Modular molding unit and method for manufacturing a foamed shoe component

Abstract

Disclosed herein is a method for manufacturing a foamed shoe component using a modular mold unit (1), a modular mold unit (1) and a foamed shoe component. The modular mold unit (1) comprises a peripheral mold portion (2) defining a cavity and comprises one or more tooling inserts (3a – 3h), which define a molding compartment (5), wherein the one or more tooling inserts (3a – 3h) are releasably arranged inside the cavity.

Description

[0001] Modular Molding Unit and Method for Manufacturing a Foamed Shoe Component

[0002] Field of disclosure

[0003] The present invention lies in the field of shoe component molding, and relates in particular to a method for manufacturing a foamed shoe component, a modular molding unit and a foamed shoe component.

[0004] Background, prior art

[0005] Foamed shoe components have found widespread application in all kinds of shoes. Most commonly, shoe soles, such as midsoles, as used in many sports shoes, are made from foamed polymer material with the goal to achieve good cushioning and rebound effects. However, also other components, such as paddings or insoles are often made from foamed polymer material.

[0006] Foaming of shoe components is typically achieved in special molds. Some methods rely on autoclave foaming, wherein a polymer material is arranged in an autoclave. The polymer material may for example be inserted as a granulate, may be introduced into the mold in molten form or as a preformed element. Further, a propellant is commonly introduced. The propellant may either be separately added or it may be, together with the polymer material, part of a polymer composition. For example, it is known to infuse a polymer material with a propellant, such as N2 or CO2 prior to introducing it into the mold. Alternatively, it is also known to use chemical propellants which can be added into the mold. Generally, two types of propellants, which are also called blowing agents, are known, namely chemical propellants and physical propellants. Common to both types of propellants is that they provide under certain conditions a gaseous propellant which effects foaming. Chemical propellants are chemical agents, which in situ form a gaseous propellant, for example by in situ forming CO2 or N2 by a chemical transformation. The formation of the gaseous propellant may for example be effected by heating, irradiation or treatment with a suitable reaction partner. In contrast, physical propellants do not undergo a chemical reaction to form the gaseous propellant, but may either already be gaseous propellants and introduced into the mold as such (for example N2) or they may be introduced in another aggregate state such as liquid, solid or supercritical. After having inserted the polymer material into the mold, the physical parameters, such as molding temperature and molding pressure are selected such that the polymer material melts and foaming occurs.

[0007] In autoclave foaming, a small prefoamed article is inserted into an autoclave. Then a blowing agent is provided in the autoclave under a certain pressure upon which it infuses into the prefoamed article. Then, the pressure is decreased which induces foaming. A common problem is that during the foaming the article then forms a relatively hard skin on its surface, which has to be removed, e.g. by buffing. Thereafter, the buffed part is then placed in a compression mold to shrink the buffed part to its final shape.

[0008] An advantage of mold foaming is its high operational capacity. Once the molding tools are in place, foam molding allows to produce a high number of foamed components within very short production times. This stands in vast contrast to alternative production methods, such as additive manufacturing, respectively 3D printing. As compared to foam molding additive manufacturing techniques allow significantly more degrees of freedom in the manufactured component, since there is almost no limitation on the complexity of the formed product. In contrast, because foam molding necessarily requires the deforming of the generated product from the mold, foam molding has the disadvantage that complex geometries cannot be achieved at all or can only be realized with relatively complicated tools using multiple sliders.

[0009] The most prominent disadvantage of additive manufacturing techniques on the other hand, is the low operational capacity as compared to molding. Additive manufacturing is well suited to produce prototypes or high end products in small quantities, but it cannot compete with the high operational capacity of molding and thus is typically unsuited for mass production. A disadvantage of molding in particular with respect to the manufacture of shoe components is however that the molds are expensive to produce. Furthermore, every shoe size and every shoe model often requires its own mold, which decreases the flexibility of molding as compared to other methods, such as additive manufacturing.

[0010] It would in general however be desirable to provide methods and devices which allow both to produce shoe components with higher degrees of freedom and thus increased complexity in their structure and concomitantly achieve a high operational capacity. Furthermore, it would be desirable to provide shoe components which have been manufactured according to such methods and thus can be produced more efficiently. It would further be desirable to achieve both fast and efficient production and also allow large degree of freedoms for manufacturing even complex components. In addition it would be desirable to overcome some or all of the disadvantages mentioned above fully or at least partly.

[0011] Summary of disclosure

[0012] It is the general object of the present invention to advance the state of the art in the field of shoe component molding, foamed shoe components and methods for producing foamed shoe components, and preferably to overcome the disadvantages of the prior art. In favorable embodiments, a method for foaming a shoe component and a modular mold unit are provided, which allow to produce shoe components with higher degrees of freedom and thus increased complexity in their structure and concomitantly achieve a high operational capacity. In other advantageous embodiments, a method and a thereby produced shoe component are provided, which are more cost-efficient and / or are more environmentally friendly.

[0013] The general object is achieved by the subject-matter of the independent claims. Further advantageous embodiments follow from the dependent claims and the overall disclosure.

[0014] According to a first aspect of the invention, the general object is achieved by a method for manufacturing a foamed shoe component. The foamed shoe component may preferably be a shoe sole, in particular a midsole or an outsole. The method may comprise the steps: a. Providing a modular mold unit, in particular a modular mold unit as described in any of the embodiments herein, such as the embodiments described with respect to the second aspect of the invention. The modular mold unit may comprise a peripheral mold portion which defines a cavity. The modular mold unit may further comprise one or more tooling inserts which define a molding compartment. The one or more tooling inserts may further be releasably arranged inside the cavity defined by the peripheral mold portion. In some embodiments, at least some or all of the one or more tooling inserts are in direct contact with the peripheral mold portion. b. Injecting a polymer composition into the molding compartment, the polymer composition comprising at least one molten thermoplastic polymer and foaming the at least one molten thermoplastic polymer inside the molding compartment to provide a foamed shoe component. Optionally, the polymer composition further comprises a propellant. c. Foaming the at least one molten thermoplastic polymer inside the molding compartment to provide the foamed shoe component

[0015] The term “modular” as used herein refers with respect to the mold unit to a mold unit which comprises elements that can be separated and recombined, in particular in different configurations or arrangements. For example, the two elements peripheral mold portion and the tooling inserts can be separated from each other and recombined.

[0016] The peripheral mold portion peripherally and particularly also circumferentially, surrounds the one or more tooling inserts. The peripheral mold portion may be considered as a peripheral frame. Furthermore, the peripheral mold portion represents a standardized mold which defines a standardized cavity into which multiple different tooling inserts can be arranged. Depending on the configuration and design of the tooling inserts, different shoe components can be manufactured with essentially the same mold. For example, it may be possible to manufacture differently sizes shoe components with the same mold or to manufacture differently shaped shoe components, simply by exchanging the one or more tooling elements which are being arranged in the cavity defined by the peripheral mold portion.

[0017] The term “releasably” as used herein means that the tooling inserts are arranged inside the cavity such that they can be removed and reintroduced into the cavity multiple times without partially or completely destroying the elements. The same holds true for any releasable connection, engagement, etc. as used and disclosed herein. Thus, releasably connected elements, such as the tooling inserts and the peripheral mold portion, are not made from single pieces, but are separate elements. Furthermore, the releasably connected elements, such as the tooling inserts and the peripheral mold portion, do not form a material bonding connection. It may for example be possible in some embodiments that the tooling inserts are inserted into the cavity, i.e. without any further connecting means. In some embodiments, it may also be possible that the tooling inserts and the peripheral mold portion form a form-locking and / or force locking connection. However, also in such embodiments, the connection is releasable such that the tooling inserts can be removed from the cavity and reintroduced and in particular be connected in the same manner again with the peripheral mold portion.

[0018] In some embodiments, the propellant is a physical propellant, in particular N2 or CO2.

[0019] The thermoplastic polymer may in some embodiments be selected from one or more of thermoplastic polyurethanes, polyamides, such as PA 6.6, PA 11 and polyether block amide, ethylene-vinyl acetate, polyesters, such as PET and PBT, and polyolefins.

[0020] In some embodiments, the method further comprises step c, namely, removing the foamed shoe component which has been provided in step b. together, i.e. at the same time, with at least one of the one or more tooling inserts from the cavity. Thereby, the foamed shoe component and the at least one of the one or more tooling inserts are separated from the peripheral mold portion. In other words, the at least one tooling inserts and the peripheral mold portion are then disconnected from each other. Preferably however, the removed foamed shoe component and the removed at least one of the one or more tooling inserts remain together, i.e. are in contact with each other. In contrast, after removing, the corresponding at least one tooling insert is not in contact anymore with the peripheral mold portion. Such embodiments have the advantage that they allow to mold significantly more complex structures as compared to known molds. This is because the tooling inserts are removed together with the foamed shoe component from the cavity and are thus separated from the peripheral mold portion. Thereby, it is not necessary to remove the tooling inserts along a linear path as it the case for sliders used in traditional moldings, but the tooling inserts can be removed from the foamed shoe component in almost any direction. For example it is even possible to use cork screw structured tooling inserts, which are screwed out of the foamed shoe component Furthermore, since the shoe component is directly foamed, the tooling inserts may even define an undercut. While deforming of such an undercut in a traditional mold using sliders is highly complex and / or potentially damages the molded part, the method according to the invention allows to separate such tooling inserts much easier due to the fact that it can be removed along basically any direction and since the manufactured shoe component is already foamed and thus allows for a certain clearance for deforming parts with an undercut.

[0021] In some embodiments, the foamed shoe component which has been provided in step b. is removed together with all of the one or more tooling inserts from the cavity.

[0022] In some embodiments, after step c. the one or more tooling inserts are separated from the foamed shoe component. Thus, during this step, the one or more tooling inserts are disconnected from the foamed shoe component. In particular embodiments, the one or more tooling inserts are automatically separated from the foamed shoe component, e.g. by a robotic arm.

[0023] In some embodiments, separating the foamed shoe component from the one or more tooling inserts consists of moving the corresponding tooling insert as a whole with respect to the foamed shoe component. In particular embodiments, in which the one or more tooling inserts comprise one or more pins as described in some of the embodiments herein, separating the foamed shoe component from the one or more tooling inserts comprises moving the corresponding tooling insert as a whole (i.e. the base portion and the one or more pins) with respect to the foamed shoe component. In this or any other embodiment described herein, the pins are preferably not retractable with respect to the base portion of the tooling inserts. Preferably, the pins are unmovable with respect to the base portion of their tooling insert. Furthermore, the pins as such can preferably not be retracted towards or into the peripheral mold portion.

[0024] In general, the one or more tooling inserts may be devoid of sliders and / or other movable elements.

[0025] In some embodiments, the modular mold unit comprises a plurality of tooling inserts, in particular a plurality of different tooling inserts, which are releasably arranged inside the cavity defined by the peripheral mold portion. It is understood that for such embodiments, the features mentioned herein for one or more of the tooling inserts may then in some embodiments also apply in the same or different way for each one of the plurality of tooling inserts. For example, the modular mold unit may comprise at least two, at least three, at least four, at least five, at least six, at least seven or at least eight tooling inserts.

[0026] In some embodiments, some or all of the tooling inserts may be lateral tooling inserts. Lateral tooling inserts define the lateral delimitation of the molding compartment and / or cover the inner cavity wall, in particular the inner cavity side wall.

[0027] In some embodiments, at least one, in particular only one, of the tooling inserts comprises, or is consists of, a bottom portion. The bottom portion typically defines the bottom delimitation of the molding compartment. It is generally understood herein that the term “comprising” is interpreted as meaning that it includes those features following this term, but that it does not exclude the presence of other features, as long as they do not render the claim unworkable. On the other hand, if the wording "consist of" is used, then no further features are present in the corresponding element apart from the ones following said wording. Therefore, if one of the tooling inserts consists of the bottom portion, it is typically a separate element. It may however also be possible that the bottom portion is comprised in one or more of the tooling inserts. For example, the bottom portion may be connected to, respectively mounted to the base portion of one of the tooling inserts. The bottom portion and the tooling inserts, for example the other tooling inserts, preferably define together the molding compartment.

[0028] In some embodiments, the one or more tooling inserts each comprise a base portion. The base portion is typically in direct contact with the peripheral mold portion when the one or more tooling inserts are releasably arranged in the cavity. Furthermore, the base portion of the one or more tooling inserts defines the molding compartment. It is understood that if a plurality of tooling inserts is arranged in the cavity, then each of them comprises preferably a base portion and these base portions define together the molding compartment. Since the one or more tooling inserts are arranged in the cavity defined by the peripheral mold portion and since the corresponding base portion in such embodiments defines the molding compartment, the molding compartment is also arranged inside the cavity, respectively is a part of the cavity defined by the peripheral mold portion.

[0029] In certain embodiments, the molding compartment defined by the base portion of the corresponding one or more tooling inserts, has the shape of the negative of a shoe sole. That is, if the produced foamed shoe component is in the molding compartment and completely fills the molding compartment, the foamed shoe component has the shape of a shoe sole.

[0030] In some embodiments, at least one or also all of the one or more tooling inserts being releasably arranged inside the cavity, comprises one or more pins protruding from the base portion, in particular protruding from the base portion into the molding compartment. Thus, the base portion, which is typically in direct contact with the peripheral mold portion, is arranged between the pin protruding therefrom and the peripheral mold portion. The pins typically serve to generate recesses, such as channels (e.g. through-going channels or blind holes), grooves, slits and the like, in, respectively of, the foamed shoe component. In some embodiments, at least one tooling insert comprises only one pin. In certain embodiments, the majority (i.e. more than 50%) of the tooling inserts comprises only one pin. In certain embodiments, each tooling insert comprising a pin comprises only a single pin.

[0031] In some embodiments, the bottom portion and / or the cover plate may also comprise one or more pins as described herein. In such embodiments, the bottom portion or the cover plate may for example comprise a base portion from which the pins protrude. Typically, such pins protrude in a vertical direction from the base portion and / or the cover plate. Using such embodiments allows therefore to generate vertically extending channels, e.g. channels which extend from the base layer of the foamed shoe component or foamed shoe sole towards the top layer (and thus in the worn state in a direction from ground to foot of the wearer).

[0032] In certain embodiments, the bottom portion may comprise two or more body portion elements which together form the bottom portion. Such body portion elements may for example be adjacently aligned with each other thereby forming the bottom portion.

[0033] In some embodiments, the tooling inserts are made by additive manufacturing, molding, forging, electrical discharge machining, milling or casting.

[0034] The tooling inserts may for example be made from metal or a polymer material, in particular synthetic polymer material or polymer-ceramic composites.

[0035] The pins of the one or more tooling inserts may have any desired shape, such as a cylindrical, pyramidal or prismatic shape, e.g. a regularly or irregularly shaped cylinder, pyramid or prism, a helical shape, a star shape, and the like.

[0036] In some embodiments, the cross-sectional shape of the one or more pins may be selected from one or more of round, in particular circular or oval, and angular, such as trigonal, tetragonal, pentagonal, hexagonal, heptagonal and octagonal.

[0037] In some embodiments, the one or more pins may extend in a curved or angled manner, in particular from the base portion towards the molding compartment. In some embodiments, the molten thermoplastic polymer and / or the foamed shoe component surround in step b. the one or more pins of the one or more tooling inserts. Thereby, one or more channels are formed, thereby generating a foamed shoe component defining one or more channels.

[0038] The one or more channels of the foamed shoe component typically comprise a channel path and a first lateral opening and optionally a second lateral opening. The first lateral opening is directly arranged adjacent the channel path. If the channel comprises only one, i.e. only the first lateral opening, the channel is typically a blind hole. If the channel comprises a second lateral opening, the channel path is arranged between the first and second lateral opening and channel is a through-going channel, i.e. a channel which penetrates through the foamed shoe component. The channels of the foamed shoe component may have openings on opposite sides of the shoe component, such as the shoe sole. It may also be possible that if the channels are blind holes, there may be such channels being blind holes which are arranged on opposite sides of the shoe component, such as the shoe sole.

[0039] In some embodiments, steps a., i.e. providing the modular mold unit comprises the following steps a1) and / or a2), and / or a3):

[0040] In some embodiments, step a1) comprises generating a pressure map of a foot of an individual, such as a runner or wearer. In particular embodiments, the pressure map is generated during running.

[0041] In some embodiments, step a2) comprises providing a model, in particular a digital model of the foamed shoe component based on the generated pressure map. In some embodiments, step a2) may be computer-implemented. The foamed shoe component and thus also the provided model, typically defines one or more channels.

[0042] In some embodiments, step a3) comprises providing the one or more pins of the one or more tooling inserts of the modular mold unit based on the provided model of the foamed shoe component. In other words, step a3) may in some embodiments comprise providing the one or more pins such that the pins are arranged at the positions where the provided model indicates the presence of one or more channels. For example, the model may indicate that a certain channel should be arranged at a specific position. Since it is understood that the pins define the channels of the foamed shoe component, a pin may therefore be arranged in step a3) at the corresponding position to generate the channel during step b.

[0043] In some embodiments, the generated pressure map is generated by determining the pressure distribution over the foot of the individual during running. In particular, the pressure distribution may be determined as a time dependent and / or position dependent pressure distribution over the foot of the individual.

[0044] In some embodiments, the pressure map is generated with a pressure plate and / or an insole pressure measurement gait analysis system. Such a pressure plate and / or insole pressure measurement gait analysis system may preferably comprise one or more pressure sensors. Preferably, the one or more pressure sensors may be configured to determine the pressure applied to them, in particular the numerical value of the pressure applied to them.

[0045] In some embodiments, generating the pressure map comprises to section the foot of the individual into a plurality of areas and associating each area with a pressure value. The pressure value of each area may for example be an averaged pressure value in this area. The areas are typically 2-dimensional areas in the x,y plane, i.e. the plane defined by the longitudinal direction (heel to toe) and transversal direction (lateral to medial). For example, the pressure value may be obtained from the one or more pressure sensors.

[0046] In some embodiments, the configuration of the one or more channels and / or the position of the one or more channels in the foamed shoe component is in step a2) determined based on the generated pressure map. The configuration of the one or more channels may comprise the dimension or shape of the channels. The shape may for example comprise the cross-sectional shape. The dimension of the channels may for example include the depth (i.e. extension from the lateral or medial side into the sole component), the height (extension in the vertical direction, i.e. in the worn state from the ground to the foot of the runner), the width (extension along the longitudinal direction, perpendicular to the height) or the maximum channel diameter (maximum distance between opposing channel walls of a line extending through the center of the channel in cross-section).

[0047] In some embodiments, the generating the pressure map may at least partially be computer- implemented. For example, the pressure values for each area of the foot of the runner may be provided to a circuit, such as a computer, and the pressure map of the foot is determined therefrom.

[0048] In some embodiments, the model is provided in step a2) in that channels are arranged in areas in which the pressure values exceed a certain threshold. In certain embodiments, a pin database of different tooling inserts with different pins and / or of different pins as such is provided, in particular stored in a memory unit. The memory unit may for example be part of the computer. It may further be possible each tooling insert, respectively each pin, in the pin database is associated with a pressure value range. Preferably, after the pressure map is generated and the pressure values are associated to the plurality of areas, the method may comprise the comparison of the pressure values obtained in step a1) with the pressure value ranges in the pin database and selecting the tooling insert or pin for the corresponding area whose pressure value range covers the pressure values associated with this area. It is understood that in such embodiments, the pressure value ranges are preferably not overlapping each other but are in particular adjacent ranges.

[0049] In some embodiments, the model provided in step a2) is sectioned in a plurality of stacked layers. Each of the stacked layer may have a certain layer thickness. Preferably, the layer thickness may be the same for each layer. The sectioned layers may only be virtual layers of the model. The layers are preferably stacked in the vertical direction. Such layers combined with the modular mold unit as described herein allows to fine tune the cushioning for the runner not only along a longitudinal direction (i.e. where the channels are longitudinally arranged, such as heel area, midfoot area or forefoot area), but also along a vertical or transversal direction. The improved flexibility of the channel geometry enabled by the modular mold unit allows to provide a more diverse range of channel configurations and to fine tune the cushioning effects.

[0050] In some embodiments, the configuration of the one or more channels and / or the position of the one or more channels in the foamed shoe component is determined for each layer, in particular separately for each layer. It may for example be possible that the configuration of the one or more channels is determined such that channels extend, particularly vertically, through multiple layers.

[0051] In some embodiments, step b. is performed as a supercritical injection. In certain embodiments, the propellant of the polymer composition being injected into the cavity in step b. is a supercritical fluid. The propellant may for example be N2 or CO2, preferably N2. In some embodiments, the polymer composition being injected into the cavity in step b. is a single phase. The propellant and the at least one molten thermoplastic polymer may thus form together a single phase.

[0052] For example, step b. may be performed by an injector unit, in particular a barrel and screw injector unit. Such barrel and screw injector units are commonly used in SCF molding.

[0053] The injector unit may in some embodiments comprise a nozzle configured for dispensing the polymer composition from the injector unit. Furthermore, in some embodiments, the injector unit comprises a cover plate. The cover plate is configured for closing the molding compartment defined by the tooling inserts (it is understood that the closed molding compartment has an inlet for injecting the polymer composition, such as the nozzle). It may for example be possible that the cover plate is arranged around the nozzle of the injector unit.

[0054] In some embodiments, foaming in step b. occurs without varying, in particular without expanding, the cavity volume. Thus, the peripheral mold portion does not have to be movable or adjustable, which simplifies the process and the modular mold unit. Furthermore, this allows to use a so-called 1 :1 mold which allows for an accurate control over the shape of the foamed shoe component.

[0055] In some embodiments, the peripheral mold portion and the at least one tooling inserts are not heated, i.e. not actively heated. The at least one tooling inserts and the peripheral mold portion are therefore preferably devoid of heating elements. This simplifies the production process and the configuration of the modular mold unit.

[0056] In some embodiments, the pressure in the molding compartment in step b. and / or step c may be between 10 to 200 bar, in particular 40 to 100 bar. In some embodiments, the pressure with which the polymer composition is in step b. injected into the molding compartment may be between 900 to 1200 bar, in particular between 1000 to 1100 bar. If an extruder is used to inject the polymer composition into the molding compartment, which may be the case for this or any other embodiment as described herein, the pressure with which the polymer composition is injected into the molding compartment may preferably be identical to the pressure in the extruder, e.g. in the barrel of a screw and barrel extruder.

[0057] In a second aspect, the general object is achieved by a modular mold unit, for example a modular mold unit as it is used and described in the embodiments herein, in particular with respect to the first aspect of the invention. The modular mold unit may comprise a peripheral mold portion and one or more tooling inserts. The peripheral mold portion may define a cavity. The one or more tooling inserts may define a molding compartment and may be releasably arranged inside the cavity. In some embodiments, at least some or all of the one or more tooling inserts are in direct contact with the peripheral mold portion.

[0058] In some embodiments, the peripheral mold portion circumferentially surrounds the one or more tooling inserts.

[0059] In some embodiments, the modular mold unit comprises a plurality of tooling inserts, in particular a plurality of different tooling inserts, which are releasably arranged inside the cavity defined by the peripheral mold portion. It is understood that for such embodiments, the features mentioned herein for one or more of the tooling inserts may then in some embodiments also apply in the same or different way for each one of the plurality of tooling inserts. For example, the modular mold unit may comprise at least two, at least three, at least four, at least five, at least six, at least seven or at least eight tooling inserts. In some embodiments, the modular mold unit may comprise at most 20, at most 15, at most 10 tooling inserts. For example, the modular mold unit may comprise between two to 20, in particular between three and 15, more particular between four and 10 tooling inserts.

[0060] In some embodiments, some or all of the tooling inserts may be lateral tooling inserts. Lateral tooling inserts define the lateral delimitation of the molding compartment and / or cover the inner cavity wall, in particular the inner cavity side wall, of the peripheral mold portion.

[0061] In some embodiments, at least one, in particular only one, of the tooling inserts comprises, or consists of, a bottom portion as described with respect to some of the embodiment of the first aspect of the invention. The bottom portion typically defines the bottom delimitation of the molding compartment. If one of the tooling inserts consists of the bottom portion, it is typically a separate element. It may however also possible that the bottom portion is comprised in one or more of the tooling inserts. For example, the bottom portion may be connected to, respectively mounted to the base portion of one or more of the tooling inserts.

[0062] In some embodiments, some or all of the one or more tooling inserts each comprise a base portion. The base portion is preferably in direct contact with the peripheral mold portion when the one or more tooling inserts are releasably arranged in the cavity. Furthermore, the base portion of the one or more tooling inserts defines a molding compartment. It is understood that if a plurality of tooling inserts is arranged in the cavity, then each of them comprises preferably a base portion and these base portions define together the molding compartment. Since the one or more tooling inserts are arranged in the cavity defined by the peripheral mold portion and since the corresponding base portion in such embodiments defines the molding compartment, the molding compartment is also arranged inside the cavity, respectively is a part of the cavity defined by the peripheral mold portion. In some embodiments at least one, or all of the tooling inserts defines one or more inlets being configured for injecting the polymer composition into the molding compartment.

[0063] In certain embodiments, the molding compartment defined by the base portion of the corresponding one or more tooling inserts, has the shape of a shoe sole.

[0064] In some embodiments, the peripheral mold portion comprises of a plurality of sub-units which may be releasably connected to each other to form the peripheral mold portion. For example, the sub-units may form together a releasable force locking and / or form locking engagement.

[0065] In some embodiments, the peripheral mold portion comprises an inner cavity wall, in particular an inner cavity side wall. The inner cavity wall defines the cavity. Furthermore, in such embodiments, the one or more tooling inserts and in particular the base portion of the one or more tooling inserts may be in direct contact with the inner cavity wall. In preferred embodiments, the one or more tooling inserts, and in particular their base portions, essentially completely cover the inner cavity wall, in particular the inner cavity side wall. That is, the inner cavity wall is typically not exposed to the molding compartment being defined by the one or more tooling inserts, particularly their base portions. The inner cavity wall may for example consist of an inner cavity side wall and an inner cavity bottom wall. Typically at least the inner cavity side wall and optionally also the inner cavity bottom wall is essentially completely covered by the one or more tooling inserts. The inner cavity wall is the wall which faces typically towards the one or more tooling inserts being releasably arranged in the cavity. In preferred embodiments, the inner cavity side wall peripherally surrounds the cavity. Furthermore, the term “essentially completely cover(ed)” means that at least 95%, in particular at least 98%, in particular at least 99% of the surface of the inner cavity wall, respectively inner cavity side wall, are covered.

[0066] In some embodiments, at least one, or also all, of the one or more tooling inserts being releasably arranged inside the cavity, comprises one or more pins protruding from the base portion, in particular protruding from the base portion into the molding compartment. Thus, the base portion, which is typically in direct contact with the peripheral mold portion, is arranged between the pin protruding therefrom and the peripheral mold portion. The pins typically serve to generate recesses, such as channels (e.g. through-going channels or blind holes), grooves, slits and the like, in the foamed shoe component.

[0067] The pins of the one or more tooling inserts may have any desired shape, such as a cylindrical, pyramidal or prismatic shape, e.g. a regularly or irregularly shaped cylinder, pyramid or prism, a helical shape, and the like.

[0068] In some embodiments, the cross-sectional shape of the one or more pins may be selected from one or more of round, in particular circular or oval, and angular, such as trigonal, tetragonal, pentagonal, hexagonal, heptagonal and octagonal.

[0069] It may be possible that at least some or all of the pins of the one or more tooling inserts have different shapes and / or different dimensions from each other, such as different lengths.

[0070] In some embodiments, the one or more pins may be releasably connected to the base portion. For example, the one or more pins may be form-locked and / or force-locked to the base portion. In particular embodiments, the pins may be snap-fitted, plugged, threaded or screwed to the base portion This is beneficial, because if it is desired to modify the geometry or dimension of the channels formed in the foamed shoe component by the pins, only the pins can be exchanged, because they are releasably connected to the base portion. Therefore, another pin having a different size, shape or geometry can be used. If it is then desired to use the original pin again, it can be easily changed back.

[0071] In some embodiments, the modular mold unit comprises only one pin per tooling insert, or at most two pins per tooling insert.

[0072] In some embodiments, the modular mold unit comprise a plurality of tooling inserts, in particular a plurality of different tooling inserts, which are releasably arranged inside the cavity defined by the peripheral mold portion. It is understood that for such embodiments, the features mentioned herein for one or more of the tooling inserts may then in some embodiments also apply in the same or different way for each one of the plurality of tooling inserts. For example, the modular mold unit may comprise at least two, at least three, at least four, at least five, at least six, at least seven or at least eight tooling inserts. Typically, the plurality of tooling inserts are not integrally formed with respect to each other. That is the tooling inserts are typically separate elements and / or typically not fixedly connected to each other, for example they are not material bonded to each other. The tooling inserts of the plurality of tooling inserts may in some embodiments be releasably connected with each other. For example, they may merely contact each other, i.e. without any further locking mechanism, or they may be releasably form-locked and / or releasably force-locked to each other.

[0073] In some embodiments, the one or more pins may extend completely through the molding compartment. In such embodiments, the modular mold unit comprises at least two tooling inserts. If the one or more pins extend completely through the molding compartment, these pins extend from the base portion of their tooling insert to a base portion of another tooling insert. Furthermore, the pins contact the base portion of the other tooling insert, in particular contact it without any further locking mechanism or the pins may be releasably form-locked and / or releasably force-locked with the base portion of the other tooling insert.

[0074] In some embodiments, the one more pins extend only through a part of the molding compartment. Therefore the pins protrude from the base portion of their tooling insert into the compartment but do not extend to, respectively directly contact, the base portion of another tooling insert. It may be possible that these one or more pins contact other pins of different tooling inserts or that they do not contact other pins of different tooling inserts and / or are spaced apart from all other tooling inserts. In the latter case, the one or more pins extending only through a part of the molding compartment form (for example in the method as described herein) channels being configured as blind holes. In some general embodiments it may be possible that oppositely arranged tooling inserts, such as laterally arranged tooling inserts, are arranged offset, in particular completely offset to each other. In some embodiments, the modular mold unit comprises at least two tooling inserts and each of these at least two tooling inserts comprises one or more pins, for example pins as described herein above.

[0075] In some embodiments, at least some of the pins of different tooling inserts contact each other, in particular directly contact each other, thereby forming a connected pin assembly. It is understood that each connected pin assembly is made of at least two pins. These at least two pins are comprised in different tooling inserts. It is however also possible that a pin assembly comprises more than two pins which contact each other, in particular directly contact each other. Also in such embodiments it is preferred that the pins of the pin assembly are, all or at least a portion thereof, pins of different tooling inserts. The term “connected pin assembly” means that the pins are in contact with each other. It may be possible that the pins of the connected pin assembly are merely contacting each other without any further locking means or locking mechanism. However, it may also be possible that the pins of the connected pin assembly undergo together a releasable force-locking and / or form-locking engagement. The pins forming a connected pin assembly are separate elements and are thus not formed from a single piece and / or are not material bonded to each other.

[0076] In some embodiments, the modular mold unit comprises at least two tooling inserts and each of these at least two tooling inserts comprises one or more pins, for example pins as described herein above. In preferred embodiments, at least one pin, or also all pins, of one of the at least one tooling inserts contacts, preferably directly contacts, one pin of another one of the at least one tooling inserts, thereby forming a connected pin assembly. It is understood that each connected pin assembly is made of at least two pins. It is however also possible that a pin assembly comprises more than two pins which contact each other, in particular directly contact each other.

[0077] In some embodiments, the pins of the connected pin assembly, respectively of the connected pin assemblies, contact each other frontally or laterally. In some embodiments, at least two pins of the connected pin assembly, respectively of the connected pin assemblies, contact each other frontally and are aligned with each other or are arranged partially offset to each other. It is understood that if the pins are arranged partially offset to each other, the foamed shoe component then defines a channel whose channel path is angled, curved and / or comprises a step. Pins contacting each other laterally are preferably arranged offset to each other, in particular completely offset to each other. It is understood that the front of a pin refers to its frontal portion which faces typically into the molding compartment and faces away from the base portion of the corresponding pin. Lateral refers to the lateral portion of the pin, which extends between the base portion and the frontal portion of the pin.

[0078] In some embodiments, the pins forming the connected pin assembly form together a releasable form locking and / or force locking engagement. For example, the pins may form a snap fit. Alternatively, the pins may be tubular and a locking strut may be arranged inside two pins of the connected pin assembly, which contact each other. Such a locking strut retains the pins in their position and particularly avoids that the pins are disconnected from each other in particular against horizontal forces, for example during step b. of the method according to the invention.

[0079] According to a third aspect, the general object is achieved by a foamed shoe component, in particular a foamed shoe sole, such as a midsole, insole or outsole, obtained, respectively manufactured, by the method according to any of the embodiments described herein, in particular with respect to the first aspect of the invention. In some embodiments, the foamed shoe component is foam molded, in particular injection foam molded.

[0080] In some embodiments, the foamed shoe component defines one or more channels. Each channel comprises a channel path and a first lateral opening. The first lateral opening being arranged directly adjacent to the channel path. In certain embodiments, at least some of the channels, or also all of the channels, may optionally each comprise a second opening, such as a second lateral opening. The second opening is typically also directly arranged adjacent to the channel path. If the channel comprises only one, i.e. only the first lateral opening, the channel is typically a blind hole. If the channel comprises a second opening, the channel path is arranged between the first lateral opening and the second opening and channel is a through-going channel, i.e. a channel which penetrates through the foamed shoe component. The term “lateral” with respect to the foamed shoe component refers to the side of the shoe component, i.e. the part which does neither face in the operative state the ground on which the wearer walks and not the foot of the wearer.

[0081] In some embodiments, the foamed shoe component comprises at least one channel having a non-linear channel path.

[0082] In some embodiments, the foamed shoe component comprises at least two channels which do not extend in parallel to each other.

[0083] In some embodiments, the one or more of the channels define an at least partially or fully angled or curved channel path. That is, the channel path is not linear but for example bent or angled. In some embodiments, the channel path may be S-shaped, C-shaped or helically shaped. The channel path may also be a wave shaped. In some embodiments, the channel path may have a non-symmetrical shape.

[0084] Additionally or alternatively, the channel path may in some embodiments comprise a step, in particular a step extending in the vertical direction. Preferably the step is composed of at least two planes, e.g. at least two even planes, which meet each other in an angle forming an edge.

[0085] In some embodiments, the one or more channels define a branch at which the corresponding channel, respectively the corresponding channels, branches into two or more channels, such as two or more sub-channels. Such a branch may for example be a fork.

[0086] In some embodiments, the first lateral opening of one or more of the channels defines a first open area. Optionally, the second opening, particularly the second lateral opening, defines a second open area. Furthermore, the channel path of the corresponding channel has a cross-sectional area being larger than the first open area and optionally than the second open area. The channel path may also include a plurality of such cross-sectional areas being larger than the first and optionally second open area. Such a plurality of cross- sectional areas may for example be arranged at different locations along the channel path. For example, the channel path may have a wave shape cross-section, such as a regular wave shape e.g. a sinusoidal wave shape, or an irregular wave shape. It may also be possible that the channel path may have an angular cross-section comprising one or more steps.

[0087] In some embodiments, the channel path of at least one channel is circumferentially completely delimited by the foamed shoe component. This means, access to the channel is only provided by the first lateral opening and optionally by the second opening. Therefore, the channel is not a groove.

[0088] In some embodiments, the foamed shoe component is made from a single piece. That is, the foamed shoe component is integrally formed.

[0089] In some embodiments, the foamed shoe component is a closed cell foamed shoe component. In alternative embodiments, the foamed shoe component is an open cell foamed shoe component.

[0090] Directional indications as used in the present disclosure are typically to be understood as follows: The longitudinal direction L of the foamed shoe component, in particular the foamed shoe sole, is described by an axis from the heel area, respectively from the heel edge, to the forefoot region, respectively to the sole tip, and thus extends along the longitudinal axis of the foamed shoe component, in particular the foamed shoe sole. The transverse direction T of the foamed shoe component, in particular the foamed shoe sole, extends transversely to the longitudinal axis and substantially parallel to the base layer of the foamed shoe component, in particular the foamed shoe sole, or substantially parallel to the ground in the operative state. Thus, the transverse direction runs along a transverse axis of the foamed shoe component, in particular the foamed shoe sole. In the context of the present invention, the vertical direction V denotes a direction from the base layer to the top layer of the foamed shoe component, in particular the foamed shoe sole, or in the operative state in the direction of the foot of the wearer, and thus runs along a vertical axis of the midsole respectively the shoe sole. The longitudinal direction, the vertical direction and the transverse direction may generally all be perpendicular to each other. Furthermore, the foamed shoe component, in particular the foamed shoe sole, may typically along the longitudinal direction be divided into a forefoot area, a heel area and a midfoot area being arranged between the forefoot area and the heel area. For example, the forefoot area extends from the sole tip against, i.e. opposite, the longitudinal direction to 30-45% of the total length of the sole in the longitudinal direction. The heel area extends, for example, from the heel edge in the longitudinal direction to 20-30% of the total length of the sole in the longitudinal direction. The midfoot area extends directly between the heel area and the forefoot area, such that the length in the longitudinal direction of the midfoot area makes up the remaining portion of the total length, particularly from 15-50% of the total length.

[0091] The general object is in a fourth aspect achieved by a kit of parts comprising a modular mold unit according to any of the embodiments described herein, in particular with respect to the second aspect of the invention and further comprising a plurality of additional tooling inserts. The additional tooling inserts may be different from the tooling inserts of the modular mold unit. For example, the additional tooling inserts may have different configurations and / or define differently sized and shaped molding compartments. In further examples, the additional tooling inserts may comprise pins which have a different shape and / or different dimensions and / or different point of attachments of the pins to the base portion. In general, also the additional tooling inserts may be tooling inserts as described with respect to any of the embodiments herein. Additionally or alternatively, the kit of parts may comprise a plurality of pins being configured for being releasably connected to the one or more tooling inserts, respectively their base portion, of the modular mold unit and / or to the additional tooling inserts, respectively their base portion. The general object is in a fifth aspect achieved by a method for manufacturing a foamed shoe component. The method of the fifth aspect may comprise the steps of: a. Providing a modular mold unit, in particular a modular mold unit as described in any of the embodiments herein, such as the embodiments described with respect to the first or second aspect of the invention. The modular mold unit may comprise a peripheral mold portion which defines a cavity. The modular mold unit may further comprise one or more tooling inserts which define a molding compartment. The one or more tooling inserts may further be releasably arranged inside the cavity defined by the peripheral mold portion. In some embodiments, at least some or all of the one or more tooling inserts are in direct contact with the peripheral mold portion. b. Providing a polymer composition into the molding compartment, the polymer composition comprising at least one molten thermoplastic polymer and subsequent solidifying of the at least one molten thermoplastic polymer to generate a preform shoe component. c. Foaming the preform shoe component to provide the foamed shoe component

[0092] Step c. may be performed in a separate foaming unit, such as an autoclave. For example, the preform shoe component may be infused with a propellant, in particular under a pressure above atmospheric pressure and / or at a temperature above room temperature (23 °C), for example at a temperature above 100 °C. Thereafter, the pressure is released and thereby liberating the infused propellant and inducing foaming.

[0093] In some embodiments, step b. may comprise to insert a granulate of the at least one thermoplastic polymer into the molding compartment and thereafter melt the granulate by heating it, i.e. up to the melting point of the at least one thermoplastic polymer. Alternatively, the at least one thermoplastic polymer is molten before being introduced into the molding compartment and the molten thermoplastic polymer is introduced into the molding compartment. In some embodiments, the preform shoe component formed in step c. is foamed in step c. while it is connected, respectively mounted to the one or more tooling inserts. For example, the preform shoe component can together with the one or more tooling inserts be released from the peripheral mold portion and inserted together into the separate foaming unit. This is particular advantageous if the one or more tooling inserts comprise one or more pins, because these pins form channels in the foamed shoe component and the pins being inserted into the channels during foaming secure the shape of the channels and thus avoid any deformation during foaming. After foaming, the one or more tooling inserts can for example be separated from the foamed shoe component, in particular automatically by one or more robotic arms.

[0094] It is further understood that also in the embodiments of the fifth aspect, step a. may in some embodiments comprises steps a1) and / or a2) and / or a3), i.e. generating a pressure map of a foot of an individual, in particular during running; and / or providing a model, in particular a digital model, of the foamed shoe component based on the generated pressure map; and / or providing the one or more pins of the one or more tooling inserts of the modular mold unit based on the provided model of the foamed shoe component.

[0095] The general object is in a sixth aspect achieved by the use of a modular mold unit according to any of the embodiments described herein, in particular for the second aspect of the invention, for molding a shoe component, in particular a sole component.

[0096] Brief description of the figures

[0097] The herein described invention will be more fully understood from the detailed description given herein below and the accompanying drawings which should not be considered limiting to the invention described in the appended claims. The drawings are showing:

[0098] Fig. 1 a top view of a modular mold unit according to an embodiment of the invention; Fig. 2 a top view of a peripheral mold portion as it can be employed in some embodiments of the invention;

[0099] Fig. 3 a perspective view of two tooling inserts as they can be used in some embodiments of a modular mold unit and the method according to the invention;

[0100] Fig. 4 a top view of the two tooling inserts shown in Fig. 3;

[0101] Fig. 5 an exploded view of the two tooling inserts shown in Fig. 3;

[0102] Fig. 6 a schematic lateral view of a shoe sole according to an embodiment of the invention and / or as it can be produced according to some embodiments of the invention;

[0103] Fig. 7 a schematic cross-sectional view along the longitudinal direction and the transversal direction of a shoe sole according to another embodiment of the invention and / or as it can be produced according to some embodiments of the invention;

[0104] Fig. 8 a schematic cross-sectional view along the transversal direction and the vertical direction of a shoe sole according to another embodiment of the invention and / or as it can be produced according to some embodiments of the invention;

[0105] Fig. 9 a schematic cross-sectional view along the longitudinal direction and the transversal direction of a shoe sole according to another embodiment of the invention and / or as it can be produced according to some embodiments of the invention;

[0106] Fig. 10 a top view of a modular mold unit according to another embodiment of the invention; Fig. 11 a schematic side view of a model of a foamed shoe component as it is used in some embodiments of the invention;

[0107] Fig. 12 a pressure map obtained for the foot of an individual as it can be used in some embodiments of the invention.

[0108] Exemplary embodiments

[0109] Fig. 1 shows a modular mold unit 1 according to the invention. Modular mold unit 1 comprises peripheral mold portion 2, which defines a cavity. Peripheral mold portion 2 circumferentially surrounds tooling inserts 3a and 3b, which may be the tooling inserts described further below with reference to Fig. 3 to 5. Fig. 2 shows only peripheral mold portion 2, i.e. after removal of tooling inserts 3a and 3b. As can be seen, peripheral mold portion 2 defines cavity 4. In particular, peripheral mold portion 2 comprises inner cavity wall 8, which defines, respectively delimits cavity 4. Referring back to Fig. 1 , it can be seen that the tooling inserts 3a and 3b are inserted into cavity 4 and essentially completely cover inner cavity wall 8 of peripheral mold portion 2. During injection of a polymer composition into molding compartment 5 defined by tooling inserts 3a and 3b and subsequent foaming, the foamed shoe component circumferentially surrounds the pins (see pins 7a and 7b shown in Fig. 3-5) of tooling inserts 3a and 3b. Then after foaming, tooling inserts 3a and 3b and the foamed shoe component are concomitantly and together taken out of cavity 4. Then, deforming is performed by separating the foamed shoe component from tooling inserts 3a and 3b. One advantage is that various different tooling inserts can be used for one and the same peripheral mold portion. This allows to readily produce different shoe components, such as shoe components having different channel geometries and / or different sizes without having to use separate molds.

[0110] Fig. 3, 4 and 5 show two tooling inserts 3a and 3b which are used in a modular mold unit and the method according to the invention. Tooling inserts 3a and 3b together define molding compartment 5. Tooling insert 3a comprises base portion 6a and tooling insert 3b comprises base portion 6b. Both tooling inserts comprise pins 7a and 7b (only one pin per tooling insert is referenced for clarity purposes), which each protrude from the base portion into molding compartment 5. As can be best seen from Fig. 4 and 5, the pins of tooling insert 3a (such as pin 7a) protrude from base portion 6a only approximately halfway into molding compartment 5. The same holds true for the pins of tooling insert 3b (such as pin 7b). Pins 7a and 7b contact each other frontally in this embodiment and form together a connected pin assembly. In total, eight pins of tooling insert 3a and eight pins of tooling insert 3b are seen in Fig. 4 which form together eight connected pin assemblies.

[0111] For producing a foamed shoe component, such as a foamed shoe sole, a polymer composition can be injected into molding compartment 5. Injection can generally be performed in different ways. For example, it may in this or any other embodiment described herein be possible to close the top side (facing the viewer in Fig. 4) by a cover plate and inject the polymer composition via an inlet formed in one of the tooling inserts 3a or 3b, or an injector unit can be used which itself comprises a cover plate and a nozzle, wherein the cover plate of the barrel and screw injector unit closes the top side. After injection and foaming, tooling inserts 3a and 3b can separated from each other to deform the foamed shoe component as it is shown in Fig. 5. In this embodiment, one of the tooling inserts, is bottom portion 9 which delimits the bottom of molding compartment 5 against the vertical direction.

[0112] Fig. 6 shows a schematic view of a lateral side of a foamed shoe sole 100 having been obtained by the method according to the invention. As can be seen, foamed shoe sole 100 comprises multiple channels 101a and 101 b (only two channels are referenced for clarity purposes), which have been defined by corresponding pins of tooling inserts as described herein.

[0113] Fig. 7 shows a schematic cross-section of foamed shoe component 100 being in this embodiment a foamed shoe sole. The cross-section extends along longitudinal direction L and transversal direction T, which are generally both perpendicular to the vertical direction. Foamed shoe component 100 has been obtained by the method according to an embodiment of the invention. As can be seen, foamed shoe component 100 comprises various different channels which completely penetrate foamed shoe component along transverse direction T. Channel 101a comprises first lateral opening 102a and second lateral opening 103a. The channel path of channel 101a is arranged directly adjacent first and second lateral opening 102a and 103a and extends there between. As can be seen, channel 101a defines an angled channel path. Such a channel path can be formed by using two tooling inserts which each comprise a corresponding pin as described herein. These two pins form together a connected pin assembly which contact each other not frontally, but laterally. The dashed line indicates where the two corresponding pins have contacted each other during manufacture.

[0114] Channel 101 b comprises also a first lateral opening 101b and a thereto adjacently arranged channel path. Furthermore, channel 101 b comprises branch 104, at which channel 101b branches into two channels 101c and 101d,w which may generally be considered as subchannels. Such branching channels can be obtained by using two tooling inserts with pins. The first tooling insert may comprise two pins which form together with a pin of the other tooling insert a connected pin assembly. In this case, the connected pin assembly consists of three pins. Again, the dashed lines indicate where the pins contact each other during manufacture.

[0115] Fig. 8 shows schematically a cross-section of a foamed shoe component 100 having been manufactured according to the method of the invention. Foamed shoe component 100 is a midsole which defines a channel 101a having a first lateral opening 102a and a second lateral opening 103a and arranged in between these two openings its channel path. Channel 101a comprises step 105 which extends in the vertical direction V. Also in this Figure, the dashed line indicates where two pins of opposing tooling inserts have contacted each other to form a connected pin assembly consisting of two pins.

[0116] Fig. 9 shows a schematic cross-section of foamed shoe component 100 being in this embodiment a foamed shoe sole. The foamed shoe sole comprises differently embodied channels. Channels 101a and 101b form together an X-shaped channel network. As in Fig. 7, the dashed lines indicate where the four corresponding pins have contacted each other during manufacture. Chanel 101c is a channel defining a curved and in this embodiment C- shaped channel path extending between first lateral opening 102c and second lateral opening 103c. The dashed line indicates where the two pins of the corresponding connected pin assembly have contacted each other during manufacture. Since during manufacture the tooling inserts are removed together with the foamed shoe component from the cavity and are thus separated from the peripheral mold portion it is possible to even readily deform such curved channel geometries. This holds particularly true, because the manufactured shoe component is elastic, foamed and therefore relatively flexible. Channel 101d comprises first lateral opening 102d and second lateral opening 103d between which a curved and in this embodiment S-shaped channel path extends.

[0117] As the pins can be formed to be not only removable along a linear path from the foamed shoe component, the curvature of the produced channels can extend in horizontal and / or vertical directions and even helical pins may be used to form corresponding helical channels. The modular construction of the mold unit with tooling inserts that can be removed from the foamed article individually outside the cavity defined by the peripheral mold portion allows for a very broad range of channel geometries. It is possible to produce a shoe sole with a helical channel, formed by an insert with a helical pin, which is removed in a corresponding helical screwing movement after a number of linear pins forming a network of linear channels have been removed along linear paths and a number of curved pins have been removed along curved paths.

[0118] Fig. 10 shows a modular mold unit 1 according to another embodiment of the invention. Modular mold unit 1 comprises peripheral mold portion 2 and eight tooling inserts 3a-3h. Peripheral mold portion 2 circumferentially surrounds the eight tooling inserts and is in direct contact with them. Also in this case, peripheral mold portion 2 defines a cavity inside which the tooling inserts 3a-h are arranged. Tooling inserts 3a-h define together molding compartment 5. Such a modular mold unit allows a great flexibility, since for example if only the geometry, e.g. the cross-sectional shape, of the first channel if the foamed shoe component defined by the pins of tooling inserts 3g and 3h should be modified, one merely has to exchange these two tooling inserts and not produce a shoe sole with a whole new channel geometry. Therefore, rapid prototyping can be achieved for producing various different shoe components having different properties, such as channel height, width or shape.

[0119] Fig. 11 shows a model 200 of a foamed shoe component. As can be seen, the model comprises a plurality of stacked layers 201a, 201b, 201c (only three layers are referenced for clarity purposes) which are stacked on top of each other along vertical direction V. Each layer has a layer thickness t. Furthermore, it can be seen that the model of the foamed shoe component also has channels 101a and 101 b (only two channels are referenced for clarity purposes).

[0120] Fig 12 shows a pressure map having been obtained for a foot of an individual. As can be seen, the foot of the individual is sectioned into different areas and during the generation of the pressure map, each area is associated with a pressure value, such as a pressure value between 0 and 20 N / cm3. In Fig. 12 the left foot of the wearer is annotated with the obtained pressure value for each area. It can further be seen that there is a significant difference for this individual between the left and right foot. For example, there are two dark areas in the heel area of right foot indicating an increased pressure in these two areas, while there is only one dark area in the hell area of the left foot. The method according to the invention can now provide a shoe which is adapted to these specific cushioning needs of the individual. For example, pins can be provided such in the right shoe that the areas with increased pressure values are sufficiently cushioned. These areas are arranged in the 2 dimensional plane defined by the longitudinal and transversal direction.

[0121] List of designations

[0122] 1 Modular mold unit

[0123] 2 Peripheral mold portion

[0124] 3a-h Tooling insert

[0125] 4 Cavity

[0126] 5 Molding compartment

[0127] 6a, 6b Base portion

[0128] 7a, 7b Pin

[0129] 8 Inner cavity wall

[0130] 9 Bottom portion

[0131] 100 Foamed shoe component

[0132] 101a,b,c,d Channel

[0133] 102a,b,c,d First lateral opening

[0134] 103a,b,c,d Second lateral opening

[0135] 104 Branch

[0136] 105 Step

[0137] 200 Model of foamed shoe component

[0138] 201a, b,c Stacked layers

Claims

Claims1. Method for manufacturing a foamed shoe component, in particular a foamed shoe sole, the method comprising the steps: a. Providing a modular mold unit (1), the modular mold unit (1) comprising a peripheral mold portion (2), the peripheral mold portion defining a cavity (4), wherein the modular mold unit (1) comprises one or more tooling inserts (3a, 3b) being releasably arranged inside the cavity (4), wherein the one or more tooling inserts (3a, 3b) define a molding compartment (5); b. Injecting a polymer composition into the molding compartment (5), the polymer composition comprising at least one molten thermoplastic polymer and optionally a propellant; and c. Foaming the at least one molten thermoplastic polymer inside the molding compartment (5) to provide the foamed shoe component.

2. The method according to claim 1 , the method further comprising step d.: removing the foamed shoe component together with at least one of the one or more tooling inserts (3a, 3b) from the cavity (4).

3. The method according to claim 2, wherein after step d. the one or more tooling inserts (3a, 3b) are separated from the foamed shoe component, in particular automatically separated therefrom by one or more robotic arms.

4. The method according to any of the previous claims, wherein the one or more tooling inserts (3a, 3b) each comprise a base portion (6a, 6b), wherein the base portion (6a, 6b) is in direct contact with the peripheral mold portion (2) and defines the molding compartment (5).

5. The method according to claim 4, wherein at least one of the one or more tooling inserts (3a, 3b) comprises one or more pins (7a, 7b) protruding from the base portion (6a, 6b).

6. The method according to claim 5, wherein during step b. the molten thermoplastic polymer and / or the foamed shoe component surrounds the one or more pins (7a, 7b) thereby forming one or more channels of the foamed shoe component.

7. The method according to claim 6, wherein providing the modular mold unit (1) comprises: step al): generating a pressure map of a foot of an individual, in particular during running; step a2): providing a model, in particular a digital model, of the foamed shoe component based on the generated pressure map; step a3): providing the one or more pins (7a, 7b) of the one or more tooling inserts (6a. 6b) of the modular mold unit (1) based on the provided model of the foamed shoe component.

8. The method according to claim 7, wherein in step a2) the configuration and / or the position in the foamed shoe component of the one or more channels is determined based on the generated pressure map.

9. The method according to claim 7 or 8, wherein the model provided in step a2) is sectioned in a plurality of stacked layers having each a layer thickness.

10. The method according to claim 8 and 9, wherein the configuration and / or the position in the foamed shoe component of the one or more channels is determined for each layer.

11. The method according to any of claims 7 to 10, wherein the generated pressure map is generated by determining a pressure distribution over the foot of the individual during running.

12. The method according to any of the previous claims, wherein the propellant of the polymer composition being injected in step b. is a supercritical fluid and / or wherein the polymer composition being injected in step b. forms a single phase.

13. A modular mold unit (1) comprising a peripheral mold portion (2) and one or more tooling inserts (6a, 6b), wherein the peripheral mold portion (2) defines a cavity (4); wherein the one or more tooling inserts (3a, 3b) are releasably arranged inside the cavity (4), and wherein the one or more tooling inserts (3a, 3b) define a molding compartment (5).

14. The modular mold unit (1) according to claim 13, wherein the one or more tooling inserts (3a, 3b) each comprise a base portion (6a, 6b), wherein the base portion (6a, 6b) is in direct contact with the peripheral mold portion (2) and defines the molding compartment (5).

15. The modular mold unit (1) according to claim 14, wherein the peripheral mold portion (2) comprises an inner cavity wall (8) which defines the cavity (4) and wherein the one or more tooling inserts (3a, 3b), and in particular the base portion (6a, 6b) of the one or more tooling inserts (3a, 3b), essentially completely cover the inner cavity wall (8).

16. The modular mold unit (1) according to claim 14 or 15, wherein at least one of the one or more tooling inserts (3a, 3b) comprises one or more pins (7a, 7b) protruding from the base portion (6a, 6b).

17. The modular mold unit (1) according to claim 16, wherein the one or more pins (7a, 7b) extend completely through the molding compartment (5) and / or wherein the one more pins (7a, 7b) extend only through a part of the molding compartment (5).

18. The modular mold unit (1) according to claim 16 or 17, wherein the modular mold unit (1) comprises at least two tooling inserts (3a, 3b) which each comprise one or more pins (7a, 7b).

19. The modular mold unit (1) according to claim 18, wherein at least some of the pins (7a. 7b) of different tooling inserts (6a, 6b) contact each other thereby forming a connected pin assembly.

20. The modular mold unit (1) according to claim 19, wherein the pins (7a. 7b) of the connected pin assembly contact each other frontally or laterally.

21. The modular mold unit (1) according to claim 19 or 20, wherein the pins (7a. 7b) forming the connected pin assembly form together a releasable form locking and / or force locking engagement.

22. A foamed shoe component (100), in particular a foamed shoe sole, obtained by the method according to any of claims 1 to 12.

23. The foamed shoe component (100) according to claim 22, wherein the foamed shoe component defines one or more channels (101a, 101 b), each channel comprising a channel path and a first lateral opening (102a, 102b) and optionally a second lateral opening (103a, 103b) wherein: a. at least one channel (101a) defines an angled or curved channel path and / or a channel path comprising a step (105); and / or b. at least one channel (101b) defines a branch (104) at which the at least one channel (101 b) branches into two or more channels (101c, 101 d); and / or c. wherein the first lateral opening (102a, 102b) defines a first open area and wherein optionally the second lateral opening (103a, 103b) defines a second open area, wherein the channel path of at least one channel has a crosssectional area being larger than first open area and optionally than the second open area.

24. The foamed shoe component (100) according to claim 22 or 23, wherein the foamed shoe component (100) is made from a single piece.

25. Kit of parts comprising the modular mold unit (1) according to any of claims 13 to 21 , and further comprising a plurality of additional tooling inserts, and / or a plurality of pins being configured for being releasably connected to the one or more tooling inserts of the modular mold unit and / or to the additional tooling inserts.

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