Manufacturing method for shoes, system for implementing the method, and shoes

Abstract

To provide a manufacturing method for shoes, especially sport shoes.SOLUTION: The method comprises the steps of providing a plurality of individual particles for a sole element in a mold, providing an upper in the mold, and fusing the plurality of individual particles and the upper together using an electromagnetic field to bond the plurality of individual particles to each other and to the upper.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a method for manufacturing shoes, particularly sports shoes, a system for implementing this method, and shoes.

Background Art

[0002] Conventional methods for manufacturing shoes generally employ an assembly-based approach (i.e., stock fitting of parts), requiring various individual parts such as pre-manufactured soles and uppers to be processed at different processing stations, which are then further joined together at another location. Such manufacturing methods are typically very complex and require a large amount of labor, and also require the chemical use of hazardous substances to bond the stock-fitted parts together. To overcome these disadvantages, the applicant has disclosed in German Patent Application Publication No. 102016208998 (A1), German Patent Application Publication No. 102016209044 (A1), and German Patent Application Publication No. 102016209045 (A1) a sole mold, method, and system for manufacturing a plurality of finished shoes. However, there is still room for improvement in these methods.

[0003] The use of particulate foam materials, i.e., materials made from individual particles of foamed plastic material (also referred to as foam beads and bead foams), has also been incorporated into the manufacture of cushioning elements for the soles of sports shoes. Specifically, the particles are fused on the particle surface by exposing them to pressurized steam in a mold (as is known in the art).

[0004] ​​​​​​​​​​​​Expanded Thermoplastic Polyurethane (eTPU) (often called "steam chest molding") The use of particles has been explored for producing shoe soles.

[0005] However, the traditional mold for steam-chest molding of shoe soles is subject to the specific requirements of the shoe production process. For example, the steel soles of shoes made from particles using conventional molds are not optimally adapted to In the arm chest molding process, since conventional molds are generally large in mass, a large amount of heat is required to heat the mold. Moreover, such a cooling process is slow and therefore Leading to long cycle times. Finally, to steam-chest mold the soles from the particles, In order to achieve homogeneous interconnection of the particles, it is necessary to uniformly supply pressurized steam to the particles. Conventional types, due to their construction, are not optimally suited to such uniform media delivery. .

[0006] Energy carriers other than pressurized steam are also considered. In particular, The method was disclosed by the applicant in DE 10 2016 223 980 A1. It is described, in which a first material including particles of a foaming material is filled into a mold, and the filling of the mold The particles are preheated by supplying energy in the form of at least one electromagnetic field during the heating. I feel heated.

[0007] A common disadvantage of these disclosed methods is that they still do not fully take into account the overall production of the finished shoe. The manufacturing of the finished shoe is not done in a way that requires specific material properties. Manufacturing modern high-performance footwear such as sports shoes remains highly complex and multifaceted. It requires a lot of labor.

[0008] Accordingly, an object of the present invention is to overcome the above-mentioned disadvantages of the prior art and provide an improved method for manufacturing shoes, in which the manufacturing labor is optimized and the method is moreover, as energy-efficient as possible, while dispensing with environmentally harmful or dangerous substances. SUMMARY OF THE INVENTION

[0009] This object is achieved by the teaching of the independent claims. Advantageous embodiments are included in the dependent claims.

[0010] According to one aspect of the invention, a method for manufacturing shoes, in particular sports shoes, comprises providing a plurality of individual particles for a sole element in a mold, providing an upper in the mold, and fusing the plurality of individual particles with each other and with the upper using an electromagnetic field. By fusing the plurality of individual particles and the upper with electromagnetic energy from an electromagnetic field, the invention provides an improved method for the overall manufacture of shoes. The individual foam-like particles may be fused together to form a sole element and joined to each other, and the upper may be fused in a durable and permanent form and joined (or connected) to this manufactured sole element. In other words, the two main parts of the shoe, namely the sole element and the upper, may be connected together in the same mold. For example, the softened (or partially melted) surface area of the particles appearing on the top surface of the sole element may be used as a joining / connecting agent to connect the upper to the top of the sole element. In this way, the amount of energy, the number of process steps, the

[0011] (or partially melted) surface area of the particles appearing on the top surface of the sole element may be used as a joining / connecting agent to connect the upper to the top of the sole element. In this way, the amount of energy, the number of process steps, the The number of additional parts or intermediate parts, the processing time, and one or more of the assembly steps (and the associated labor hours) can be reduced. In the context of this application, fusing and joining may be performed at different processing times and / or temperatures. For example, a plurality of individual particles may be fused at a lower temperature than the joining of a plurality of individual particles to the upper, or may be performed simultaneously because the local energy amount of the electromagnetic field is different and / or the mold temperature is different. It should be noted that when a connection layer such as an adhesive layer is used, different processing times for fusing and joining may also be considered.

[0012] Furthermore, using electromagnetic energy from an electromagnetic field for the manufacture of the sole element and the entire shoe shortens the molding time, for example, by avoiding excessive energy absorption by the mold, saves energy, and also promotes the cooling and stabilization of the molded sole element because, for example, the energy supply is not linked to any kind of material transfer such as the injection of an energy stream. In addition, the electromagnetic field may be selected such that the electromagnetic field penetrates the mold filled with a plurality of individual particles and the upper for the sole element, and improved fusing / molding and joining can be achieved throughout the entire shoe and at any depth of the shoe. In this way, the shoe can be manufactured in one process step by joining the compact material of the upper to the foam-like material of the sole element, so that the entire manufacture of the shoe can be significantly simplified.

[0013] The individual particles of this application are "foamed material", "foamed particles", "foamed pellets", "foamed beads", "foam particles", "foam-like particles", "foam-like pellets" or "fo ​​​​​Sometimes called "pelletized beads," thus, the manufactured sole element may be referred to as a "particle foam," "bead foam," "pellet foam" part or element. Other terms by which such foamed particles may be called in the field of particle foams may also be used. Sometimes used.

[0014] The upper material and the upper itself of the present application may be made using various techniques known in the art. In one embodiment, the upper material may be a fabric material upper. Generally, the fabric of the present application may be a flexible material produced by making the yarns of the material. The yarns may be single-fiber yarns or multi-fiber yarns, and the multi-fiber yarns are bundles of fibers or yarns intertwined produced by spinning raw fibers (either of natural or synthetic origin) into long twisted lengths, and the fabric may be formed as an upper part by weaving, knitting, crocheting, knotting, tatting, felting, joining, or by twisting such yarns together. Further, the term "cloth" may sometimes be used as a synonym for the fabric of the present application. Also, it is conceivable that the upper may be made of leather, particularly synthetic leather material using thermoplastic polyurethane, or a composite material of one of the above-described fabrics and a non-fabric material.

[0015] In the context of the present application, it should be noted that the term "bonding" is used synonymously with the terms "attaching," "firmly connecting," "fixing," "interconnecting," or "connecting" in cases where the sole element is manufactured from individual particles and bonded to the fabric upper in a durable, strong, and permanent form.

[0016] The method may further include the step of providing a support element for the sole element within the mold and / or the step of providing an outsole element for the sole element within the mold, and the fusing step described above may further include the step of fusing the support element and the outsole element using an electromagnetic field to join the plurality of individual particles to each other, to the support element, to the outsole element, and to the upper. Also, it is conceivable that at least two of the plurality of individual particles, the support element, the outsole element, or the upper are fused using an electromagnetic field and joined to each other. The support element may be at least one of a reinforcing element, a knitted fabric, a woven fabric, a fabric sheet such as a non-woven fabric, a molded part, a heel counter, a shoe sole plate, an inner support element, a lateral support element, a toe support element, a bonding layer, a composite element, for example, an element made of leather or synthetic leather, and other elements generally used in the prior art. It should be noted that in the context of the present application, the term "element" may be used synonymously with the term "component". By providing one or both of these two main elements of the sole element, i.e., the support element and the outsole element, it may not be necessary to have pre- or post-production steps related to one or both of these two elements, thus shortening the processing time of the sole element and further improving the overall manufacture of the shoe. Also, there is no need for multiple automated production stations for the two elements, which reduces the required floor space of the manufacturing system within the facility. Furthermore, these described embodiments may provide special sole characteristics such as selective support for preventing pronation or supination, for example, thus providing the stated improved

[0017] It can help to provide improved shoes with material properties, especially sports shoes.

[0018] One or more of the above-described fusing steps may be performed in a single step. This simplifies and optimizes the overall manufacture of the shoe by a single process step in the mold, strengthening the above-described advantages of the claimed method. The expression “one or more of the above-described fusing steps” as used herein refers to the step of fusing a plurality of individual particles to each other and to the upper using an electromagnetic field, the step of fusing a plurality of individual particles, the support element, the outsole element, and the upper to each other by fusing the support element and the outsole element using an electromagnetic field, and the step of fusing at least two of the plurality of individual particles, the support element, the outsole element, or the upper using an electromagnetic field to join them to each other. It should be noted that for joining to each other and to the upper, the step of fusing the support element and the outsole element using an electromagnetic field, and the step of fusing at least two of the plurality of individual particles, the support element, the outsole element, or the upper using an electromagnetic field to join them to each other. a plurality of individual particles, the support element, the outsole element, or the upper are fused using an electromagnetic field and joined to each other. It should be noted that

[0019] The electromagnetic field may be in the radio frequency range of 30 kHz to 300 MHz, preferably in the range of 1 MHz to 200 MHz, more preferably in the range of 1 MHz to 50 MHz, most preferably in the range of 25 to 30 MHz, or in the microwave range of 300 MHz to 300 GHz. In a preferred embodiment, the electromagnetic field may have a frequency in the radio frequency range around 27.12 MHz. It is also contemplated that one or more radio frequencies or radio frequency ranges may be used.

[0020] Also, radio frequency generators are commercially available and can be easily implemented in a system for manufacturing shoes. Further, the radio frequency radiation may be focused on each part of the system. It may be focused on each part of the system. Ku, its intensity and frequency may be adapted according to requirements.

[0021] Microwave generators are commercially available and can be implemented in a system for manufacturing shoes for using the method of the present invention with relatively little effort. In addition, in order to improve energy efficiency, microwave radiation can basically be focused on a cavity of the type where a plurality of individual particles and a fabric upper are provided. Furthermore, the intensity and frequency of microwave radiation can be easily varied and adapted according to the respective requirements of shoe parts such as the sole element and the fabric upper. It is also possible to supply electromagnetic fields, particularly electromagnetic radiation, in a frequency range different from the above-mentioned frequency range. One or more of the above-described fusing steps may be performed without an adhesive. This can help reduce the amount of toxic or dangerous substances such as glue during the manufacture of the sole and the whole shoe, and also avoid causing harm to the manufacturing facility and its environment. One or more of the above-described fusing steps may be performed without using infrared radiation. This can help avoid unwanted destruction of each element of the individual particles, the support element or the outsole element, and of course, the sole elements such as the upper. It is conceivable to further harden the shoe by supplying thermal energy from infrared radiation, which should not be excluded from the claimed invention. The above-described fusing steps may also include gluing, welding, high-frequency welding, ultrasonic welding, laser welding, pressing, sewing, screwing, riveting, melting

[0022]

[0023]

[0024] ​​​​​​​​​​​​​It may be performed without involving at least one of other joining techniques such as crimping, sealing, application of thermo-pressure treatment, exposure to steam treatment. It may be performed without involving at least one of them.

[0025] The method may further include the step of locally adjusting the electromagnetic field intensity distribution of the electromagnetic field in the mold. This enables a constant energy application to elements in a mold having varying thicknesses, such as a sole element (or midsole) or the upper of a shoe, or to the varying thickness of the mold itself. For example, a high-density material in a shoe element heats up faster for fusing, and thus, the electromagnetic field intensity distribution of the electromagnetic field may be locally adjusted so that more energy can be absorbed by those elements to balance the energy absorption of the low-density areas. In this way, it may affect the properties of individual shoe elements in a simpler form than applying varying electromagnetic fields having, for example, varying different frequencies. The energy supplied using the electromagnetic field may be varied over time. For example, the energy supplied using at least one electromagnetic field may be gradually increased over time. In this way, the time-varying magnetic flux from the electromagnetic induction of the varying electromagnetic field can create eddy currents in the conductive materials of the particles and the upper, which heats the materials and thus contributes to the fusion of the surface of the particles and the upper. More energy by the electromagnetic field may be supplied to a plurality of individual particles and / or the upper in a first partial region of the mold than in a second partial region of the mold. This may apply to both preheating of the particles and / or the upper in the mold and the fusion of the particles and the upper. In this way, it may affect the properties of individual shoe elements in a simpler form than applying varying electromagnetic fields having, for example, varying different frequencies.

[0026] The energy supplied using the electromagnetic field may be varied over time. For example, the energy supplied using at least one electromagnetic field may be gradually increased over time. In this way, the time-varying magnetic flux from the electromagnetic induction of the varying electromagnetic field can create eddy currents in the conductive materials of the particles and the upper, which heats the materials and thus contributes to the fusion of the surface of the particles and the upper. In this way, the time-varying magnetic flux from the electromagnetic induction of the varying electromagnetic field can create eddy currents in the conductive materials of the particles and the upper, which heats the materials and thus contributes to the fusion of the surface of the particles and the upper. In this way, the time-varying magnetic flux from the electromagnetic induction of the varying electromagnetic field can create eddy currents in the conductive materials of the particles and the upper, which heats the materials and thus contributes to the fusion of the surface of the particles and the upper. In this way, the time-varying magnetic flux from the electromagnetic induction of the varying electromagnetic field can create eddy currents in the conductive materials of the particles and the upper, which heats the materials and thus contributes to the fusion of the surface of the particles and the upper.

[0027] More energy by the electromagnetic field may be supplied to a plurality of individual particles and / or the upper in a first partial region of the mold than in a second partial region of the mold. This may apply to both preheating of the particles and / or the upper in the mold and the fusion of the particles and the upper. More energy by the electromagnetic field may be supplied to a plurality of individual particles and / or the upper in a first partial region of the mold than in a second partial region of the mold. This may apply to both preheating of the particles and / or the upper in the mold and the fusion of the particles and the upper. This may apply to both preheating of the particles and / or the upper in the mold and the fusion of the particles and the upper. In this way, a plurality of different sub-regions may be created within the shoe, each of which differs in its own thickness, hardness, breathability, flexibility, elasticity, feel, appearance, or other characteristics that facilitate manufacturing.

[0028] One or more of the above-described fusing steps may further include fusing the surfaces of a plurality of individual particles and / or the surface of the upper. This can enable the production of sole elements and / or the entire shoe with various thicknesses and complex shapes because supplying energy is not associated with any kind of material transfer of the sole element and / or the upper, such as the introduction of a binder or vapor. As described above, the electromagnetic field is selected such that the electromagnetic field penetrates basically homogeneously into the individual particles for the sole element and the mold filled with the upper, and supplies basically a certain amount of energy to all the particles and the upper, thereby enabling a homogeneous and constant fusion of the surfaces of the particles and / or the upper to be achieved throughout the entire shoe and at any depth of the individual shoe parts. Alternatively, the electromagnetic field may be selected such that the supply of energy to the particles and the upper arranged in the mold varies locally as described above. In this way, the nature and degree of fusion of the surfaces of the particles and / or the upper may be locally influenced. Specifically, the fusion of the particle surfaces inside the sole element may be controlled independently of the fusion of the particle surfaces on the surface of the sole element. Summarizing the above, these embodiments may help to provide a better bond between the sole element and the fabric upper.

[0029] ​​​​​​​​​​​​​​The method may further include, before one or more of the above-described fusing steps, placing a connecting layer between a plurality of individual particles for the sole element and the fabric upper. Such an embodiment may provide a certain protective layer for the particles in order to avoid the uneven surface of the manufactured sole element, which uneven surface may penetrate into the fabric upper and cause an uncomfortable wearing feeling for the shoe wearer. Protection of the fabric upper by such a connecting layer is also conceivable. One or more of the above-described fusing steps may further include forming the sole element from a plurality of individual particles. Forming the sole element from a plurality of individual particles is a particularly efficient method for manufacturing shoes. In addition, forming the particles as a certain particle form part as the sole element does not require toxic or dangerous substances. The plurality of individual particles and / or the upper may be preheated in a mold before one or more of the above-described fusing steps. The preheating may be realized by an electromagnetic field. The type / property of the electromagnetic field used for preheating may be different from the type / property of the electromagnetic field used for fusing the particles and the upper. However, it is also possible that the type / property of the electromagnetic field used for preheating is the same as the type / property of the electromagnetic field used for fusing the particles and the upper. By preheating the particles and / or the upper, the amount of energy that has to be supplied to the particles and / or the upper in the mold can be reduced, which further shortens the processing time and, for example, avoids excessive energy absorption by the mold.

[0030]

[0031] ​​​​​​​​​​​​​​It can help reduce energy consumption and, as described above, promote the cooling and stabilization of the manufactured shoes. Preheating of the particles and / or the upper can also, for example, enable a more finely tuned control of the manufacturing method, since different subsets of the particles used in the manufacture of the sole element can be preheated to different degrees. It can also contribute to enabling a more finely tuned control of the manufacturing method, since different subsets of the particles used in the manufacture of the sole element can be preheated to different degrees. For example, different subsets of the particles used in the manufacture of the sole element can be preheated to different degrees. This can generally contribute to enabling a more finely tuned control of the manufacturing method.

[0032] The molds used in the methods described above may include one or more of a polymer material, preferably a thermoplastic material, more preferably polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyoxymethylene (POM), polyamideimide (PAI), polycarbonate (PC), polyketone (PK), polyetheretherketone (PEEK), polyvinylidene fluoride or polyvinylidene difluoride (PVDF), thermoplastic polyurethane (TPU), or polyethylene (PE). Further, the polymer material of the mold may consist of a foam-like material. These materials have been found to be convenient and can therefore be used in the context of the present invention. For example, POM has a dielectric loss factor D of approximately 0.008 with respect to radio frequency radiation. Thus, this material is basically transparent to radio frequency radiation as it absorbs a portion of the electromagnetic field, and due to its relatively low loss factor, it can be formed to a certain thickness. The polymer material may be adapted to increase the dielectric constant of the mold compared to the shoe or its elements being manufactured. The polymer material may be adapted to increase the dielectric loss factor of the mold. It has been found to be convenient and can therefore be used in the context of the present invention. For example, POM has a dielectric loss factor D of approximately 0.008 with respect to radio frequency radiation. Thus, this material is basically transparent to radio frequency radiation as it absorbs a portion of the electromagnetic field, and due to its relatively low loss factor, it can be formed to a certain thickness. The polymer material may be adapted to increase the dielectric constant of the mold compared to the shoe or its elements being manufactured. The polymer material may be adapted to increase the dielectric loss factor of the mold.

[0033] The plurality of individual particles used in the methods described above are foam-like materials, preferably foamed materials. ​​Based on one or more of thermoplastic polyurethane (eTPU), foamed polyamide (ePA), foamed polyether block amide (ePEBA), polylactide (PLA), polyether block amide (P EBA), foamed polyethylene terephthalate (ePET), foamed polybutylene terephthalate (ePBT), foamed thermoplastic polyester ether elastomer (eTPEE), foamed polystyrene (ePS), and may include. For example, for use in the manufacture of shoe soles Particles of eTPU, ePEBA and / or ePA have been found to be convenient and may therefore be used in the context of the present invention. Using a foamed material on both the particles and the surface of the mold leads to a similar loss rate, thereby providing substantially uniform heating of both the particles and the mold, and the mold may be prepared to obtain better fusion of the shoe sole elements.

[0034] The upper used in the method described above may be a fabric upper, and may include one or more of a knitted structure, a woven structure, a non-woven structure, randomly deposited fibers, a multi-directional layered material, a mesh structure. Some of these fabric structures can be beneficially used in parts of the upper that require good breathability or respiratory properties. Furthermore, the knitted structure can provide much higher stretchability due to the intertwined mesh fabric structure. Furthermore, the non-woven structure can provide a suitable feel on the inner surface of the upper and can provide appropriate stability at the desired parts of the fabric upper.

[0035] For reinforcement and reduction of elongation, fusible yarns added with a thermoplastic material may be used in the fabric upper which fixes the knitted structure after fusion. Heat A plastic thread, a non-plastic thread surrounded by a thermoplastic thread, or a pure fused thread of a thermoplastic material can be considered for use. Such a fused thread may be knitted into the knitting structure of the fabric upper .

[0036] The strength of the joint in the method described above may be higher than the strength of the weakest post-fusion material . In other words, the weakest post-fusion material is subject to the strength of the joint between the plurality of individual particles and the upper . In the context of the present application, the term "strength" is a mechanical property that enables a material to resist a deformation load , which means that the strength of a material is the ability of the material to withstand breakage under the action of an external load . The higher the strength of a material, the more it can withstand a large load . Furthermore, the expression "weakest post-fusion" corresponds to a certain degree of fusibility between different materials .

[0037] The present invention also relates to a system comprising means for implementing the method described above so that a shoe is manufactured in one step by joining a compact material of the upper to a particulate material of the sole element .

[0038] The present invention also relates to a shoe, in particular a sports shoe, manufactured by one of the methods described above . Furthermore, this shoe may not contain an adhesive for the reasons explained above

[0039] The present invention includes the following embodiments 1. A method for manufacturing a shoe, in particular a sports shoe, comprising a. providing a plurality of individual particles for the sole element in a mold b. providing an upper in the mold c. joining the plurality of individual particles to each other and to the upper to join the plurality of individual particles ​A method including the step of fusing the upper using an electromagnetic field. The step of providing a support element for the sole element in a 2.d. mold, The step of providing an outsole element for the sole element in an e. mold, Further including one or more of f. Step c is the step of fusing the support element and the outsole element using an electromagnetic field to join a plurality of individual particles to each other, the support element, the outsole element, and the upper. The method according to the above embodiment, further including 3. A method according to one of the above embodiments, wherein step c is performed in a single step. 4. An electromagnetic field in a radio frequency range of 30 kHz to 300 MHz, preferably in a range of 1 MHz to 20 0 MHz, more preferably in a range of 1 MHz to 50 MHz, most preferably in a range of 25 to 3 0 MHz, or in a microwave range of 300 MHz to 300 GHz, one method according to the above embodiment 22. 5. A method according to one of the above embodiments, wherein step c is performed without an adhesive. 6. A method according to one of the above embodiments, further including the step of locally adjusting the electromagnetic field intensity distribution of the electromagnetic field in the mold. 28. 7. A method according to one of the above embodiments, wherein the energy supplied using the electromagnetic field is changed over time. 32. 8. A method according to one of the above embodiments, wherein more energy by the electromagnetic field is supplied to a plurality of individual particles and / or the upper in a first partial region of the mold than in a second partial region of the mold. 36. 38. 9. A method according to one of the above embodiments, wherein step c further includes the step of fusing the surfaces of a plurality of individual particles and / or the surface of the upper. 42. 10. Before step c, a connection layer is provided between a plurality of individual particles for the sole element and the upper. 4. The method of any one of the preceding embodiments, further comprising the step of: 11. Step c further comprises molding a sole element from a plurality of individual particles; 11. The method of any of the above embodiments. 12. The plurality of individual particles and / or uppers are preheated in the mold prior to step c. The method of any one of the above embodiments. 13. The mold is made of a polymeric material, preferably a thermoplastic material, more preferably a polyethylene terephthalate. Polybutylene terephthalate (PET), Polybutylene terephthalate (PBT), Polyoxymethylene (POM), polyamide-imide (PAI), polycarbonate (PC), polyketone (P K), polyetheretherketone (PEEK), polyvinylidene fluoride or polydifluoromethane Polyvinylidene fluoride (PVDF), thermoplastic polyurethane (TPU), or polyethylene ( PE). 14. A plurality of individual particles are formed of a foam material, preferably foamed thermoplastic polyurethane ( eTPU), Expanded Polyamide (ePA), Expanded Polyether Block Amide (ePEBA) ), polylactide (PLA), polyether block amide (PEBA), foamed polyethylene Expanded Polybutylene Terephthalate (ePET), Expanded Polybutylene Terephthalate (ePBT), Expanded Thermoplastic polyester ether elastomer (eTPEE), Expanded polystyrene (ePS ) based on one or more of the following: 15. The upper is a fabric upper, and may be knitted, woven, non-woven, or randomly piled. The above embodiments include one or more of stacked fibers, multi-directional layered materials, and mesh structures. One way. 16. A system comprising means for carrying out the method of one of the above embodiments. 17. A shoe manufactured by the method according to one of the above embodiments, in particular a sports shoe. 18. The shoe according to the above embodiment, wherein the shoe does not contain an adhesive.

[0040] Hereinafter, possible embodiments of the present invention will be further described with reference to the following figures.

Brief Description of the Drawings

[0041]

Figure 1

Figure 2a

Figure 2b

Modes for Carrying Out the Invention

[0042] Possible embodiments of various aspects of the present invention are mainly related to the manufacture of shoes in general, such as sports shoes, casual shoes, laced shoes, or boots such as work boots, and will be described in the following detailed description. However, it is emphasized that the present invention is not limited to those embodiments Rather, the present invention may be used for various sports clothing products using foam materials and fabric materials, such as knee protectors or elbow protectors, and at least a part of the sports clothing is formed from individual particles, for example, tennis rackets, golf clubs baseball bats, badminton rackets, cricket bats, ice hockey sticks, hockey sticks, squash rackets, table tennis bats, thigh pads, etc. Further, the use The term "sports clothing" may refer to clothing, including accessories such as shoes and sports equipment, worn for sports or physical activities. Sport-specific clothing or apparel may be worn for most sports and physical activities for reasons of utility, comfort, or safety. Typical sport-specific clothing may include tracksuits, shorts, T-shirts, and polo shirts. Specialized clothing may include swimwear (for swimming), wetsuits (for diving and surfing), ski suits (for skiing), and leotards (for gymnastics). Sports shoes may include training shoes, running shoes, soccer shoes, basketball shoes, volleyball shoes, tennis shoes, rugby shoes, golf shoes, riding boots, snowboard boots, and ice skating boots. Additionally, sport-specific clothing or apparel may include bikinis, some crop tops, and undergarments such as men's jockstraps and sports bras. It will be further mentioned below that only individual embodiments of the present invention may be described in more detail. However, those skilled in the art will understand that any optional features and possible modifications described with reference to those specific embodiments may be further modified and / or combined with each other in another way or in another sub-combination without departing from the scope of the present invention. Individual features may be omitted in cases where they are not necessary to obtain the desired result. Therefore, to avoid redundancy, reference is made to the description in the previous paragraphs, which also applies to the following detailed description.

[0043]

[0044] ​​​​​​​​​​​​​​​FIG. 1 shows providing a plurality of individual particles 105 for a sole element 110 within a mold 120, providing an upper, such as a fabric upper 130, to produce a completed shoe 100, particularly a sports shoe, according to the method of the present invention.

[0045] Providing a plurality of individual particles 105 may include, for example, filling and / or transferring particles from a container to the mold 120 via at least one raw material line within an automated manufacturing line. This may be included.

[0046] Providing the fabric upper 130 may be done manually by an operator and / or automatically by a machine, such as a robot.

[0047] Next, the plurality of individual particles 105 and the fabric upper 130 are fused using an electromagnetic field 140 to join the plurality of individual particles 105 to each other and to the fabric upper 130. The joining of the plurality of individual particles 105 and the fabric upper 130 is schematically shown by two double-headed arrows. The joining of the plurality of individual particles 105 and the fabric upper 130 is schematically shown by two double-headed arrows.

[0048] The electromagnetic field 140 may be emitted from a radiation source 145, such as two capacitor plates, in which case one capacitor plate is connected to a radio frequency generator and the other capacitor plate is grounded. However, it is also possible to use a plurality of radiation sources or energy sources, or one energy source may emit radiation at different frequencies, etc., in which case a plurality of electromagnetic fields are (in the linguistic sense) referred to. These electromagnetic fields overlap at a given point in space to form a physical electromagnetic field at this point in space. grounded. However, it is also possible to use a plurality of radiation sources or energy sources, or one energy source may emit radiation at different frequencies, etc., in which case a plurality of electromagnetic fields are (in the linguistic sense) referred to. These electromagnetic fields overlap at a given point in space to form a physical electromagnetic field at this point in space. grounded. However, it is also possible to use a plurality of radiation sources or energy sources, or one energy source may emit radiation at different frequencies, etc., in which case a plurality of electromagnetic fields are (in the linguistic sense) referred to. These electromagnetic fields overlap at a given point in space to form a physical electromagnetic field at this point in space. of radiation at different frequencies, etc., in which case a plurality of electromagnetic fields are (in the linguistic sense) referred to. These electromagnetic fields overlap at a given point in space to form a physical electromagnetic field at this point in space. of radiation at different frequencies, etc., in which case a plurality of electromagnetic fields are (in the linguistic sense) referred to. These electromagnetic fields overlap at a given point in space to form a physical electromagnetic field at this point in space.

[0049] The electromagnetic field 140 may be, for example, radiation in the microwave range, i.e., radiation having a frequency in the range of 300 MHz to 300 G Hz. The electromagnetic field 140 may also be radiation in the radio frequency range , i.e., radiation having a frequency in the range of 30 kHz to 300 MHz.

[0050] It is further possible for energy to be supplied in the form of radiation from an electromagnetic field 140 having a frequency range different from the frequency ranges described above. As a specific example, the energy may be supplied in the form of ultraviolet (UV) radiation.

[0051] When the electromagnetic field 140 is radiation in the microwave range, irradiating the microwave radiation onto water leads to heating of the water, so water may be suitable as an energy absorption material in the particles 105 and / or the fabric upper 130. Also, for the electromagnetic field 140 in the radio frequency range, water may be considered as an energy absorption material. Further, it is conceivable that the energy absorption material may be made of metal, particularly metal powder. For example, a metal in the form of, for example, metal powder can absorb a particularly large amount of energy from at least one electromagnetic field and is convenient because it is easy to handle and inject at the same time. The metal can further serve the purpose of affecting the appearance of the particles 105 and / or the (fabric) upper 130, for example, to give a metallic luster, if necessary. 130.

[0052] The particles 105 may be randomly arranged or a combination of arranged particles 105 and randomly arranged particles 105 may be used. The particles 105 may be connected at their surfaces. The materials used for the particles 105 and their advantages have been described above. ​​​​​​​​​

[0053] The mold 120 may consist of different portions (not shown), such as a bottom, a top, and sides. Other mold shapes as well as more or fewer portions of the mold 120 are contemplated.

[0054] The textile upper 130 may be constructed in one or more of the following structures: knitted, woven, and / or non-woven. The textile material may comprise randomly deposited fibers, multi-directional layered materials, and / or may comprise a mesh structure.

[0055] Also, the (fabric) upper 130 is an interface between the particles 105 and the (fabric) upper 130. At least one of the fusible yarns may act as a fusible intermediate layer or connecting layer for efficient fusion bonding. It is also contemplated that a hot melt layer may be provided. Such a layer may be optional and may be used in accordance with the present invention. The particles 105 are fused to the (fabric) upper 130 using an electromagnetic field, may be implemented by joining the upper 130 to each other and to the (textile) upper 130. It should be noted.

[0056] As mentioned above, the particles 105 are pre-wetted prior to actually fusing the particles 105 to the textile upper 130. and / or pre-heating the textile upper 130. The particles 105 and / or the textile upper 130 are then subjected to an applied electromagnetic field for fusing. It is first heated to a specific temperature so that it has a favorable absorption range for electromagnetic radiation from 140 This pre-heating may be performed to heat the particles 105 and / or the textile upper 130 to the mold 120. This may be done in the mold 120 before or during feeding to / into the mold.

[0057] Similar to the use of the energy-absorbing material as described above, the particles 105 and / or The preheating of the fabric upper 130 may be used, for example, when attempting to take account of the variance in the absorption of the electromagnetic field 140 by the plurality of materials of the shoe.

[0058] The preheating of the particles 105 and / or the fabric upper 130 may advantageously be carried out before supplying the material for the above-described steps, and further, it may be advantageous to preheat when the mold 120 is being closed. Such preheating can reduce the time required for the actual fusing step, and thus the time required to hold the particles 105 and the fabric upper 130 in the mold 120, and thus there is a possibility of improving the throughput of the system when implementing the method of the present invention.

[0059] Additionally or alternatively, in one example, in order to preheat the material to a specific temperature, it is possible to apply the electromagnetic field 140 at a first, lower power or voltage (e.g., while providing the particles 105 and the fabric upper 130, and / or when they are in the mold 120). Thereafter, the power or voltage may be increased gradually or abruptly. The power or voltage may be increased in some different partial regions of the mold 120 after being applied at a lower value (not shown). In this way, it is possible to obtain only partial preheating of the particles 105 and / or the fabric upper 130. This can be useful when using particles 105 and a fabric upper 130 having different properties (e.g., size or absorption material).

[0060] ​​​​​​​​​​​​​​In some embodiments, at least one portion of the bottom, top, or side of mold 120 may be preheated. These options may be carried out with or without providing the particles 105 and / or (fabric) upper 130 materials to the mold 120.

[0061] The power or voltage of the electromagnetic field 140 may be increased gradually. For example, the increase in the radiated power may be selected such that the total cycle time for producing the shoe 100 is within a desired range for production. For example, the fusing may be in the range of 40 to 70 seconds. Additionally, the cooling time of the shoe 100 after fusing may be in the range of 10 to 20 minutes. Thus, compared to conventional methods for manufacturing shoes, the method of the present invention can be significantly faster. In general, the time for increasing the radiated power can be selected quite freely and can be adjusted to control the fusing process between the surface of the particles 120 and the fabric upper 130, and thus the overall fusing of the shoe. For example, depending on the material of the particles 120, an overly rapid increase may damage the cellular structure of the particles.

[0062] After preheating, electromagnetic radiation 140 may then be applied to achieve an optimal transfer of power. This technique may also be useful when materials with a temperature-dependent dielectric loss factor are used.

[0063] Here, the advantage of this method is again emphasized that mold 120 may absorb only a limited amount of energy compared to the materials of the particles 105 and the fabric upper 130. For example, it has been found advantageous to use an epoxy resin for manufacturing is being processed. The epoxy resin is processed to fit the mold 120 with a cavity of complex shape and may have a low absorption capacity for electromagnetic fields. Other methods known in the art for manufacturing molds with low absorption capacity may be used.

[0064] Figures 2a and 2b show a sole element 110 manufactured according to the present invention, made from individual particles 105 that have been fused together using an electromagnetic field to join them to each other. is shown.

[0065] Figure 2a shows the bottom surface of the sole element 110, where an outsole element 115 is provided and fused using an electromagnetic field to join it to a plurality of individual particles 105.

[0066] Such an outsole element 115 may protect the plurality of individual particles 105 of the sole element 110.

[0067] Figure 2b shows the top surface of the sole element 110 after the plurality of individual particles 105 have been fused to each other and to a fabric upper 130 using an electromagnetic field, showing (for better understanding) a portion of the fabric upper 130 together with it.

Explanation of Signs

[0068] 100 Shoe 105 Particle 110 Sole Element 115 Outsole Element 120 Mold 130 Upper 140 Electromagnetic Radiation, Electromagnetic Field 145 Radiation Source​​​

Claims

Claim 1 A method for manufacturing shoes, particularly sports shoes, comprising: a. providing a plurality of individual particles for a sole element in a mold; b. providing an upper in the mold; c. fusing the plurality of individual particles with each other and with the upper using an electromagnetic field to join the plurality of individual particles to each other and to the upper. Claim 2 d. providing a support element for a sole element in the mold, e. providing an outsole element for a sole element in the mold, wherein the method further comprises one or more of the steps of: f. step c further comprises fusing the support element and the outsole element using an electromagnetic field to join the plurality of individual particles to each other, to the support element, to the outsole element, and to the upper. The method according to claim 1. Claim 3 The method according to claim 1, wherein step c is performed in a single step. Claim 4 The electromagnetic field is in the radio frequency range of 30 kHz to 300 MHz, preferably in the range of 1 MHz to 200 MHz, more preferably in the range of 1 MHz to 50 MHz, most preferably in the range of 25 to 30 MHz, or in the microwave range of 300 MHz to 300 GHz. The method according to claim 1. Claim 5 The method according to claim 1, wherein step c is performed without an adhesive. Claim 6 The method according to claim 1, further comprising locally adjusting the electromagnetic field intensity distribution of the electromagnetic field in the mold. Claim 7 The method according to claim 1, wherein the energy supplied using the electromagnetic field is varied over time. Claim 8 More energy from the electromagnetic field is supplied to the plurality of individual particles and / or the upper in a first partial region of the mold than in a second partial region of the mold. The method according to claim 1. Claim 9 Step c further comprises fusing the surfaces of the plurality of individual particles and / or the surface of the upper. The method according to claim 1. Claim 10 The method according to claim 1, further comprising disposing a connection layer between the plurality of individual particles for a sole element and the upper before step c. Claim 11 Step c further comprises forming a sole element from the plurality of individual particles. The method according to claim 1. Claim 12 。 The plurality of individual particles and / or the upper are preheated in the mold before step c. The method according to claim 1. Claim 13 ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ The type is one or more of a polymer material, preferably a thermoplastic material, more preferably polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyoxymethylene (POM), polyamideimide (PAI), polycarbonate (PC), polyketone (PK), polyetheretherketone (PEEK), polyvinylidene fluoride or polyvinylidene difluoride (PVDF), thermoplastic polyurethane (TPU), or polyethylene (PE), the method according to claim 1.

14. The method according to claim 1, wherein the plurality of individual particles are based on one or more of a foam material, preferably expanded thermoplastic polyurethane (eTPU), expanded polyamide (ePA), expanded polyether block amide (ePEBA), polylactide (PLA), polyether block amide (PEBA), expanded polyethylene terephthalate (ePET), expanded polybutylene terephthalate (ePBT), expanded thermoplastic polyester ether elastomer (eTPEE), expanded polystyrene (ePS).

15. The method according to claim 1, wherein the upper is a fabric upper and includes one or more of a knitted structure, a woven structure, a non-woven structure, randomly deposited fibers, a multi-directional layered material, a mesh structure.

16. A system comprising means for implementing the method according to any one of claims 1 to 15.

17. A shoe, in particular a sports shoe, manufactured by the method according to any one of claims 1 to 15.

18. The shoe according to claim 17, wherein the shoe does not contain an adhesive. ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​

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