibit higher friction values shown as "CoF" (coefficent of friction) than simple TPU soles.

[0104] The relationship between normal force and friction force is defined as coefficient of friction (CoF). For determining the CoF of the sole structures, a sample of a sole structure according to the present invention is placed on a test surface and a given load is applied, which corresponds to the normal force. Subsequently, the surface is moved relative to the sample through lateral force which is measured as the friction force. The measurement is performed using a Footwear / Shoe Slip Resistance Tester.

[0105] In particular, sole structures comprising the polymer layer 30 in the second areas 45 reach the highest CoF value, and an improvement in friction of 30% as compared to conventional TPU soles. This demonstrates that the sole structures of the present invention provide for a considerable enhancement of traction as compared to conventional TPU soles.

[0106] Coming now to Figs. 7a to 7c which show embodiments of sport shoes 20 or portions thereof comprising the sole structure 10 according to the present invention.

[0107] In Fig. 7a, the sports shoe 20 has a sole structure 10 wherein the base layer 40 is a midsole 65. The sports shoe 20 can be a running shoe 26. The first and second areas 35, 45 which are arranged in an undulating manner provide for a sine-waved shape. The polymer layer 30 of the sports shoe 20 is arranged in the toe section 21, the forefoot section 22, the heel section 23 and the midfoot section 24. It is further conceivable that the polymer layer 30 is arranged in the sidewall section 27 and the upper section 28 (not shown in Fig. 7a) of the sports shoe 20.

[0108] As can be seen, the essentially perpendicular arrangement of the first and second areas 35, 45 differs in the heel section 23 from the arrangement of the first and second areas 35, 45 in the toe, forefoot and midfoot sections 21, 22, 24 and are tilted of about 10° as compared to the longitudinal axis of the sole structure 10.

[0109] The first and second areas 35, 45 can have a different arrangement and be tilted of at most 35°, preferably 25°, more preferably 20°, even more preferred 20°, most preferred 15° as compared to the longitudinal axis of the sole structure 10.

[0110] As can be seen in Fig. 7b, the pattern 50 of the sole structure 10 has a line shaped pattern. In particular, the first and second areas 35, 45 are arranged as lines in a perpendicular arrangement as compared to the longitudinal axis of the sports shoe 20. The arrangement of the first and second areas 35, 45 in the heel section differ from their arrangement in the toe, forefoot and midfoot sections 21, 22, 24. In particular, the first and second areas 35, 45 comprise an outlined design. In other words, the pattern 50 of the sole structure is outlined. The outline comprises the polymer layer 30 in the heel section and the midfoot to toe section 24-21.

[0111] In Fig. 7c, the sports shoe 20 comprises an outsole based on the sole structure 10, which comprises additives. Furthermore, the sole structure 10 has been mechanically post-treated. The addition of silica- and rubber-based materials together with the mechanical post-treatment lead to an uneven surface of the sole structure 10 with a matt and rough design. Furthermore, the second areas 45 which are obtained by post-treating the sole structure 10, comprise essentially the same amount of polymer layer 30 as the first areas 35. In this embodiment, the surface area of the first areas 35 is at least two times the surface area of the second areas 45.

[0112] Coming to Fig. 8, which depicts a flowchart of a method 1000 according to the invention.

[0113] The method 1000 for manufacturing a sole structure 10, which is preferably for a sports shoe 20, comprises the first step 1010 of providing a polymer. The polymer is TPU. The polymer can be also from polyurethanes (PU), thermoplastic polyamides (TPE-A or TPA), thermoplastic polyesters (TPE-E or TPE), thermoplastic styrenic block copolymers (TPE-S or TPS), thermoplastic polyurethanes (TPE-U or TPU), thermoplastic vulcanizates (TPE-V or TPV), rubber or ethylene-vinyl copolymer (EVA).

[0114] In a second step 1020, a solvent is provided. The solvent is a mixture selected from the group of solvent-borne solvents. The solvent can be also a mixture based on water-borne solvents. Preferably the solvent is from the group of solvent-borne solvents, more preferably from the group of (C1-C6) ethers, (C1-C10) esters, (C1-C8) ketones, (C1-C8) alkanes, and / or combinations thereof.

[0115] In the next step 1030 the polymer is mixed with the solvent. In this manner, a liquified polymer is formed. The ratio of the polymer to solvent in step 1030 is in the range of 10 to 90 wt.%. Preferably the ratio can be from 20 to 80 wt. %, more preferably 30 to 70 wt. %. Subsequently, the liquified polymer is arranged onto a base layer in step 1040. When arranging the liquified polymer, the liquified polymer has a dynamic viscosity of 10000 to 50000 mPa·s, preferably of 20000 to 40000 mPa·s. Afterwards, in step 1050, the arranged liquified polymer is cured on the base layer. Curing takes place at a temperature of between 20°C to 150°C. Preferably curing takes place at 30°C to 100°C, more preferably 40°C to 50°C, and the curing time is between 2 min to 750 min, preferably, 5 min to 390 min, more preferably 10 min to 30 min.

[0116] In this manner, the sole structure is provided in step 1060 with a pattern comprising first and second areas. Arranging the liquified polymer in step 1050 provides for an alternating arrangement of first and second areas 35, 45 such that a longitudinal extension of the first and second areas 35, 45 is essentially perpendicular to a longitudinal axis of the sole structure.

[0117] In addition, or alternatively the surface area of the first areas 35 is at least two times the surface area of the second areas 45.

[0118] The method 1000 further comprises the step 1070 of texturing, which occurs prior to the step of curing the liquified polymer 1050. The step 1070 of texturing comprises adding additives and in addition or alternatively post-treating mechanically the cured polymer.

[0119] In addition, or alternatively, the pattern is obtained by post-processing the cured polymer in step 1080. Post-processing 1080 comprises laser treatment. In this manner, the second areas 45 are provided by post-processing the sole structure 10. It is noted that the above embodiments and / or examples may be combined with further aspects as described herein and details of the embodiments and / or examples may also be omitted, as will be understood by the skilled person. The scope of protection is determined by the claims and is not limited by the embodiments and / or examples disclosed in the above figures.

[0120] The invention is further described by the following embodiments: 1. A sole structure (10), preferably for a sports shoe (20), comprising: a. a base layer (40); and b. a polymer layer (30) arranged on a ground-facing side of the base layer (40) in a pattern (50); wherein the pattern (50) comprises one or more first areas (35) and one or more second areas (45); wherein the one or more second areas (45) have a lower thickness than the one or more first areas (35); and wherein the pattern (50) comprises an alternating arrangement of first areas (35) and second areas (45) such that a longitudinal extension of the first areas (35) and of the second areas (45) is essentially perpendicular to a longitudinal axis of the sole structure, and / or wherein the surface area of the first areas (35) is at least two times the surface area of the second areas (45). 2. The sole structure (10) according to the preceding embodiment, wherein the polymer layer (30) in the one or more first areas (35) has a thickness of 0.1 mm - 0.9 mm, preferably 0.2 mm - 0.8 mm, more preferably 0.3 mm - 0.7 mm, even more preferred 0.4 mm- 0.6 mm, most preferred 0.5 mm. 3. The sole structure (10) according to one of the preceding embodiments, wherein the polymer layer (30) in the one or more second areas (45) has a thickness of 0 mm. 4. The sole structure (10) according to one of the preceding embodiments, wherein the pattern (50) is a grid, lattice, line, spiral, honeycomb, dots, wave, sine wave pattern or any combination thereof. 5. The sole structure (10) according to one of the preceding embodiments, wherein each of the one or more first areas (35) comprises a higher amount of polymer than each of the one or more second areas (45). 6. The sole structure (10) according to one of the preceding embodiments, wherein the surface area of the one or more first areas (35) is at least 2.5 times the surface area of the one or more second areas (45), preferably at least 3 times. 7. The sole structure (10) according to one of the preceding embodiments, wherein the pattern (50) comprises an alternating arrangement of first areas (35) and second areas (45) such that a longitudinal extension of the first areas (35) and of the second areas (45) is essentially perpendicular to a longitudinal axis of the outsole, wherein the first areas (35) have a length, depth and / or width in a direction essentially perpendicular to the longitudinal extension of at least 1.0 mm, preferably at least 2.0 mm, more preferably at least 2.5 mm, most preferred at least 3.0 mm; and / or of at most 9.0 mm, preferably at most 7.0 mm, more preferably at most 5.0 mm, most preferred at most 3.5 mm, and / or wherein the second areas (45) have a length, depth and / or width in a direction essentially perpendicular to the longitudinal extension of at least 0.2 mm, preferably at least 0.3 mm, more preferably at least 0.4 mm, most preferred at least 0.5 mm; and / or of at most 3.0 mm, preferably at most 2.5 mm, more preferably at most 2.0 mm, most preferred at most 1.5 mm. 8. The sole structure (10) according to one of the preceding embodiments, wherein the polymer in the polymer layer (30) is from the group of polyurethanes (PU), thermoplastic polyamides (TPE-A or TPA), thermoplastic polyesters (TPE-E or TPE), thermoplastic styrenic block copolymers (TPE-S or TPS), thermoplastic polyurethanes (TPE-U or TPU), thermoplastic vulcanizates (TPE-V or TPV), rubber or ethylene-vinyl copolymer (EVA), preferably thermoplastic polyurethanes (TPE-U or TPU), and / or combinations thereof. 9. The sole structure (10) according to one of the preceding embodiments, wherein the one or more first areas (35) and the one or more second areas (45) have an undulating shape. 10. The sole structure (10) according to embodiment 9, wherein the undulating shape has an amplitude of at least 1 mm, preferably at least 2 mm, more preferably at least 3 mm, most preferred at least 3.5 mm; and / or at most 9 mm, preferably at most 8 mm, more preferably at most 7 mm, even more preferably at most 6 mm, even more preferably at most 5 mm, most preferred at most 4.5 mm. 11. The sole structure (10) according to one of embodiments 9 or 10, wherein the undulating shape essentially corresponds to a sine wave. 12. The sole structure (10) according to one of embodiments 9 - 11, wherein the undulating shape has a wavelength of at least 2 mm, preferably at least 4 mm, more preferably at least 6 mm, most preferred at least 7 mm; and / or at most 14 mm, preferably at most 12 mm, more preferably at most 10 mm, most preferred at most 9 mm. 13. The sole structure (10) according to one of embodiments 9 - 12, wherein the ratio between amplitude and wavelength is of at least 0.1:4, preferably at least 0.2:3, more preferably at least 0.3:2, most preferred at least 0.8:3.5 and / or at most 3:0.5; preferably at most 2:1, more preferably at most 1:1, most preferred at most 1:2. 14. The sole structure (10) according to one of embodiments 1 to 8, wherein the pattern is a line-shaped pattern and the width of the first area (35) of the one or more first areas (35) is of at least 1 mm, preferably at least 1.5 mm, more preferably at least 2 mm, most preferred at least 3 mm and / or wherein the second area (45) of the one or more second areas (45) has a width of at least 0.3 mm, preferably at least 0.7 mm, most preferred at least 1 mm. 15. The sole structure (10) according to one of the preceding embodiments, wherein the shoe (20) is a running shoe (25). 16. The sole structure (10) according to one of the preceding embodiments, wherein the base layer is a midsole (65) of the sports shoe (20) or a portion thereof. 17. The sole structure (10) according to one of the preceding embodiments, wherein the polymer layer (30) is arranged in one or more sections corresponding to sections of the sports shoe (20), including a toe section (21), a forefoot section (22), a heel section (23), a midfoot section (24), a sidewall section (27) and / or an upper section (28). 18. A sports shoe (20) comprising the sole structure (10) according to one of the preceding embodiments. 19. The sports shoe (25) of the preceding embodiment, wherein the sports shoe (25) is a running shoe (26). 20. Method (1000) for manufacturing a sole structure (10), preferably for a sports shoe (20), comprising the steps of: a. providing a polymer (1010), b. providing a solvent (1020), c. mixing the polymer with the solvent, thereby forming a liquified polymer (1030), d. arranging the liquified polymer of step c) onto a base layer (1040), e. curing the arranged liquified polymer on the base layer (1050), and f. thereby providing the sole structure with a pattern comprising one or more first areas and one or more second areas (1060), wherein in step d) the liquified polymer is arranged on the base layer in the pattern and / or wherein after step e) the pattern is obtained by post-processing the cured polymer, and wherein arranging the liquified polymer provides for an alternating arrangement of first areas (35) and second areas (45) such that a longitudinal extension of the first areas (35) and of the second areas (45) is essentially perpendicular to a longitudinal axis of the sole structure, and / or wherein the surface area of the first areas (35) is at least two times the surface area of the second areas (45). 21. The method (1000) according to the preceding embodiment, further comprising the step of texturing (1070), wherein the step of texturing occurs prior to the step of curing the liquified polymer; and wherein the step of texturing comprises adding additives and / or post-treating mechanically the cured polymer. 22. The method (1000) according to any one of embodiments 20 or 21, further comprising post-treating (1080) mechanically the cured polymer. 23. The method (1000) according to embodiment 20, wherein post-processing the cured polymer comprises laser treatment. 24. The method (1000) according to one of embodiments 20 to 23, wherein the solvent is a mixture selected from the group of solvent-borne and / or water-borne solvents, preferably from the group of solvent-borne solvents, more preferably from the group of (C1-C6) ethers, (C1-C10) esters, (C1-C8) ketones, (C1-C8) alkanes, and / or combinations thereof. 25. The method (1000) according to one of embodiments 20 to 24, wherein in step e) (1050) curing takes place at a temperature of between 20°C to 150°C, preferably 30°C to 100°C, more preferably 40°C to 50°C, and the curing time is between 2 min to 750 min, preferably, 5 min to 390 min, more preferably 10 min to 30 min. 26. The method (1000) according to one of embodiments 20 to 25, wherein during step c) (1030) the ratio of the polymer to solvent in the mixture is in the range of 10 to 90 wt.%., preferably 20 to 80 wt. %, more preferably 30 to 70 wt. %. 27. The method (1000) according to one of embodiments 20 to 26, wherein arranging the liquified polymer of step c) onto a base layer (1040) is performed with a dynamic viscosity of 10000 to 50000 mPa·s, preferably of 20000 to 40000 mPa·s. 28. The method (1000) according to one of embodiments 20 to 27, wherein the outsole is a sole structure according to one of embodiments 1-19. 29. An outsole (10) obtained by the method (1000) of one of embodiments 20 to 28.

Claims

1. A sole structure (10), preferably for a sports shoe (20), comprising: a. a base layer (40); and b. a polymer layer (30) arranged on a ground-facing side of the base layer (40) in a pattern (50); wherein the pattern (50) comprises one or more first areas (35) and one or more second areas (45); wherein the one or more second areas (45) have a lower thickness than the one or more first areas (35); and wherein the pattern (50) comprises an alternating arrangement of first areas (35) and second areas (45) such that a longitudinal extension of the first areas (35) and of the second areas (45) is essentially perpendicular to a longitudinal axis of the sole structure, and / or wherein the surface area of the first areas (35) is at least two times the surface area of the second areas (45).

2. The sole structure (10) according to the preceding claim, wherein the polymer layer (30) in the one or more first areas (35) has a thickness of 0.1 mm - 0.9 mm, preferably 0.2 mm - 0.8 mm, more preferably 0.3 mm - 0.7 mm, even more preferred 0.4 mm- 0.6 mm, most preferred 0.5 mm; and wherein preferably the polymer layer (30) in the one or more second areas (45) has a thickness of 0 mm.

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

4. The sole structure (10) according to one of the preceding claims, wherein each of the one or more first areas (35) comprises a higher amount of polymer than each of the one or more second areas (45); and wherein preferably the surface area of the one or more first areas (35) is at least 2.5 times the surface area of the one or more second areas (45), preferably at least 3 times.

5. The sole structure (10) according to one of the preceding claims, wherein the pattern (50) comprises an alternating arrangement of first areas (35) and second areas (45) such that a longitudinal extension of the first areas (35) and of the second areas (45) is essentially perpendicular to a longitudinal axis of the outsole, wherein the first areas (35) have a length, depth and / or width in a direction essentially perpendicular to the longitudinal extension of at least 1.0 mm, preferably at least 2.0 mm, more preferably at least 2.5 mm, most preferred at least 3.0 mm; and / or of at most 9.0 mm, preferably at most 7.0 mm, more preferably at most 5.0 mm, most preferred at most 3.5 mm, and / or wherein the second areas (45) have a length, depth and / or width in a direction essentially perpendicular to the longitudinal extension of at least 0.2 mm, preferably at least 0.3 mm, more preferably at least 0.4 mm, most preferred at least 0.5 mm; and / or of at most 3.0 mm, preferably at most 2.5 mm, more preferably at most 2.0 mm, most preferred at most 1.5 mm.

6. The sole structure (10) according to one of the preceding claims, wherein the one or more first areas (35) and the one or more second areas (45) have an undulating shape, wherein preferably the undulating shape has an amplitude of at least 1 mm, preferably at least 2 mm, more preferably at least 3 mm, most preferred at least 3.5 mm; and / or at most 9 mm, preferably at most 8 mm, more preferably at most 7 mm, even more preferably at most 6 mm, even more preferably at most 5 mm, most preferred at most 4.5 mm, wherein preferably the undulating shape essentially corresponds to a sine wave, wherein preferably the undulating shape has a wavelength of at least 2 mm, preferably at least 4 mm, more preferably at least 6 mm, most preferred at least 7 mm; and / or at most 14 mm, preferably at most 12 mm, more preferably at most 10 mm, most preferred at most 9 mm, wherein preferably the ratio between amplitude and wavelength is of at least 0.1:4, preferably at least 0.2:3, more preferably at least 0.3:2, most preferred at least 0.8:3.5 and / or at most 3:0.5; preferably at most 2:1, more preferably at most 1:1, most preferred at most 1:2.

7. The sole structure (10) according to one of claims 1 to 6, wherein the pattern is a line-shaped pattern and the width of the first area (35) of the one or more first areas (35) is of at least 1 mm, preferably at least 1.5 mm, more preferably at least 2 mm, most preferred at least 3 mm and / or wherein the second area (45) of the one or more second areas (45) has a width of at least 0.3 mm, preferably at least 0.7 mm, most preferred at least 1 mm.

8. The sole structure (10) according to one of the preceding claims, wherein the shoe (20) is a running shoe (25); and wherein preferably the base layer is a midsole (65) of the sports shoe (20) or a portion thereof.

9. The sole structure (10) according to one of the preceding claims, wherein the polymer layer (30) is arranged in one or more sections corresponding to sections of the sports shoe (20), including a toe section (21), a forefoot section (22), a heel section (23), a midfoot section (24), a sidewall section (27) and / or an upper section (28).

10. A sports shoe (20) comprising the sole structure (10) according to one of the preceding claims, preferably wherein preferably the sports shoe (25) is a running shoe (26).

11. Method (1000) for manufacturing a sole structure (10), preferably for a sports shoe (20), comprising the steps of: a. providing a polymer (1010), b. providing a solvent (1020), c. mixing the polymer with the solvent, thereby forming a liquified polymer (1030), d. arranging the liquified polymer of step c) onto a base layer (1040), e. curing the arranged liquified polymer on the base layer (1050), and f. thereby providing the sole structure with a pattern comprising one or more first areas and one or more second areas (1060), wherein in step d) the liquified polymer is arranged on the base layer in the pattern and / or wherein after step e) the pattern is obtained by post-processing the cured polymer, and wherein arranging the liquified polymer provides for an alternating arrangement of first areas (35) and second areas (45) such that a longitudinal extension of the first areas (35) and of the second areas (45) is essentially perpendicular to a longitudinal axis of the sole structure, and / or wherein the surface area of the first areas (35) is at least two times the surface area of the second areas (45).

12. The method (1000) according to the preceding claim, further comprising the step of texturing (1070), wherein the step of texturing occurs prior to the step of curing the liquified polymer; and wherein the step of texturing comprises adding additives and / or post-treating mechanically the cured polymer; wherein preferably post-processing the cured polymer comprises laser treatment.

13. The method (1000) according to claim 11 or 12, wherein arranging the liquified polymer of step c) onto a base layer (1040) is performed with a dynamic viscosity of 10000 to 50000 mPa·s, preferably of 20000 to 40000 mPa·s.

14. The method (1000) according to one of claims 11 to 13, wherein the outsole is a sole structure according to one of claims 1-9.

15. An outsole (10) obtained by the method (1000) of one of claims 11 to 13.

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