Soling, footwear articles comprising such soleing, and manufacturing processes for said soleing and said footwear article

Abstract

The present invention relates to a sole (250) comprising a molded sole shell (200) having an outer face, an inner base, and first (216) and second lateral walls between which said inner base extends. Said sole (250) comprises a sole element (300) including a rim, said rim including a first male main interlocking portion having a determined shape, and said sole shell (200) including an inner volume for receiving said sole element (300) and a second female main interlocking portion, having a determined shape configured to cooperate by interlocking with said first main interlocking portion so as to maintain said sole element (300) in position relative to the sole shell (200), said second main interlocking portion being formed in the first lateral wall (216), and optionally by at least a portion of said inner base.The present invention also relates to a footwear article comprising said sole (250). Figure 11.

Description

Title of the invention: Sole assembly, footwear article comprising such a sole assembly, and methods of manufacturing said sole assembly and said footwear article Technical field

[0001] The present invention relates to the field of soles, and footwear articles, in particular sports shoes, comprising such soles.

[0002] The present invention also relates to the field of methods for manufacturing such soles, and footwear articles comprising such soles. Prior art

[0003] Conventional footwear articles generally comprise an upper and a sole structure. The upper is secured to the sole structure and forms a void within the footwear article to comfortably receive and secure a foot. The sole structure is secured to a lower area of ​​the upper, and operatively disposed between the ground, and the upper.

[0004] In articles of footwear for practicing a sport, the sole structure may include a wear sole and a midsole. The midsole often includes a polymeric foam material that absorbs shock from the ground upon impact to lessen the effects on the foot and leg during walking, running, or other ambulatory activities. The sole structure may also include a liner positioned near the bottom surface of the foot to enhance the comfort of the article of footwear.

[0005] The soles are traditionally joined to the uppers using a system called Strobel, during which the different elements of the sole (inner sole, midsole and outsole in particular) are assembled. The manufacturing processes for a conventional shoe require dozens of steps and produce a lot of waste from the cutting of materials.

[0006] It is sought to simplify the manufacturing processes of footwear articles, in particular by reducing the number of steps and / or the energy and material consumption. This problem is also part of the search for a manufacturing process that can be implemented as close as possible to the place of use of the footwear article in order to reduce its carbon impact, facilitate stock management, and allow the personalization of the footwear article.

[0007] One solution is to eliminate the sewing steps required to shape the initially flat upper in three dimensions. The upper is obtained from the assembly of one or a few pieces, and no longer from multiple pieces. stitched together.

[0008] WO 2019 / 234374 A1 thus proposes a first textile slipper formed in three dimensions directly at the outlet of a textile loom (for example a knitting loom), partially heat-meltable, used in the construction of the upper, then to secure this first slipper to a wear sole. The first textile slipper is reinforced by placing a second textile slipper, in three dimensions, partially heat-meltable, around the first slipper by wrapping the junction between the first slipper and the wear sole in order to improve resistance to delamination. The assembly comprising the first and second textile slipper and the wear sole undergoes a heat treatment to melt the heat-meltable threads and fix the shape of an upper. The manufacturing process is simplified by significantly reducing the number of manufacturing steps.

[0009] However, it is sought to further improve these footwear articles, in order to lighten them, improve their resistance to abrasion and tearing, and their breathability.

[0010] Limiting the number of steps in the manufacture of a footwear item restricts the range of technical functions and aesthetic renderings available.

[0011] Footwear articles manufactured by a thermocompression process have fairly rigid outsoles due to the compaction of the thermomelted material. It is not possible to reliably use foam which is in fact crushed during the thermocompression process. The outsoles of such articles therefore lack flexibility and cushioning.

[0012] It is possible to partially overcome this problem by selecting very flexible hot-melt materials. However, it is difficult to find flexible hot-melt materials whose melting or softening temperature is suitable for processing by thermocompression, and which also have good abrasion resistance if they are to form outsoles.

[0013] Indeed, the melting temperature(s) used must be lower than the melting or degradation temperature of the textile elements of the footwear article which are not intended to be at least partially heat-melted.

[0014] Furthermore, if one seeks to use recycled materials, at least in part thermofusible, for the manufacture of the outsole by thermocompression, it is difficult to control the resulting hardness and therefore flexibility because the precise composition of said recycled materials is not always known precisely.

[0015] There is thus a need for a footwear article comprising one or more thermofused or partially thermofused textile portion(s) which is light, flexible and breathable, while offering satisfactory resistance to abrasion and tearing, and comfortably conforming to the shape of the foot.

[0016] There is a need for a comfortable sole and footwear article comprising said soles which can be manufactured by thermocompression and whose sole is adapted to the use of the footwear article, and which can use recycled and at least partly thermofusible waste.

[0017] There is also a need for a method of manufacturing such a sole assembly and an article of footwear comprising said sole assembly which are simplified while offering numerous possibilities as to the technical and aesthetic functions which can be imparted to the sole assembly and to the article of footwear comprising said sole assembly. Statement of the invention

[0018] The present invention relates, according to a first aspect, to a sole assembly, in particular for a sports shoe, comprising a molded sole shell, in particular a molded outsole shell. Said sole shell comprises an external face, an internal bottom and first and second side walls between which said internal bottom extends.

[0019] Said sole assembly comprises a sole element comprising a border, said border comprising a first main male or female interlocking portion having a determined shape.

[0020] Said sole shell comprises an interior volume for receiving said sole element and a second main female or male interlocking portion having a determined shape configured to cooperate by interlocking with said first main interlocking portion so as to hold said sole element in position relative to the sole shell, said second main interlocking portion being formed in the first side wall, and possibly by at least one portion of said inner bottom.

[0021] Advantageously, the sole shell is hollow and is adapted to house the sole element in its interior volume, in particular in a removable manner.

[0022] In one exemplary embodiment, the sole shell is a wear sole shell.

[0023] In particular, the outsole shell comprises an external face: - at least one portion of which is a portion of engagement with the ground; and / or - at least one portion of which is directly opposite the ground, in particular said portion is not a portion of engagement with the ground; and / or - comprises one or more abrasion-resistant sole element(s) arranged on said external face of said sole shell, for example one or more elements in an elastomeric material (in particular not covering the entire surface of the external face).

[0024] Advantageously, the sole shell comprises first and second side walls, and optionally front and rear side walls, the thickness of which average is fine, that is to say a few millimeters, in particular ranging from 0.5 mm to 8 mm, more particularly ranging from 0.5 mm to 5 mm.

[0025] Advantageously, the sole shell is not full. This arrangement makes it possible to give flexibility to the sole shell, and makes it possible to manufacture the latter, totally or in part, with thermofusible material(s), the hardness of which would not be suitable for obtaining a sole, in particular a wear sole, which is full and sufficiently flexible to allow the foot to roll comfortably.

[0026] Furthermore, the sole shell being hollow, is lightened, compared for example to the outsoles of the state of the art.

[0027] In the state of the art, an adult-sized outsole has an average mass of around 300g.

[0028] Advantageously, the sole shell, for example for a shoe size 43FR or 9.5US, has a mass less than or equal to 300g, in particular of the order of 225g.

[0029] Advantageously, said sole shell has a mass greater than or equal to 180 g.

[0030] Advantageously, when the sole element is arranged inside the sole shell, the sole element is configured to fill a portion, in particular substantially all, of the interior receiving volume of the sole shell.

[0031] Advantageously, this arrangement makes it possible to form a sole assembly comprising the sole shell and the sole element occupying the volume occupied by a prior art outsole while providing the function of an outsole and the function of an additional sole element distinct from the sole shell, said sole element thus being able to be a shock-absorbing intermediate sole and / or an insole.

[0032] Preferably, the first main interlocking portion and the second main interlocking portion are adapted to cooperate together in a removable manner in order to maintain the sole element in position relative to the sole shell, and in order to disengage the sole element from the sole shell on demand, thus making it possible to separate the sole shell and the sole element.

[0033] In one embodiment, the sole shell, in particular the wear shell, comprises one or more materials chosen from: thermoplastic polyurethanes, thermoplastic polyolefins (PP, PE), polyurethane elastomers, polyolefin elastomers, preferably chosen from thermoplastic polyurethanes and polyurethane elastomers.

[0034] Preferably, the sole shell comprises a forefoot region, a midfoot region, and a rearfoot region.

[0035] Preferably, the sole shell comprises a front side and a rear side between which said sole shell extends, and a lateral side and a medial side between which the sole shell extends.

[0036] Preferably, the sole shell comprises an internal face and an external face, possibly substantially opposite the internal face, in particular the internal face is the surface of the inner bottom of the sole shell.

[0037] Preferably, the outer face of the outsole shell is an outer face of which at least a portion engages with the ground.

[0038] Preferably, the first side wall of the sole shell extends on the lateral or medial side of the sole shell, preferably on the medial side.

[0039] Preferably, the second side wall extends on the lateral or medial side of the sole shell, preferably on the lateral side.

[0040] Preferably, the first side wall and the second side wall of the sole shell extend vertically on either side of the inner bottom of the sole shell and above said inner bottom.

[0041] Preferably, the sole shell comprises a rear side wall extending from the rear side of the sole shell and a front side wall extending from the front side of the sole shell.

[0042] Preferably, the rear side wall and / or the front side wall of the sole shell extends (each) vertically from the inner bottom of the sole shell and above said inner bottom.

[0043] Preferably, the first side wall and / or the second side wall of the sole shell is / are (each) curved towards the interior volume of the sole shell.

[0044] Preferably, the rear side wall and / or the front side wall is / are (each) curved towards the interior volume of the sole shell.

[0045] Preferably, the sole element comprises a forefoot region, a midfoot region, a rearfoot region.

[0046] Preferably, the sole element comprises a front side and a rear side between which said sole element extends, and a lateral side and a medial side between which said sole element extends.

[0047] In the present text, the term “lateral side of the footwear / sole / upper and, in general, of any element relating to a footwear article according to the invention” means any element or part of the footwear / sole / upper arranged between the central longitudinal axis of the footwear / sole / upper and the natural external side of the foot.

[0048] In this text, the medial side of the footwear / sole / upper and, in general, of any element relating to a footwear item means any element or part of the footwear / sole / upper arranged between the central longitudinal axis of the footwear / sole / upper and the side natural external part of the foot.

[0049] Preferably, the sole element comprises an internal face and an external face, more preferably the internal face is substantially opposite the external face.

[0050] Preferably, said edge of the sole element comprising the first main male or female interlocking portion is an edge extending on the lateral side or the medial side of the sole element, preferably on the medial side. When the border extends to the medial side, said border is referred to in this text as the medial border, and when the border extends to the lateral side, said border is referred to as the lateral border.

[0051] Preferably, the sole element comprises a lateral border extending between the inner and outer faces of the sole element, on the lateral side of the sole element.

[0052] Preferably, the sole element comprises a medial border extending between the inner and outer faces of the sole element, on the medial side of the sole element.

[0053] Preferably, the sole element comprises a front edge and a rear edge each extending between the inner and outer faces of the sole element.

[0054] Preferably, said interior volume of the sole shell is delimited, at least in part, between the interior bottom, and the first and second side walls, as well as the front and rear side walls of the sole shell.

[0055] Advantageously, the front and rear side walls, and the first and second side walls, form a substantially continuous rim, projecting vertically above the inner bottom, and around the entire perimeter of the inner bottom.

[0056] In one embodiment, - said edge of the sole element comprising said first main male or female interlocking portion, having a determined shape, is a medial edge, and - the sole element further comprises a lateral edge comprising a first male, respectively female, auxiliary fitting portion having a determined shape, and - said second main female or male interlocking portion is formed in the first side wall of the sole shell, and possibly in at least one portion, in particular in at least one medial portion, of the inner bottom of the sole shell, and - the sole shell comprises a second female, respectively male, auxiliary fitting portion formed in the second side wall of the sole shell, and possibly in at least one portion, in particular at least one lateral portion, of the inner bottom of the sole shell, said second female, respectively male, auxiliary fitting portion being configured to cooperate by fitting with said first male, respectively female, auxiliary fitting portion, so as to hold said sole element in position relative to the sole shell.

[0057] This arrangement makes it possible to maintain the sole element laterally and medially in position in the sole shell.

[0058] The first main and / or auxiliary male or female interlocking portion(s) of the sole element may each be substantially continuous, or may each be discontinuous, i.e. in several separate parts, each part of which individually takes on the characteristics of the first main or auxiliary interlocking portion.

[0059] In one example, the first main or auxiliary male, respectively female, nesting portion, in particular formed in the lateral or medial border: - extends respectively partly in the forefoot region and partly in the midfoot region; and / or - is lying down.

[0060] The second main and / or auxiliary female, respectively male, interlocking portion(s) of the sole shell may be substantially continuous, or may be discontinuous, i.e. in several distinct parts, each part of which individually takes on the characteristics of the second main or auxiliary interlocking portion.

[0061] In one example, the second main or auxiliary female, respectively male, fitting portion, in particular formed in the first side wall or the second side wall, and possibly by at least one lateral or medial portion of the inner bottom of the sole shell: - extends respectively partly in the forefoot region and partly in the midfoot region; and / or - is lying down.

[0062] In one embodiment, the sole shell, in particular the wear shell, in particular corresponding to a size of the footwear article 43 FR (in particular to a US size 9.5), has a mass less than or equal to 300g, preferably less than or equal to 280g or 260g or 240g or 225g.

[0063] In particular, the sole shell, in particular the wear shell, has a mass greater than or equal to 150g or 180g or 190g or 200g or 205g.

[0064] Within the range indicated above, the mass of the sole shell varies according to the size of the footwear item (in particular for an adult shoe size).

[0065] In one example, the sole shell comprises non-thermally fused particles at least in part.

[0066] In one example, said non-thermally melted particles at least in part have an average size ranging from 0.5 mm to 10 mm, in particular from 1 mm to 5 mm.

[0067] In one example, the sole shell comprises, in particular is essentially made of, one or more polymer material(s) having a Shore A hardness ranging from 40 to 90.

[0068] Shore A hardness can be measured, for example, using ISO 48-4:2018 entitled “Vulcanized or thermoplastic rubber - Determination of hardness - Part 4: Indentation hardness by the durometer method (Shore hardness)”.

[0069] In an alternative embodiment, the sole element is a flexible and deformable sole element compared to the sole shell so that it can be deformed during its positioning in the interior receiving volume of the sole shell.

[0070] Advantageously, the sole element can be folded in two, and deformed, without significant degradation of its properties, which facilitates its insertion by deformation into the interior receiving volume of the sole shell.

[0071] In a variant, the density of the sole element is greater than or equal to 40 g / L and less than or equal to 120 g / L, preferably greater than or equal to 50 g / L and less than or equal to 110 g / L, more preferably greater than or equal to 60 g / L and less than or equal to 80 g / L.

[0072] In one variant, the impact energy absorption of the material of the sole element ranges from 2 joules to 7 joules, in particular from 2.2 joules to 5.7 joules.

[0073] This energy absorption value is preferably measured according to ASTM F 1976-13 entitled "Standard test method for measuring impact attenuation of athletic shoe cushioning systems".

[0074] In one variant, the sole shell comprises one or more recesses arranged in one or more walls of the shell, in particular arranged in the first side wall and / or the second side wall and / or the front side wall and / or the rear side wall.

[0075] This arrangement makes it possible to lighten the sole shell and refine the wall comprising one or more recesses in order to give it greater flexibility to receive by deformation the sole element in its interior volume and to make the male and female interlocking portions cooperate with each other.

[0076] In a variant, the internal face of the sole element, housed in the interior receiving volume of the sole shell, forms a foot support zone configured to be arranged opposite the foot when the footwear item is worn, and the support zone is vertically set back from the upper edge of the first or second side wall of the sole shell along all or part of the first or second side wall, and optionally the support zone of the sole element is vertically set back from the upper edge along all or part of the front side wall and / or along all or part of the rear side wall of the sole shell.

[0077] The vertical withdrawal is in one example at least 5 mm or at least 10 mm or at least 15 mm, in particular less than or equal to 25 mm.

[0078] This arrangement advantageously makes it possible to reduce the weight of the sole shell and the sole element, and makes it easier to maintain the sole element relative to the sole shell.

[0079] In a variant, the sole shell (in particular its inner bottom) comprises, in cross-section, an external layer comprising a polymer material A forming at least part of the external face of the sole shell, at least one intermediate layer comprising a polymer material B optionally mixed with a polymer material C, an external layer comprising a polymer material D forming at least part of the internal face of the sole shell, said at least one intermediate layer being arranged between the external layer and the internal layer.

[0080] In particular, materials A, B, C and D are different from each other by at least one property, more particularly said distinctive property is chosen from: a difference in Shore A hardness, the nature of the polymer material, the Young's mode of the polymer material (E in Pa).

[0081] In one example, polymer material D has a Shore A hardness greater than the Shore A hardness of polymer material B and possibly greater than the Shore A hardness of polymer material C.

[0082] In one example, the polymer materials A, B, optionally C, and D are chosen from polyurethanes (optionally thermoplastic polyurethane elastomers), and / or polyolefins (optionally thermoplastic polyolefin elastomers).

[0083] In one variant, the sole element is a midsole and / or an insole.

[0084] Preferably, the midsole is a cushioning midsole attenuating impact forces with the ground.

[0085] In an exemplary embodiment, a first layer of cleanliness is secured to the internal face of the midsole.

[0086] In one variant, the sole element is a sole comprising one or more foamed polymer(s), for example chosen from polyurethanes, polyamides, such as (polyether block amide) for example PEBAX®, and polyolefins.

[0087] In an alternative embodiment, the sole element is designed to be secured to the sole shell, in particular the wear shell, in a removable manner.

[0088] This arrangement allows a user to personalize the sole by choosing the sole element adapted to a specific use, for example according to the morphology of the user or the sport practiced.

[0089] In an alternative embodiment, said first main fitting portion is a first male main fitting portion, and said second main fitting portion is a second female main fitting portion consisting essentially of a cavity, in particular a main cavity, comprising an upper wall and a lower wall together forming an open clamp, in particular the upper wall forms an upper stop for the sole element.

[0090] This advantageous shape of the second main interlocking portion of the sole shell makes it possible to pinch the first main interlocking portion arranged along the edge of the sole element.

[0091] The sole element being advantageously flexible and deformable, the first main interlocking portion deforms to fit the second main interlocking portion.

[0092] Preferably, the upper wall is formed in the first side wall, in particular arranged on the medial or lateral side.

[0093] Preferably, the lower wall is formed by a portion, in particular medial or lateral, of the inner bottom of the sole shell.

[0094] In particular, the lower and upper walls are inclined towards each other and meet on the medial, or lateral, side of the sole shell.

[0095] In particular, the cavity is open to the interior volume of the sole shell.

[0096] In one embodiment, said first auxiliary fitting portion is a first male auxiliary fitting portion, and said second auxiliary fitting portion is a second female auxiliary fitting portion consisting essentially of a cavity, in particular an auxiliary cavity, comprising an upper wall and a lower wall together forming an open clamp, in particular the upper wall forms an upper stop for the sole element.

[0097] In an alternative embodiment, the sole shell comprises a main cavity formed in the first side wall, in particular the lateral wall, and a portion of the inner bottom of the sole shell; said sole shell further comprises an auxiliary cavity formed in the second side wall, in particular the medial wall, and a portion of the inner bottom of the sole shell.

[0098] In one embodiment, the edge of the sole member extends between an upper edge and a lower edge, and the lower edge projects outwardly from the edge relative to the upper edge such that the upper edge is recessed relative to the lower edge.

[0099] In an exemplary embodiment, the edge of the sole element is an edge medial and extends between a superior medial border and a inferior medial border, and the inferior medial border projects outward from the medial border relative to the superior medial border so that the superior medial border is recessed relative to the inferior medial border.

[0100] In an exemplary embodiment, the sole member further comprises a lateral border extending between an upper lateral edge and a lower lateral edge, and the lower lateral edge projects outwardly from the lateral border relative to the upper lateral edge such that the upper lateral edge is recessed relative to the lower lateral edge.

[0101] In an alternative embodiment, the first main male interlocking portion of the sole element has a substantially beveled shape from the lower edge, in particular the lateral edge, of the border, in particular the lateral edge.

[0102] Preferably, the first male auxiliary fitting portion of the sole element has a substantially beveled shape from the lower edge, in particular medial, of the border, in particular medial.

[0103] In an alternative embodiment, the sole shell, in particular the wear shell, comprises a rearfoot region, a midfoot region and a forefoot region, and said second main interlocking portion, and possibly said second auxiliary interlocking portion, is / are arranged in the forefoot region, and possibly partly in the midfoot region of the sole shell.

[0104] The connection between the sole shell and the sole element is carried out at least in the forefoot region where the greatest mechanical stresses are exerted on the sole assembly, in particular in bending. This arrangement thus improves the support, in particular in a removable manner, and improves the support of the deformation of the sole element relative to the sole shell.

[0105] In an alternative embodiment, the sole element comprises a rearfoot region, a midfoot region and a forefoot region, and said one first main interlocking portion, and optionally said one first auxiliary interlocking portion, is / are arranged in the forefoot region, and optionally partly in the midfoot region, of the sole element.

[0106] In an alternative embodiment, the sole element comprises a rear rim projecting vertically above an inner bearing face of the foot of said sole element, and the sole shell comprises a rear side wall comprising an upper edge inclined towards the inside of the sole shell and forming an upper stop for said rear rim of the sole element.

[0107] This arrangement advantageously makes it possible to further improve the positioning of the sole element in the interior receiving volume of the sole shell.

[0108] This configuration of the rear side wall of the sole shell can be obtained by the thermocompression method described below using an inflatable bladder. During demolding, despite the undercut shape of the rear side wall of the sole shell, the bladder is in a deflated state, which facilitates demolding and thus allows complex (undercut) shapes to be obtained.

[0109] In one exemplary embodiment, the upper edge of the rear rim of the sole element is substantially flush with the inclined upper edge of the rear side wall of the sole shell.

[0110] In an alternative embodiment, the first side wall comprises an upper edge of which at least a portion is inclined towards the inside of the sole shell.

[0111] Preferably, the second side wall of the sole shell comprises an upper edge of which at least a portion is inclined towards the inside of the sole shell.

[0112] In an alternative embodiment, the sole element comprises, in particular is essentially made up of, particles agglomerated in at least one expanded polymer.

[0113] The inventors have determined that the sole element thus has good deformability facilitating its placement in the sole shell, and the cooperation by interlocking of the first main interlocking portion, respectively auxiliary, with the second main interlocking portion, respectively auxiliary.

[0114] In addition, this type of sole element has good cushioning properties to act as a midsole, and is lightweight.

[0115] Preferably, said expanded polymer is chosen from: thermoplastic polyurethanes, polyurethane elastomers, polyamides, for example (polyether block amide), such as PEBAX®, polyolefins (such as polypropylenes and polyethylenes), and polyolefin elastomers.

[0116] By "the particles are agglomerated" is meant that said particles form a monolithic block in which the particles are secured to each other, in particular the particles are bonded to each other by means of thermofused portions of said at least one expanded polymer.

[0117] The particles can be of any shape but are preferably beads.

[0118] In an alternative embodiment, the sole element comprises an internal foot support face, and said internal foot support face is set back vertically from the inclined upper edge of the rear side wall of the sole shell, in particular by a setback RAr greater than or equal to 10 mm, more particularly less than or equal to 30 mm, in particular greater than or equal to 20 mm.

[0119] This arrangement makes it possible to improve the rear support of the sole element in the sole shell.

[0120] In an alternative embodiment, the sole element comprises an internal foot support face, and said internal foot support face is set back vertically from the upper edge, possibly inclined, of the first or second side wall of the sole shell, in particular by a setback RM greater than or equal to 10 mm, more particularly less than or equal to 25 mm, in particular greater than or equal to 15 mm.

[0121] This arrangement makes it possible to improve the lateral support and / or the medial support of the sole element in the sole shell.

[0122] In an alternative embodiment, the sole element comprises an internal foot support face, and said internal foot support face is set back vertically from the upper edge of the front side wall of the sole shell, in particular by a RAV setback greater than or equal to 3 mm, more particularly less than or equal to 30 mm, in particular less than or equal to 20 mm or 10 mm.

[0123] Advantageously, the foot is not held in place solely by the upper but also by the sole shell via the recesses RAv RmêI Rar.

[0124] In an alternative embodiment, the sole shell is hollow, in particular comprises an empty interior receiving volume.

[0125] In an alternative embodiment, the sole shell comprises first and second side walls, and front and rear side walls, in particular connected to each other and forming a vertical rim around the entire perimeter of the inner bottom.

[0126] Preferably, each of said side walls having a thickness greater than or equal to 1 mm and less than or equal to 10 mm, in particular less than or equal to 6 mm, more particularly less than or equal to 4 mm.

[0127] Preferably, the inner bottom has a thickness ranging from 3 mm to 15 mm, in particular ranging from 3 mm to 6 mm.

[0128] Preferably, the height of the side walls is greater than or equal to 10 mm, in particular greater than or equal to 20 mm, more particularly greater than or equal to 30 mm, in particular in the rear foot region of the sole shell.

[0129] In an alternative embodiment, the thickness of the sole shell decreases substantially from the inner bottom towards the first side wall and / or towards the second side wall.

[0130] The present invention relates, according to a second aspect, to an article of footwear, in particular a sports shoe, comprising a sole according to any one of the variant embodiments with reference to the first aspect of the invention.

[0131] Advantageously, the sole assembly can be secured to an upper in a conventional manner, for example using a strobel assembly, or by thermocompression as described in particular below with one or more tubular textile element(s) comprising one or more thermofusible and therefore thermo- textile portion(s). melted after thermocompression.

[0132] In an alternative embodiment, the footwear article comprises at least one textile tubular element, optionally comprising at least one textile portion at least partially heat-melted, the sole shell and said at least one textile tubular element are bonded by at least one heat-melted portion, in particular by at least one heat-melted portion of the sole shell and / or at least one heat-melted textile portion of said textile tubular element.

[0133] In one embodiment, the textile tubular element is a woven or knitted tubular element, preferably knitted.

[0134] The textile tubular element is preferably a knitted sock.

[0135] Advantageously, a textile tubular element, for example internal or external, comprises a textile part, in particular internal or external, covering at least part of the foot and a sole part, in particular internal or external, in textile connection, in particular knitted, with said textile part covering at least part of the foot.

[0136] Advantageously, the textile tubular element, in particular whether internal or external, is of unitary knitted construction.

[0137] Unitary knitted construction means that the tubular element is in a single knitted piece and does not include one or more knitted inserts secured by sewing or welding to the single knitted piece after the latter has been knitted. The knitted tubular element may include seams for finishing purposes, for example closing the toe.

[0138] In a first embodiment, the textile tubular element is an internal textile tubular element comprising one or more thermofused textile portion(s), and the sole portion of the internal textile tubular element is arranged between the sole shell and the sole element. In particular, the internal sole textile portion of the internal textile tubular element is thermofused in part or in full and covers all or part of the internal face of the internal bottom and all or part of the internal faces of the side walls, in particular the first and second side walls and possibly the front and rear side walls, of the sole shell.

[0139] In a second embodiment, the footwear article comprises an inner textile tubular element and an outer textile tubular element, and the sole shell according to the first aspect is arranged between the inner sole portion of the inner textile tubular element and the outer sole portion of the outer textile tubular element. In particular, the inner textile tubular element is arranged in whole or in part in the foot-receiving volume of the outer textile tubular element, the sole shell being arranged between said inner and outer textile tubular elements.

[0140] In particular, the inner sole textile portion of the inner textile tubular element is partially or completely heat-melted and covers all or part of the internal face of the inner bottom and all or part of the internal faces of the side walls, in particular the first and second side walls and possibly the front and rear side walls, of the sole shell.

[0141] In one example, the outer sole portion of the outer textile tubular element, partly or entirely heat-fused, covers at least part, or entirely, of the outer face, in particular the outer face of engagement with the ground, of the sole shell of the footwear article.

[0142] In a third embodiment, the footwear article comprises an inner textile tubular element and an outer textile tubular element, and the sole shell according to the first aspect, the outer sole portion of the outer textile tubular element being arranged between the sole shell according to a first aspect of the invention, and the inner sole portion of the inner textile tubular element. In particular, the inner textile tubular element is arranged in whole or in part in the foot-receiving volume of the outer textile tubular element, the outer textile tubular element being arranged at least in part between the sole shell and the inner textile tubular element.

[0143] In particular, the inner sole textile part and the outer sole textile part are partially or completely heat-fused and cover all or part of the inner face of the inner bottom and all or part of the inner faces of the side walls, in particular the first and second side walls and possibly the front and rear side walls, of the sole shell.

[0144] In one example, the outer face of the sole shell forms at least a portion, or entirely, of the outer ground-engaging face of the footwear article.

[0145] Advantageously, in particular in the embodiments below, the inner sole textile portion of the inner textile tubular element is partially or fully heat-melted (in particular is heat-compressed), against the inner surface of the inner receiving volume of the sole shell so that the inner face of the inner bottom, the inner faces of the first and second side walls and the inner faces of the front and rear side walls of the sole shell are coated, in whole or in part, with the inner sole portion of the inner textile tubular element, said inner sole portion being partially or fully heat-melted.

[0146] The textile sole portion of the inner textile tubular element, and possibly the sole portion of the outer textile tubular element, is / are thin so that the sole shell of the footwear article comprises all of the characteristics / variants / embodiments defined with reference to the sole shell of the sole assembly according to the first aspect of the invention.

[0147] Advantageously, the sole shell, coated with one or more element(s) tubular internal and / or external textile(s) thermofused in part or in full, therefore comprises a first main male, respectively female, fitting part, configured to cooperate by fitting with the second main female, respectively male, fitting part of the sole element for holding the sole element in position relative to the sole shell, and in particular comprises any one of the variant embodiments defined with reference to the first aspect of the invention (first auxiliary male, respectively female fitting part, beveled medial or lateral lower edge, etc.).

[0148] Advantageously, in the first, second and third preceding embodiments, the sole element is arranged against the internal sole part of the internal textile tubular element which is wholly or partly thermofused.

[0149] In one embodiment, the upper comprises the covering textile part, in particular internal, of at least a part of the foot of the textile tubular element, in particular internal, and the sole assembly comprises the sole textile part, in particular internal, of said textile tubular element, in particular internal, and possibly a part of the covering textile part at least partly of the foot.

[0150] In embodiments, the footwear article comprises internal and external textile tubular elements superimposed at least in part, the internal textile tubular element being arranged at least in part in the foot-receiving volume of the external textile tubular element.

[0151] Textile tubular element (in particular whether internal or external)

[0152] A textile tubular element, in particular whether it is an internal or external textile tubular element, comprises (in particular is essentially made up of) one or more multifilament yarn(s), in particular partially or totally heat-melted, and / or one or more spun yarn(s) of fibers, in particular partially or totally heat-melted, and / or one or more monofilament yarn(s), in particular partially or totally heat-melted.

[0153] The textile part covering at least in part the foot of a textile tubular element, in particular whether it is internal or external, may comprise one or more non-thermally melted thread(s) entirely or in part with one or more thermomelted thread(s) entirely or in part.

[0154] The textile tubular element is preferably a knitted tube, in particular a tube knitted on a circular knitting machine of small diameter (i.e. the diameter of which is between 5 cm and 20 cm, in particular between 5 cm and 15 cm).

[0155] The textile tubular element is preferably a tube comprising a bent part, in particular intended to receive the heel.

[0156] The textile tubular element preferably comprises an open front end, in particular which is closed, more particularly closed by sewing. Preferably, the open front end is a toe landing area.

[0157] Advantageously, the textile tubular element comprises a volume for receiving or accommodating the foot and an opening for introducing the foot for accommodating the foot in said receiving volume.

[0158] The textile portion covering at least part of the foot of a textile tubular element may cover all or one or more regions of the top of the foot.

[0159] The textile sole portion of a textile tubular element may cover all or one or more regions of the underside of the foot.

[0160] The textile covering part and / or the textile sole part is / are arranged according to the configuration of the desired footwear article.

[0161] Preferably, the covering textile portion, in particular of the inner or outer textile tubular element, covers one or more regions of the top of the foot chosen from: the forefoot region arranged on the lateral side and / or the forefoot region arranged on the medial side; and / or the forefoot region extending between the lateral side and the medial side; and / or the instep area; and / or the midfoot region arranged on the lateral side and / or the midfoot region arranged on the medial side; and / or the rearfoot region arranged on the lateral side and / or the rearfoot region arranged on the medial side; and / or the rearfoot region extending between the lateral side and the medial side; and optionally at least partly the leg region.

[0162] The region(s) of the underside of the foot in which a part of the sole, in particular of the internal or external textile tubular element, extends, is / are chosen from: the forefoot region extending between the lateral and medial sides of the footwear article; and / or the midfoot region extending between the lateral and medial sides of the footwear article; and / or the rearfoot region extending between the lateral and medial sides of the footwear article.

[0163] Preferably, a textile tubular element comprises an external face and an internal face, in particular substantially opposite.

[0164] Preferably, the internal face of the external textile tubular element is oriented opposite the external face of the internal textile tubular element.

[0165] Preferably, the external face of the external textile tubular element is oriented facing the exterior of the footwear article.

[0166] Advantageously, a textile tubular element comprises one or more non-thermally melted thread(s), and / or one or more thermomelted thread(s) at least in part, in particular entirely or in part.

[0167] In one embodiment, the inner textile tubular element and the outer textile tubular element are two distinct and separate knitted pieces.

[0168] In this case, when the internal and external textile tubular elements are su- perposed at least in part, the internal textile tubular element being arranged in a receiving volume of the foot of the external textile tubular element, the internal mounting face of the external textile tubular element is oriented opposite the external mounting face of the internal textile tubular element.

[0169] The internal mounting face of the internal textile tubular element is then oriented opposite the volume for receiving the foot of the footwear article.

[0170] In one embodiment, the internal textile tubular element and the external textile tubular element are in the same textile piece (in particular knitted), in particular are in textile connection (in particular knitted) at the level of their openings for introducing the foot into their respective foot reception volumes or at the level of their respective open toes.

[0171] In this case, the internal textile tubular element being arranged in the receiving volume of the foot of the external textile tubular element by turning over, said internal and external textile tubular elements being superimposed at least in part, the internal mounting face of the external textile tubular element is oriented opposite the internal mounting face of the internal textile tubular element.

[0172] The external mounting face of the internal textile tubular element is then oriented opposite the volume for receiving the foot of the footwear article.

[0173] Advantageously, on the footwear article corresponding to the finished article, in practice, the external face of the internal textile tubular element is oriented directly opposite the internal face of the external textile tubular element.

[0174] In one embodiment, the external face of the sole shell, in particular the outsole shell, possibly coated in all or part of the sole part (in particular external) with a tubular textile element (in particular external), forms all or part of the external face of engagement with the ground of the footwear article.

[0175] In particular, the textile sole part of the textile tubular element (in particular external) fits, in particular forms a covering fitting, the contour of one or more slot(s) opening out and open on the external face of said sole shell. Textile portion at least partially melted

[0176] Advantageously, a textile portion at least partly thermofused is: - a portion of one or more thread(s) which is partially heat-melted so that said portion retains a recognizable textile structure, the thread(s) being glued to each other and / or to another or other thread(s), and / or is / are stiffened (in particular without being glued to each other); or - a portion of one or more thread(s) which is heat-melted so that said portion forms a film or coating or a polymeric melt such as a binder (in particular the textile structure is no longer recognizable).

[0177] Advantageously, in all cases, a change in state of the thermofusible textile portion is observed, in particular making it possible to bond threads together and / or to form a film or a coating or a binder or a matrix, and / or to stiffen the thread(s), in order to retain the shape given during thermocompression and to form differentiated technical zones.

[0178] The textile tubular element, in particular the internal textile tubular element (ETTI) and / or the external textile tubular element (ETTE), may (each) comprise one or more thermofused or partially thermofused textile portion(s) (also referred to in this text as at least partially thermofused textile portion(s)).

[0179] A textile portion that is at least partly thermofused may be a portion: - a single-component monofilament yarn which is at least partially heat-melted (and therefore in particular heat-meltable before its transformation) or two-component comprising at least a first component which is at least partially heat-melted (and therefore in particular heat-meltable before its transformation) and at least a second component which is not heat-melted (and therefore in particular not heat-meltable before its transformation) as defined in this text, - a multifilament yarn comprising one or more single-component filament(s) which are at least partially heat-melted (and therefore in particular heat-meltable before transformation) or two-component filament(s), each filament comprising at least one first component which is at least partially heat-melted (and therefore in particular heat-meltable) and at least one second component which is not heat-melted (and therefore in particular not heat-meltable before transformation) as defined in the present text, optionally mixed with one or more single-component filament(s) which are not heat-melted (and therefore in particular not heat-meltable) as defined in the present text.

[0180] For example, a single-component yarn is a polyurethane monofilament yarn, for example having a melting temperature ranging from about 80°C-120°C.

[0181] For example, a bi-component yarn comprises filaments each of which is of the core-mantle type, i.e. comprising a mantle comprising said first component having a melting temperature ranging from about 80°C-120°C and a core comprising said second component, in particular said second component having a melting or softening temperature higher than that of the first component, for example ranging from 150°C to 190°C.

[0182] Said thermofused (or thermofusible) yarn(s) at least partially single-component or two-component preferably has / have (each) a linear mass ranging from 300 dtex to 1200 dtex, in particular ranging from 400 dtex to 800 dtex, in particular ranging from 600 dtex to 700 dtex.

[0183] One or more thermofused wires at least partially means: one or more fully melted wire(s), and one or more partially melted wire(s).

[0184] Preferably, said at least partially thermofused yarn(s) is / are one or more single-component multifilament yarn(s).

[0185] Preferably, said single-component or two-component thermofusible multifilament yarn(s) each has / have an elongation at break greater than or equal to 80% or 100%, more preferably greater than or equal to 115%, preferably less than or equal to 200%. Son)

[0186] The monofilament yarn(s) and / or the spun fiber yarn(s) and / or the multifilament yarn(s) defined in the present text may be in one or more materials chosen from: - a list I comprising: polyesters, in particular chosen from polyethylene terephthalate (PET) and polybutylene terephthalate (PBT) or a combination thereof; polyamides, in particular chosen from PA 6, PA 6-6, and a combination thereof; polyolefins, in particular polyethylene, polypropylene, and a combination thereof; elastanes; and a combination thereof; and / or - a list II comprising: cotton, regenerated cellulose, for example viscose, linen, sisal, wool, jute, silk, hemp, and a combination of these; - a list III comprising: para-aramids, meta-aramids and carbon; and / or - a list IV including: recycled textiles, in particular recycled clothing, for example thermal protective clothing such as clothing for firefighters.

[0187] The material(s) listed in list I, and / or list II, and / or list III and / or list IV, can be recycled and / or biosourced at least in part. The monofilament yarn(s) preferably has / have a diameter greater than or equal to 0.01 mm and less than or equal to 5 mm, more preferably greater than or equal to 0.1 mm and less than or equal to 2 mm.

[0188] The multifilament yarn(s) and / or spun yarn(s) of fibers preferably have a linear mass greater than or equal to 10 dtex and less than or equal to 1000 dtex, more preferably greater than or equal to 30 dtex and less than or equal to 500 dtex.

[0189] Advantageously, the non-thermally melted thread(s) comprises / comprise, in particular is / are essentially made up of one or more polymer material(s) whose melting or degradation temperature is higher than the maximum temperature used in the manufacturing process of the footwear article.

[0190] The thread(s), in particular non-thermal melted, may also be one or more elastic thread(s).

[0191] Elastic thread is understood to mean any thread whose elongation at break is greater than or equal to 100% or 200%, in particular greater than or equal to 300%, in particular greater than or equal to 400%. The elastic thread preferably comprises an elastic core, in particular made of elastane, and optionally one or more covering threads. Elongation can be measured using ASTM D 1578-93 (2016). By definition, elastic thread is not heat-melted. Definitions

[0192] In the present text, the term "hot-melt" or "first hot-melt component" means any material or first component which is hot-melted or partially hot-melted during the manufacture of the footwear article according to the invention.

[0193] In the present text, the term non-hot-melt is understood to mean any material / component which is not hot-melted during the manufacture of the footwear article according to the invention. This material or component may be a thermoplastic material or not, but which has a melting or softening temperature or even a degradation temperature which is higher than the highest heating temperature used in the method of manufacturing the footwear article according to the invention.

[0194] In the present text, the term “at least partially thermofusible thread(s)” is understood to mean that said thread(s) is / are totally thermofusible or comprises / comprises only a portion of its structure which is thermofusible.

[0195] The present invention relates, according to a third aspect, to a method of manufacturing a sole assembly, in particular according to any one of the variant embodiments with reference to the first aspect of the invention, said method comprising: - a thermocompression step a) of one or more at least partly thermofusible sole material(s) with a molding assembly comprising a mold and an inflatable bladder, and said mold comprises a molding impression of a sole shell, in particular a wear sole shell, said molding impression comprising an inner bottom and first and second side walls between which said inner bottom extends, and said molding impression of the sole shell, in particular the wear sole shell, comprises a second main female, respectively male, interlocking portion having a determined shape formed, in particular undercut, in the first side wall of the molding impression, and possibly by at least a portion of said inner bottom; - a step b) of demolding the sole shell, in particular after deflation of said inflatable bladder; - a step of providing c) a sole element comprising a border, said border comprising a first male, respectively female, main interlocking portion having a determined shape configured to cooperate by interlocking with said a second female, respectively male, main interlocking portion of the molded sole shell so as to hold said in position sole element relative to the sole shell, in particular wear, said sole shell comprising an interior volume for receiving said sole element.

[0196] The at least partly heat-fusible sole material(s) may be as described above with reference to the first aspect of the invention.

[0197] For example, the sole material(s) comprise particles from waste which is at least partly thermofusible, for example said particles have been ground.

[0198] Said waste may be shoe soles and / or shoes and / or textiles.

[0199] In an alternative embodiment, the molding imprint of the sole shell, in particular the wear shell, comprises a rear side wall comprising an undercut upper edge.

[0200] In the present text, an undercut element is understood to mean that said element (for example the upper edge of the rear side wall of the molding cavity) is slightly oblique relative to the wall of the molding cavity and thus tends to prevent the extraction of the molded object.

[0201] A backsloping slope is a slope opposite to that of the undercut.

[0202] The present invention relates, according to a fourth aspect, to a method of manufacturing an article of footwear comprising the method of manufacturing a sole according to any one of the variant embodiments with reference to the third aspect of the invention, and comprising the thermocompression of at least one tubular textile element comprising at least one thermofusible textile portion, said thermocompression step is carried out: - during thermocompression step a), the mold also comprising an upper imprint, and the inflatable bladder being configured to compress the sole material(s) and at least said textile tubular element against the sole and upper imprints; or - in a thermocompression step additional to thermocompression step a) with a molding assembly comprising a mold comprising an upper imprint, a sole imprint, and an inflatable bladder for thermocompressing and bonding said textile tubular element to the sole shell, in particular the wear shell.

[0203] Preferably, the sole shell is secured to the textile tubular element by at least one thermofused portion, in particular at least one thermofused portion of the sole shell and / or at least one thermofused textile portion of said textile tubular element.

[0204] In an exemplary embodiment, said method comprises the thermocompression of an ETTE and an ETTI, the sole shell being arranged between the ETTE and the ETTI, in particular between the sole part of the ETTE, and the sole part of the ETTI.

[0205] In an exemplary embodiment, the sole portion of the ETTE and / or the sole portion of the ETTI, comprises / comprise (each) one or more heat-fusible wire(s) in part or in full.

[0206] In an exemplary embodiment, said method comprises thermocompression of an ETTE and an ETTI, the sole portion of the ETTE is disposed between the sole shell and the sole portion of the ETTI.

[0207] Advantageously, the sole shell is secured to the ETTI and / or to the ETTE by means of a thermofused portion of the sole shell and / or by means of at least one thermofused textile portion of the ETTI and / or at least one thermofused textile portion of the ETTE.

[0208] In a variant, the sole portion of the textile tubular element comprises at least 80% by mass of at least partially hot-melt thread(s).

[0209] In a variant, at least 80% by mass of the inner sole portion of the ETTI and / or at least 80% by mass of the outer sole portion of the ETTE each comprises / comprises at least in part of the thermofusible thread(s).

[0210] The embodiment variants according to a first aspect, a second aspect, a third aspect, and a fourth aspect can be combined with each other and independently of each other. Description of the drawings

[0211] The invention will be better understood on reading the following description of the embodiments of the invention given as non-limiting examples, with reference to the appended drawings, in which:

[0212] [Fig.l] [Fig.l] schematically represents in perspective, seen from the medial side, a first example of a sole shell, in particular a wear shell, according to the invention;

[0213] [Fig.2] [Fig.2] schematically represents in perspective the first example of a sole shell, in particular wear, of [Fig.l] seen from its lateral side;

[0214] [Fig.3] [Fig.3] schematically represents the sole shell shown in [Fig.l] according to section plane III-III;

[0215] [Fig.4] [Fig.4] schematically represents the sole shell of [Fig.l] according to section plane IV-IV;

[0216] [Fig.5] [Fig.5] schematically represents the sole shell of [Fig.l] according to section plane VV;

[0217] [Fig.6] [Fig.6] schematically represents, seen from the medial side, a first example of a sole element according to the invention;

[0218] [Fig.7] [Fig.7] schematically represents the sole element of the [Fig.6] view along section plane VII-VII;

[0219] [Fig.8] [Fig.8] schematically represents the sole element of [Fig.6] seen along section plane VIII-VIII;

[0220] [Fig.9] [Fig.9] schematically represents, seen from above, the first example of a sole element;

[0221] [Fig. 10] [Fig. 10] schematically represents, seen from below, the first example of a sole element;

[0222] [Fig. 11] [Fig. 11] schematically represents a second example of a sole shell seen from its lateral side, receiving in its internal receiving volume the first example of a sole element;

[0223] [Fig. 12] [Fig. 12] schematically represents, seen from the medial side, a first example of an article of footwear according to the invention;

[0224] [Fig. 13] [Fig. 13] schematically represents the external face of engagement with the ground of the footwear article shown in figures 12 and 13. Description of the embodiments

[0225] A first example of a sole shell 10 is shown in FIGS. 1 to 5; in this particular example, it is a wear sole shell.

[0226] This sole shell 10 is molded, in particular by thermocompression of one or more thermoplastic material(s) at least in part, and therefore at least in part thermofusible, using a mold assembly and an inflatable bladder, in particular as described above. Advantageously, the sole shell 10 is solid because the molten material is pressed against the walls of the molding assembly.

[0227] Advantageously, the sole shell 10 comprises an external face 11, and an internal face 12. The sole shell 10 also comprises an inner bottom 14, a first side wall 16 arranged on the medial side of the sole shell 10, also designated as medial wall 16, a second side wall 18 arranged on the lateral side of the sole shell 10, also designated as side wall 18, a front side wall 20 arranged on the front side of the sole shell 10, and a rear side wall 22 arranged on the rear side of the sole shell 10. Advantageously, the walls 16, 18, 20 and 22 form a rim extending substantially continuously from and along the periphery of the inner bottom 14, and project vertically above said inner bottom 14.

[0228] Advantageously, the inner bottom 14 extends between the first and second side walls 16, 18 and between the front 20 and rear 22 side walls.

[0229] Preferably, the sole shell 10 comprises a forefoot region 30, a midfoot region 32 and a rearfoot region 34.

[0230] Advantageously, the sole shell 10 comprises a second portion female main interlocking portion 40 formed in the first side wall 16 and by at least one medial portion 42 of said inner bottom 14 as well as a second female auxiliary interlocking portion 50 formed in the second side wall 18 and by at least one lateral portion 52 of said inner bottom 14.

[0231] For example, the second main female fitting portion 40 consists essentially of a cavity 44 comprising an upper wall 44a and a lower wall 44b forming an open clamp 46, in particular the upper wall 44a forms an upper stop for the sole element 100 described below.

[0232] Preferably, the lower wall 44b corresponds to the medial portion 42 of the inner bottom 14.

[0233] For example, the second female auxiliary fitting portion 50 consists essentially of a cavity 54 comprising an upper wall 54a and a lower wall 54b forming an open clamp 56, in particular the upper wall 54a forms an upper stop for the sole element 100 described below.

[0234] Preferably, the lower wall 54b corresponds to the lateral portion 52 of the inner bottom 14.

[0235] For example, the open clips 56 and 46 are arranged respectively on the lateral side and on the medial side of the sole shell 10, and are open to the interior volume 13 of the sole shell 10.

[0236] The second female auxiliary fitting portion 50 is here formed in the lateral wall 18 but could be formed indifferently in the medial wall 16.

[0237] The second female main interlocking portion 40 and / or the second female auxiliary interlocking portion 50 is / are (each) here substantially continuous, in particular the clamp 46 and / or the clamp 56 is / are substantially continuous, and extends partly in the forefoot region 30 and partly in the midfoot region 32. The clamp 46 and / or the clamp 56 could also be discontinuous, that is to say a clamp 46 or 56 can consist essentially of several sub-clamps substantially aligned so as to form a general clamp.

[0238] The sole shell 10 may comprise a recess 60 hollowed out in the medial wall 16 or first lateral wall 16, from its inner face. The sole shell 10 may comprise a recess 70 hollowed out in the lateral wall 18 or second lateral wall 18, from its inner face. These recesses 60, 70 make it possible to lighten the sole shell 10. Preferably, the second main 40 and auxiliary 50 interlocking portions are arranged in the forefoot region 30 and partly in the midfoot region, in this example the second main 40 and auxiliary 50 interlocking portions extend substantially continuously.

[0239] Preferably, the cavities 44,54 or the clamps 46,56 are elongated and extend horizontally. zonally from the midfoot region to the forefoot region of the sole shell 10. However, these cavities 44,54 could not be substantially continuous but be discontinuous, i.e. arranged in several horizontally arranged portions extending towards the front side of the sole shell 10 as discussed above. Preferably, the cavities 44,54 or clips 46,56 substantially follow the general shape of the first or second side wall 16,18 in which they are formed.

[0240] Preferably, the main cavities 44, 54 or clamps 46, 56 substantially follow the general shape of the first or second side wall 16, 18 in which they are formed.

[0241] Advantageously, the rear side wall 22 of the sole shell 10 comprises an upper edge 24 inclined towards the inside of the outsole shell 10. The rear side wall 22 is in particular curved towards the interior volume 13 of the sole shell 10.

[0242] Advantageously, the first side wall 16 comprises an upper edge 17 of which at least a portion is inclined towards the inside of the sole shell 10, and the second side wall 18 comprises an upper edge 19 of which at least a portion is inclined towards the inside of the sole shell 10.

[0243] Advantageously, the volume 13 of the sole shell 10 is configured to receive a first example of sole element 100 described with reference to FIGS. 6 to 10.

[0244] The sole element 100 comprises a border, in particular a medial border 110 because it is arranged on the medial side of the sole element 100, a lateral border 120 arranged on the lateral side of the sole element 100, a front border 130 arranged on the front side of the sole element 100, and a rear border 140 arranged on the rear side of the sole element 100.

[0245] The sole element 100 comprises an internal face 102 and an external face 104, in particular substantially opposite the internal face 102.

[0246] The medial border 110 extends between an upper edge 112 and a lower edge 114, and in particular between the internal 102 and external 104 faces.

[0247] The lateral edge 120 extends between an upper edge 122 and a lower edge 124, and in particular between the inner 102 and outer 104 faces. Advantageously, the sole element 100 comprises a forefoot region, a midfoot region and a rearfoot region.

[0248] Advantageously, the lower edge 114 extends outwardly from the medial border 110 relative to the upper edge 112 so that the upper edge 112 is set back relative to the lower edge 114. For example, the medial border 110 comprises a first male main interlocking portion 150 formed in the lower edge 114, in particular the first male main fitting portion has a general shape substantially beveled from the lower edge 114 of the medial border 110.

[0249] Advantageously, the lower edge 124 extends outwardly from the lateral border 120 relative to the upper edge 122 so that the upper edge 122 is set back relative to the lower edge 114. For example, the lateral border 120 comprises a first male auxiliary fitting portion 170 formed in the lower edge 124, in particular the first male auxiliary fitting portion 170 has a generally substantially beveled shape from the lower edge 124 of the lateral border 120.The first male main and auxiliary fitting portions 150 and 170 each have a determined shape, and the second female main and auxiliary fitting portions 40 and 50 also each have a determined shape and are configured to cooperate by fitting respectively with the first male main and auxiliary fitting portions 150 and 170, so as to hold the sole element 100 in position relative to the sole shell 10 when the sole element 100 is housed in the interior receiving volume 13.

[0250] Thus, the first male main portion 150 is pinched by the clamp 46, and the first male auxiliary portion 170 is pinched by the clamp 56.

[0251] Advantageously, the sole element 100 can thus be arranged in the interior receiving volume 13 of the sole shell 10, and is held in position relative to the sole shell 10 on the medial side and on the lateral side of the sole shell 10, and this in a removable manner.

[0252] Advantageously, the sole element 100 is a flexible and deformable sole element which facilitates its insertion and the cooperation between the male 150, 170 and female 40, 50 interlocking portions.

[0253] For example, the sole element 100 is made of a polyurethane or polyamide foam or else consists essentially of balls in at least one expanded polymer which are agglomerated together, in particular glued together. Said expanded polymer may be, for example, made of polyurethane or polyamide or even polyolefin, for example polypropylene or polyethylene, or even preferably in an elastomer of the latter.

[0254] Advantageously, the sole element 100 comprises a rear edge 144 projecting vertically above the internal face 102 of said sole element 100. The internal face 102 forms a support face for the foot.

[0255] Advantageously, the inclined upper edge 24 of the sole shell 10 forms an upper stop for the inclined upper edge 145 of the rear rim of the sole element 100 when the sole element 100 is housed in the interior volume of reception 13 of the sole shell 10. This arrangement promotes the maintenance in position of the sole element 100 in the sole shell 10 by ensuring an anchoring point complementary to those provided on the medial side and the lateral side of the sole shell 10.

[0256] For example, the sole shell 10 can be secured directly to a conventional upper of a footwear article (for example a flat knitted or woven upper without a sole part), for example by sewing, or even by gluing. Then, the sole element 100 is arranged in the interior receiving volume 13 of the sole shell 10 and held in position via the first and second interlocking portions 40, 50, 150, 170 and forms with the latter a sole assembly 90.

[0257] For example, the sole shell 10 may be secured to a textile tubular element, in particular a so-called internal element, such as a knitted sock, during a thermocompression step. The textile tubular element thus comprises a textile sole portion comprising one or more thermofusible thread(s) at least in part, in particular consisting essentially of thermofusible thread(s), and its textile sole portion is housed in the internal receiving volume 13 of the sole shell 10.During the thermocompression step, an inflatable bladder configured to have second main and auxiliary molding nesting portions is implemented under appropriate conditions (for example, the inflation pressure is 4 bars, and the heating temperature ranges from 110°C to 160°C) so that the sole portion of the textile tubular element conforms to the interior volume of the sole shell 10 while maintaining the determined functional shapes of the second main 40 and auxiliary 50 nesting portions of the sole shell 10 as described above. Furthermore, this thermocompression step makes it possible to secure a textile tubular element to the sole shell 10.

[0258] Advantageously, the textile tubular element comprises a textile part covering at least part of the foot, possibly comprising one or more heat-fusible thread(s) in part or completely, said covering part forms all or part of the upper of the final footwear article.

[0259] Preferably, in the preceding variants, the sole shell 10 is a wear sole shell whose external face 14 forms the external face of engagement with the ground of the footwear article.

[0260] It is also possible to secure one or more distinct and separate abrasion-resistant elements to the outer face of the sole shell 10 so that the outer face of the sole shell 10 does not come into direct contact with the ground.

[0261] It is possible in the previous variant to add a so-called external textile tubular element.

[0262] In one example, the sole shell 10 is arranged between the wholly or partly heat-meltable sole portion of an external textile tubular element and the wholly or partly heat-meltable sole portion of an internal textile tubular element whose sole portion is housed in the interior receiving volume 13 of the sole shell 10.

[0263] [Fig. 11] shows a second example of sole assembly 250 comprising a sole shell 200 and a sole element 300. The sole shell 200 may be similar to the sole shell 10, and the sole element 300 may be similar to the sole element 100.

[0264] The sole element 300 comprises a rear rim 310 projecting vertically above an inner support face of the foot 320 of said sole element 300, and the sole shell 200 comprises a rear side wall 220 comprising an upper edge 240 inclined towards the inside of the sole shell 200 and forming an upper stop for said rear rim 310 of the sole element 300.

[0265] In one example, the bearing face of the foot 320 of the sole element 300 is set back vertically from the upper edge 240 of the rear side wall 220 by a height RAr, for example of the order of 28 mm, and the inclined upper edge 315 of the rear rim 310 of the sole element 300 is flush with the upper edge 240.

[0266] In one example, the medial wall 216 or first lateral wall 216 has an upper edge 216a projecting vertically above the bearing face of the foot 320. Thus, the bearing face of the foot 320 is set back vertically from the upper edge 216a of the medial wall 216 of RM, the RM setback being for example of the order of 20 mm.

[0267] In one example, the support face of the foot 320 is set back vertically from the upper edge 230a of the front side wall 230 of RAV, the RAV setback being for example of the order of 5-6 mm.

[0268] In one example, the sole element 300 housed in the interior receiving volume of the sole shell 200 does not project vertically above one of the side walls (first and second side walls, front and rear side walls) of the sole shell 200. The sole shell 200 is therefore hollow, and comprises a volume large enough to receive and house the sole element 300, while arranging one or more side walls projecting vertically above the bearing face of the foot 320 of the sole element 300.

[0269] Figures 12 to 14 represent a first example of an article of footwear 400, in particular a sports shoe, comprising for example the sole shell 10 and the sole element 100 or the sole shell 200 and the sole element 300.

[0270] The footwear article 400 comprises an upper 500 and a sole 600 connected to the upper 500 by means of at least one thermofused portion.

[0271] In one example, the upper 500 comprises an outer textile foot covering portion 510 and an inner textile foot covering portion 520 partially overlaid with the outer textile foot covering portion 510.

[0272] In particular, the outer textile foot covering portion 510 extends between the medial and lateral sides of the upper 500 and between the front and rear sides of the upper 500. In this example, the outer textile covering portion 510 extends into the forefoot 430, midfoot 432 and rearfoot 433 regions but does not include an instep area.

[0273] In this example, the external covering textile portion 510 combines transparent monofilament yarns, for example polyethylene terephthalate, with thermofused yarns so as to form thermofused textile portions which are in particular transparent or translucent.

[0274] In this example, the internal textile foot covering portion 520 also extends between the medial and lateral sides and between the front and rear sides of the upper 500. In this example, the internal textile foot covering portion 520 comprises an instep area, and in particular a region surrounding all or part of the foot insertion opening covering more of the lower leg than the region surrounding all or part of the foot insertion opening of the external textile foot covering portion 510.

[0275] The sole assembly 600 comprises a sole shell 650 similar to the sole shell 10 or 200, as well as a sole element (not visible in FIGS. 12 to 14), similar to the sole assembly element 100 or 300, arranged in the interior receiving volume of the sole shell 650 and held in position in a removable manner with the latter.

[0276] The sole assembly 600 also comprises an external textile sole part which is wholly or partly thermofused, in textile connection with the external textile foot covering part 510, as well as an internal textile sole part which is wholly or partly thermofused, in textile connection with the internal textile foot covering part 520.

[0277] Advantageously, the external and internal textile covering parts of the foot 510 and 520 are glued together by means of thermofused textile portions, in particular those which comprise the external textile covering part 510 and possibly the internal textile covering part 520.

[0278] For example, the region surrounding all or part of the foot insertion opening of the internal textile foot covering part 520 comprises one or more elastic thread(s), in particular based on elastane.

[0279] The footwear article 400 is preferably manufactured by a thermocompression method comprising a preliminary step of manufacturing the outsole shell 650 by thermocompression, and a step of assembling the sole shell 650 with internal and external textile tubular elements at least partially superimposed.

[0280] In one example, the inner textile tubular element preferably comprises an inner textile foot covering portion, and an inner textile sole portion in textile connection with said inner textile foot covering portion and consisting essentially of thermofusible thread(s) optionally mixed with one or more non-thermofusible thread(s). Preferably, the inner textile tubular element is a sock.

[0281] Similarly, the outer textile tubular element preferably comprises an outer textile foot covering portion, and an outer textile sole portion in textile connection with said inner textile foot covering portion and consisting essentially of thermofusible thread(s) optionally mixed with one or more non-thermofusible thread(s). Preferably, the outer textile tubular element is a sock.

[0282] In this example, the outer textile tubular element and the inner textile tubular element are separate knitted pieces.

[0283] During the preliminary thermocompression step a) of the sole shell 650, an assembly comprising one or more at least partly thermofusible sole material(s), for example thermofusible particles (for example comprising polyurethane) mixed with non-thermofusible particles (for example crushed waste), is thermocompressed with a molding assembly comprising a mold and an inflatable bladder. The mold comprises a molding impression of the outsole shell 650, said molding impression comprising an inner bottom and first and second side walls between which said inner bottom extends, and said molding impression of the outsole shell comprises a second female, respectively male, main interlocking portion having a determined shape formed in an undercut, in the first side wall of the molding impression, and by at least a portion of said inner bottom.In particular, the molding impression comprises molding impressions of the first and second main and auxiliary nesting portions as described above. During the thermocompression step, the assembly comprising the particles is heated to a temperature allowing the melting of the thermofusible particles, and an inflation pressure of the order of 3 bars to 5 bars is applied to the inflatable bladder under appropriate conditions so that the thermofused mixture comprising non-thermofusible particles is compressed against the molding impression.

[0284] The heating temperature is determined so as to melt the targeted hot melt particles.

[0285] The method then comprises a step of demolding the outsole shell. after deflation of the bladder, in particular before the sole shell 650 has cooled, that is to say before it reaches room temperature so as to facilitate demolding given the numerous undercut shapes.

[0286] In an additional thermocompression step with a molding assembly comprising a mold comprising an upper imprint, a sole imprint, similar to the molding imprint implemented in the preliminary thermocompression step a), and an inflatable bladder, the partly superimposed inner and outer textile tubular elements associated with the sole shell are thermocompressed under conditions suitable for obtaining the joining of the sole shell with the inner and outer tubular elements, melting all or part of the sole parts of the textile tubular elements, and melting at least partially any textile portions that comprise the outer textile covering part of the foot and / or that comprise the inner textile covering part of the foot.

[0287] In the additional thermocompression step, the sole shell may be disposed between the inner and outer textile sole portions, or the outer sole portion may be disposed between the inner sole portion and the sole shell.

[0288] In any thermocompression step, preliminary or additional, an inflatable bladder configured to have first main and auxiliary molding nesting portions is implemented.

[0289] Finally, the method for manufacturing the footwear article 400 comprises a step c) of providing a sole element similar to the sole element 100 or 300. The sole element is arranged in the interior receiving volume of the sole shell 650 and removably secured to the sole shell 650 by making the first male interlocking portions cooperate with the second female interlocking portions.

[0290] The internal textile part of the sole and / or the external textile part of the sole, in whole or in part thermofused, is / are very thin so that the second female, respectively male, interlocking portions perfectly match the first female, respectively male interlocking portions, so that their constructions are preserved.

[0291] The sole shell according to the invention is hollow and comprises an empty interior receiving volume filled in part by the sole element providing cushioning and / or recovery functions and forming a sole that is at least partly recycled and lightweight. The footwear article has an original construction, the sole shell being held in connection with the upper by means of thermofused textile portions. It is thus advantageously possible to manufacture a footwear article, in particular a lightweight sports shoe, the sole of which is also manufactured by thermocompression while associating it with a flexible and deformable sole element.

Claims

Claims

1. Sole assembly (90,600), in particular for a sports shoe (400) characterized in that it comprises a molded sole shell (10,200,650) comprising an external face (11), an inner bottom (14) and first (16,216) and second (18) side walls between which said inner bottom (14) extends, in that said sole assembly (90,600) comprises a sole element (100,300) comprising a border (110,120), said border (110,120) comprising a first main male (150), respectively female, interlocking portion having a determined shape, and in that said sole shell (10,200,650) comprises an internal receiving volume (13) for said sole element (100,300) and a second main female (40), respectively male, interlocking portion having a determined shape configured to cooperate by fitting with said first main fitting portion (150) so as to hold said sole element (100,300) relative to the sole shell (100,200,650), said second main interlocking portion (40) being formed in the first side wall (16,216), and optionally by at least one portion (42,52) of said inner bottom (14), and in that the sole shell comprises one or more sole material(s) at least partly thermo-melted and compressed.,

2. Sole assembly (90,600) according to claim 1, characterized in that the sole element (100,300) is a sole element (100,300) flexible and deformable compared to the sole shell (10,200,650) so as to be able to be deformed during its positioning in an interior receiving volume (13) of the sole shell (10,200,650).

3. Sole assembly (90,600) according to either of claims 1 and 2, characterized in that the sole element (100,300) is designed to be secured to the sole shell (10,200,650) in a removable manner.

4. Sole assembly (90,600) according to any one of claims 1 to 3, characterized in that said first main fitting portion (150) is a first male main fitting portion, and said second main fitting portion (40) is a second female main fitting portion consisting essentially of a cavity (44) comprising an upper wall (44a) and a lower wall (44b) together forming an open clamp (46), in particular the upper wall (44a) forms an upper stop for the sole element (100,300).

5. Sole assembly (90,600) according to any one of claims 1 to 4, characterized in that the edge (110,120) of the sole element (100,300) extends between an upper edge (112,122) and a lower edge (114,124), and in that the lower edge (114,124) advances towards the outside of the edge (110,120) relative to the upper edge (112,122) so that the upper edge (112,122) is set back relative to the lower edge (114,124).

6. Sole assembly (90,600) according to any one of claims 1 to 5, characterized in that the first main male interlocking portion (150) of the sole element (100,300) has a generally beveled shape from the lower edge (114,124) of the border (110,120).

7. Sole assembly (90,600) according to any one of claims 1 to 6, characterized in that the sole shell (10,200,650) comprises a rearfoot region, a midfoot region and a forefoot region, and in that said second main interlocking portion (40) is arranged in the forefoot region, and possibly partly in the midfoot region.

8. Sole assembly (90,600) according to any one of claims 1 to 7, characterized in that the sole element (100,300) comprises a rear edge (144,310) projecting vertically above an inner bearing face (102,320) of the foot of said sole element (100,300), and in that the sole shell (10,200,650) comprises a rear side wall (22,220) comprising an upper edge (24,240) inclined towards the inside of the sole shell (10,200,650) and forming an upper stop for said rear edge (144,310) of the sole element (100,300).

9. Sole assembly (90,600) according to claim 8, characterized in that the sole element (90,600) comprises an internal foot support face (102,320), and said internal foot support face (102,320) is set back vertically from the inclined upper edge (24,240) of the rear side wall (22,220) of the sole shell (10,200,650), in particular by a setback RAr greater than or equal to 10 mm.

10. Sole assembly (90,600) according to any one of claims 1 to 9, characterized in that the first side wall (16,216) comprises an upper edge (216a) of which at least a portion is inclined inwards. the sole shell (10,200,650).

11. Sole assembly (90,600) according to any one of claims 1 to 10, characterized in that the sole element (100,300) comprises agglomerated particles which are each in at least one expanded polymer.

12. Footwear article (400), in particular a sports shoe (400), characterized in that it comprises a sole assembly (90,600) according to any one of claims 1 to 11.

13. Footwear article (400) according to claim 12, characterized in that it comprises at least one textile tubular element, optionally comprising at least one at least partially heat-melted textile portion, and in that the sole shell (10,200,650) and said at least one textile tubular element are bonded by at least one heat-melted portion, in particular at least one heat-melted portion of the sole shell (10,200,650) and / or at least one heat-melted textile portion of said textile tubular element.

14. Method for manufacturing a sole assembly (90,600), in particular according to any one of claims 1 to 11, characterized in that it comprises: - a step of thermocompression a) of one or more at least partly thermofusible sole assembly material(s) with a molding assembly comprising a mold and an inflatable bladder, and in that said mold comprises a molding impression of a sole shell, said molding impression comprising an inner bottom and first and second molding side walls between which said inner bottom extends, and in that said molding impression of the sole shell comprises a second main female, respectively male, molding interlocking portion having a determined shape formed, in particular undercut, in the first side wall of the molding impression, and possibly by at least one molding portion of said inner bottom;- a step b) of demolding the sole shell (10,200,650), in particular the outsole shell, in particular after deflation of said inflatable bladder; - a step c) of providing a sole element (100,300) comprising a border (110,120), said border (110,120) comprising a first male (150), respectively female, main interlocking portion having a determined shape configured to cooperate by interlocking with a second interlocking portion; main female molded part (40), respectively male, of the sole shell (10,200,650) so as to hold said sole element (100,300) in position relative to the sole shell (10,200,650), said sole shell (10,200,650) comprising an interior receiving volume (13) of said sole element (100,300).

15. Manufacturing method according to claim 14, characterized in that the molding imprint of the sole shell, in particular the wear shell, comprises a rear side wall comprising an undercut upper edge.

16. Method for manufacturing an article of footwear (400), in particular according to any one of claims 12 and 13, characterized in that it comprises the method for manufacturing a sole assembly (90, 600) according to either of claims 14 and 15, and in that it comprises the thermocompression of at least one tubular textile element comprising at least one thermofusible textile portion, said thermocompression step is carried out: - during thermocompression step a), the mold also comprising an upper imprint, and the inflatable bladder being configured to compress the sole material(s) and at least said textile tubular element against the sole shell and upper imprints in an inflated state; or - in a thermocompression step, additional to thermocompression step a), with a molding assembly comprising a mold comprising a rod imprint, a sole shell imprint, and an inflatable bladder for thermocompressing and bonding said textile tubular element to the sole shell (10,200,650).

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