shoe upper with a layered structure for athletic shoes

Abstract

This invention provides an improved shoe upper. [Solution] The present invention provides a shoe upper having a layered structure 105 comprising a first layer 110, a second layer 120, and an intermediate foamed layer 130 containing a polyamide (PA) foamed material between the first and second layers, or an athletic shoe having such a shoe upper.

Description

Technical Field

[0001] The present invention relates to a layer structure having a first layer, a second layer, and an intermediate foam layer containing a polyamide (PA) foam material between the first layer and the second layer, particularly to a shoe upper for sports shoes.

[0002] The present invention also relates to a sports shoe comprising such a shoe upper.

Background Art

[0003] Shoes are generally described as a combination of an upper and a sole. Typically, the shoe upper covers areas such as the wearer's instep, toe, inner side, outer side, and heel, and provides an opening for the wearer to insert their foot into the footwear. The shoe upper typically performs several different functions such as protection, support, and comfort. The sole is connected to the upper such that, during normal use of the shoe, the upper side of the sole faces the underfoot portion of the upper and the lower side contacts the ground.

[0004] Foam materials have become important components in the design and manufacture of modern footwear, particularly in soles for competitive and sports shoes. The development and use of foams in shoes is based on the need to improve comfort, cushioning, support, and performance. Over time, the technologies and materials used in foam production have advanced significantly. Manufacturers have developed various types of foam materials, each with its own unique properties tailored to specific performance requirements. For example, shape memory foams provide a customized fit by molding to the shape of the foot, while polyurethane (PU) foams offer higher durability and energy reduction.

[0005] European Patent Application Publication No. 3,253,247 discloses footwear having a multilayered upper in which the outermost layer of the upper is cut to a mold. The cut portion of the upper is mounted on a continuous base layer such that the edges of the cut portion are visible and can be confirmed by touch. The upper possesses durability with respect to abrasion resistance, interlayer adhesion, tensile strength, and flexural testing.

[0006] European Patent Application Publication No. 3,765,640 discloses a method for producing a layered material having a base layer and a polyurethane layer bonded to the base layer, wherein leather, preferably sanded grain leather, a fibrous material, preferably a woven or knitted fabric, a bonded leather material, or a microfiber nonwoven fabric is used as the base layer and bonded to the layer.

[0007] U.S. Patent No. 10,499,706 discloses a method for manufacturing an upper for footwear, comprising the steps of forming a foam layer, forming a preliminary upper by laminating an outer layer, an inner layer and an intermediate foam layer between the outer and inner layers, and providing at least a portion of an upper for footwear by molding the preliminary upper into a shape having a contour that substantially conforms to at least a portion of the foot.

[0008] U.S. Patent Application Publication No. 2006 / 051566 relates to a comfort element for footwear or clothing, a method for manufacturing the same, and footwear or clothing containing such an element. The comfort element is manufactured by overlapping a first layer of material having a melting temperature theta 1, a layer of foamed material having a melting temperature theta 2, and a second layer of material having a melting temperature theta 3, and assembling the three layers by welding them together along a predetermined welding line such that the temperature theta 2 is lower than thetas 1 and 3, thereby making the foamed material layer a temperature theta 4 between theta 2 and thetas 1 and 3 along the welding line. At least one film of a heat-meltable adhesive, pre-cut along a predetermined welding line and having a melting temperature theta 5 approximately theta 2, is inserted between one of the material layers and the foamed material layer.

[0009] While the aforementioned document claims to be an improvement over previously known prior art, the proposed solution still has some shortcomings in providing the shoe upper with the requirements mentioned above. One common drawback of known shoe uppers is that some foam materials are relatively stiff and lack the flexibility desired in high-quality football shoes.

[0010] Against this backdrop, the objective of the present invention is to provide an improved shoe upper. [Prior art documents] [Patent Documents]

[0011] [Patent Document 1] European Patent Application Publication No. 3,253,247 [Patent Document 2] European Patent Application Publication No. 3,765,640 [Patent Document 3] U.S. Patent No. 10,499,706 [Patent Document 4] U.S. Patent Application Publication No. 2006 / 051566 [Overview of the Initiative]

[0012] The above-mentioned objectives are achieved at least in part by the subject matter of the independent claims. Preferred embodiments are the subject matter of the dependent claims, and other preferred aspects of the invention are described throughout the overall disclosure of this application. It should be noted that any headings that may exist in this disclosure are provided solely for the purpose of assisting in understanding the overview in reading. The headings do not imply that the features of each embodiment cannot be combined.

[0013] In one embodiment, the object of the present disclosure is at least partially solved by a shoe upper, particularly for athletic shoes, comprising a layered structure having (a) a first layer, (b) a second layer, and (c) an intermediate foamed layer between the first and second layers, comprising a polyamide (PA) foamed material.

[0014] In this way, several properties such as flexibility and cushioning are improved. For example, PA foam is known for its high tensile strength and abrasion resistance, thereby significantly improving the overall durability of footwear. The foam layer helps protect the layer from wear and tear, extending the lifespan of the shoes.

[0015] Furthermore, the PA foam layer provides additional structural support to the shoe upper, maintaining its shape and form over extended periods. This is particularly important in preventing deformation or sagging of the upper during prolonged use.

[0016] Furthermore, PA foam provides excellent cushioning properties, contributing to wearer comfort by absorbing shocks and impacts during exercise. This makes the shoes more comfortable even when worn for extended periods, reducing foot fatigue.

[0017] Furthermore, despite its high strength, PA foam is lightweight, which helps reduce the overall weight of the shoe. This contributes to improved performance, especially in athletic footwear, by minimizing the energy required for movement.

[0018] Furthermore, the PA foam layer can be adjusted in terms of density and thickness to achieve specific performance characteristics, such as flexibility or rigidity in certain areas of the shoe. This allows for a more personalized fit and feel. Unlike other foam materials that may compress or lose their elasticity over time, PA foam retains its properties for longer, ensuring consistent performance throughout the shoe's lifespan.

[0019] In addition, the PA foam layer can also provide insulation, helping to maintain a comfortable temperature inside the shoe. This is beneficial in various weather conditions, keeping feet warm in cold environments and cool in hot environments.

[0020] Furthermore, the PA foam is processed to have moisture-wicking properties, which helps manage perspiration and keep feet dry. This contributes to better hygiene and comfort.

[0021] In some embodiments, the PA foam layer may have perforations, preferably fine perforations, to further improve its moisture absorption and wicking properties, thereby helping to manage perspiration and keep the feet dry.

[0022] In summary, by incorporating an intermediate foam layer containing PA foam material between the first and second layers in the shoe upper, a balanced combination of durability, comfort, lightweight construction, and thermal regulation is achieved, making it an excellent choice for high-performance footwear.

[0023] In preferred embodiments of the shoe upper described herein, at least one of the following is applied: a first layer is adapted to be on the inside of the shoe upper; a second layer is adapted to be on the outside of the shoe upper; or an intermediate layer is adapted to provide elasticity and cushioning upon ball contact.

[0024] This multi-layered upper design brings together comfort, durability, flexibility, and performance, making it ideal for athletic footwear where both protection and functionality are of utmost importance. For example, the first inner layer touches the foot directly, providing a soft and comfortable inner surface. This design reduces friction with the skin, minimizes the risk of blisters and inflammation, and improves overall comfort during wear. Additionally, the second outer layer faces the external environment, providing a robust and durable exterior. This layer protects the shoe upper from environmental factors such as abrasion, scratches, and dirt or moisture, allowing the shoe to maintain its appearance and longevity. Furthermore, the middle layer designed to provide stretchability and cushioning improves the performance of the shoe upon ball contact. The stretchable nature of the foam allows for better fit and flexibility during active movement, while the cushioning absorbs shock and improves ease of handling and comfort when the foot contacts the ball. This is particularly advantageous for sports such as soccer where precise ball handling is crucial. Additionally, the stretchability of the middle layer allows the shoe to conform to the natural movement of the foot, providing a snug yet flexible fit. This feature is essential for athletic footwear where freedom of movement and foot flexibility are important for optimal performance. Moreover, the cushioning provided by the middle layer offers excellent shock absorption, protecting the foot from impacts during activities such as running or jumping. This reduces the risk of injury and improves the comfort and safety of the wearer. The layer structure with a cushioned middle layer also contributes to insulation, keeping the foot warm in colder conditions. Additionally, when the layers are designed with breathable materials, the shoe can effectively manage humidity and keep the foot dry and comfortable. Furthermore, the different layers can be customized for the customer in terms of material and properties. For example, the outer fiber layer can be made from a durable water-resistant material, while the inner layer can be a soft moisture-wicking fabric. This flexibility in design allows the shoe to adapt to various conditions and user preferences.

[0025] In a preferred embodiment of the shoe upper described herein, the first layer forms the innermost surface of the shoe upper. By disposing the first layer as the innermost surface of the shoe upper, a direct soft and smooth interface against the foot is provided. This reduces the possibility of inflammation, rubbing or discomfort, especially during long-term wear. Further, the first layer is designed to have moisture absorption and dissipation properties and can help draw sweat away from the skin to the outer layer of the shoe. This keeps the foot dry and comfortable, and reduces the risk of blisters. The breathable material as the innermost layer helps promote air circulation around the foot, regulate temperature and prevent overheating. This contributes to overall foot health and comfort, especially in warm conditions. Further, as the innermost layer, this layer provides a protective barrier between the foot and other structural components of the shoe such as stiffeners and reinforcements, allowing the foot to be cushioned from impacts and shielded from potentially uncomfortable or hard elements.

[0026] In a preferred embodiment of the shoe upper described herein, the second layer forms the outermost surface of the shoe upper. The second layer, being the outermost surface, functions as the first line of defense against environmental elements such as abrasion, dirt and moisture, protects the inner layer and extends the useful life of the shoe. Further, the outermost layer can be designed in a variety of textures, colors and patterns, allowing for greater design flexibility and customer-tailored manufacturing. This enhances the visual appeal of the shoe and makes it more attractive to consumers. Further, when the second layer is treated with a water-repellent or stain-resistant coating, it thereby keeps the shoe clean and dry in wet or dirty conditions and improves the overall utility of the footwear. Further, depending on the material selected for the second layer, it can contribute to the breathability of the shoe, allow air to circulate and keep the foot cool and comfortable.

[0027] In a preferred embodiment of the shoe upper described herein, a layered structure is placed in the bump area of ​​the shoe upper. The bump area, which covers the upper part of the foot and includes the area covering the toes, is subjected to greater pressure and movement. A cushioning layered structure, such as foam, provides additional comfort by more evenly distributing pressure across the foot. The bump area also needs to accommodate various foot shapes and dimensions. The layered structure allows the material to conform better to the contours of the foot, resulting in a snug, stable, and secure fit that conforms to the individual foot shape. The bump area is subjected to frequent bending and flexing. A reinforced layered structure improves the durability of the upper and prevents premature wear in this critical area. By incorporating materials that effectively manage moisture, the layered structure can improve the breathability of the bump area. This is important for maintaining foot comfort and reducing the risk of odor caused by blisters or trapped moisture. Furthermore, the bump area plays a crucial role in controlling the movement of the foot during walking or running. A well-designed layered structure provides the necessary support to maintain stability and can prevent excessive movement that could lead to discomfort or injury.

[0028] In a preferred embodiment of the shoe upper described herein, the layered structure is positioned in the forefoot region of the shoe upper. The forefoot is subjected to significant pressure and impact during walking, running, and other activities. The layered structure provides additional cushioning and shock absorption to this critical area, protecting the foot from injury and discomfort. By incorporating a layered structure with cushioning properties in the forefoot, the shoe can provide better energy return with each step. This can improve athletic efficiency, enhance the responsiveness of the shoe, and improve the performance of sports footwear in particular.

[0029] In a preferred embodiment of the shoe upper described herein, the layered structure is positioned in the toe area of ​​the shoe upper. The layered structure in the toe area provides additional cushioning and impact protection, reducing the risk of injury from impacts or external forces. Furthermore, the toe area is subject to significant abrasion, particularly during activities such as running or hiking. The layered structure reinforces this area, increasing the durability of the shoe and preventing premature wear.

[0030] In a preferred embodiment of the shoe upper described herein, the first layer is a first fiber layer. By incorporating a fiber layer, manufacturers can produce a shoe upper that balances breathability, comfort, and durability while maintaining flexibility in both function and design. For example, the fiber layer can improve breathability, thereby allowing air to circulate through the shoe and keep the foot cool and dry. Furthermore, the fiber layer allows for greater flexibility and conformity to the movement of the foot. This flexibility can result in a more natural fit and better comfort, particularly in areas that undergo a lot of flexion, such as the forefoot and midfoot.

[0031] In preferred embodiments of shoe uppers described herein, the first layer comprises a coating, film, synthetic leather, or leather. This combination of materials allows shoe designers to optimize the shoe to specific performance requirements, such as making it suitable for athletic, casual, or outdoor use. For example, coatings, films, and synthetic or natural leather provide improved abrasion resistance, protecting the shoe from environmental factors such as water, dirt, or wear. These materials can extend the lifespan of the shoe, especially in high-stress areas such as the toe or sides of the upper. Furthermore, coatings and films can be processed to provide water resistance, preventing moisture from seeping into the shoe. This is important in outdoor or athletic shoes that are often exposed to water. Leather and synthetic leather also naturally provide a certain level of water resistance. In addition, the use of films and coatings can add lightweight structural support without the need for heavier materials. This helps to allow for flexibility and movement in specific areas while maintaining the shape and fit of the shoe.

[0032] In a preferred embodiment of the shoe upper described herein, the second layer is a second fiber layer. The aforementioned advantages of the first fiber layer also apply to the second fiber layer.

[0033] In preferred embodiments of the shoe uppers described herein, the second layer includes a coating, a film, synthetic leather, or leather. The aforementioned advantages of the first layer also apply to the second layer.

[0034] In preferred embodiments of the shoe uppers described herein, one or more of the first and second layers include a fabric, preferably a knitted fabric. Knitted fabrics offer greater flexibility and elasticity compared to woven fabrics. This flexibility allows the shoe upper to conform more comfortably to the shape of the foot, resulting in a better fit and improved comfort. The open structure of knitted fabrics improves airflow and ventilation within the shoe. This breathability helps maintain a cooler and more comfortable environment for the foot, reduces moisture buildup, and enhances overall foot comfort. The softness and elasticity of knitted fabrics contribute to a more comfortable wearing experience. The ability of the fabric to stretch and adapt to foot movements can reduce pressure points and friction, alleviating foot fatigue and discomfort.

[0035] In some embodiments, the knitted fabric is either weft-knitted or warp-knitted.

[0036] In some embodiments, one or more of the first and second fiber layers may also include woven and / or nonwoven fabrics. Woven fabrics are known for their durability and resistance to abrasion. The interlocking of fibers in woven fabrics results in greater strength compared to nonwoven fabrics, thereby helping the layers withstand wear and extending the lifespan of the shoe. The use of woven fabrics in critical areas can provide additional reinforcement and support, improving the overall performance and lifespan of the shoe. Nonwoven fabrics are often designed to be more breathable than conventional woven fabrics. This helps improve air circulation within the shoe, regulate temperature, and reduce moisture buildup, thereby improving overall foot comfort. Furthermore, nonwoven fabrics can be lighter than woven alternatives due to their unique manufacturing process. This helps reduce the overall weight of the shoe, contributing to improved athletic performance and comfort for the wearer.

[0037] In preferred embodiments of the shoe uppers described herein, one or more of the first and second layers comprise PA material. This provides benefits such as improved durability, strength, moisture management, thermal regulation, and comfort, making it a favorable choice for creating high-quality, high-performance footwear. For example, using PA in the fiber layer improves the overall durability of the shoe upper, giving it greater resistance to abrasion and thereby extending the life of the footwear. Furthermore, PA fabric has good moisture-wicking properties, which help manage sweat and keep feet dry. This moisture management contributes to better comfort and hygiene, reducing the possibility of foot odor and fungal infections. In this way, PA fibers can be processed to be flexible and provide a comfortable, snug fit. The material's ability to stretch and conform to the shape of the foot improves the overall comfort of the shoe, reduces pressure points, and improves wearability. In addition, being of the same material classification as the intermediate PA foam layer improves the manufacturing of the layer structure.

[0038] Furthermore, one or more of the first and second layers may also include polyurethane (PU) material and / or thermoplastic polyurethane (TPU) material.

[0039] In preferred embodiments of the shoe upper described herein, one or more of the first and second fiber layers have a thickness of 0.05 mm to 1.0 mm, preferably 0.1 mm to 0.8 mm, more preferably 0.2 mm to 0.6 mm, and most preferably about 0.3 mm. Fiber layers within this thickness range contribute to effective breathability, thereby aiding in humidity control and temperature regulation. This thickness is sufficient to provide adequate coverage and protection while allowing air circulation. The thickness of the fiber layers within this range allows for an optimal balance between flexibility and support. Thicker layers provide greater cushioning and support, while thinner layers ensure better flexibility and breathability. The specific thickness of about 0.3 mm provides a good balance between these two factors, improving comfort without impairing movement. Furthermore, this thickness range provides sufficient durability to withstand wear and tear, while maintaining the overall integrity of the shoe upper. This thickness helps prevent premature damage or fraying, extending the lifespan of the footwear.

[0040] In preferred embodiments of the shoe uppers described herein, the intermediate foam layer has a thickness of 0.5 mm to 1.5 mm, preferably 0.7 mm to 1.2 mm, and more preferably about 1.0 mm. This specific thickness range, preferably about 1.0 mm, allows the intermediate foam layer to provide optimal cushioning, support, flexibility, and durability while maintaining a lightweight design. For example, the thickness range provides an optimal balance between cushioning and support. It provides sufficient cushioning to absorb shock and improve comfort without compromising the structural integrity of the shoe. This specific thickness helps maintain responsiveness while achieving effective shock absorption. At this thickness, the intermediate foam layer maintains sufficient flexibility to adapt to the movement of the foot. This flexibility is important for athletic and casual footwear, allowing for natural foot movement while providing support. Furthermore, the thickness range ensures that the foam layer adds minimal weight to the shoe. This weight is beneficial for high-performance footwear, as it can improve speed and agility without sacrificing comfort or support by reducing weight.

[0041] In a preferred embodiment of the shoe upper described herein, the intermediate foam layer has a thickness of 1.0 mm to 7.0 mm, preferably 2.5 mm to 6.0 mm, and more preferably about 4.5 mm or about 6.0 mm.

[0042] In preferred embodiments of the shoe uppers described herein, the material for the intermediate foam layer is manufactured by a supercritical foaming process. Supercritical foaming is a technique used to create foams with specific properties by utilizing a supercritical fluid, which is a substance at temperatures and pressures above its critical point. Therefore, supercritical foaming allows for precise control of the foam's structure and properties, resulting in a material with improved mechanical properties such as a higher strength-to-weight ratio and better impact resistance. This contributes to the overall durability and performance of the intermediate layer. Furthermore, supercritical foaming typically produces a more uniform cellular structure compared to conventional foaming methods. This uniformity improves the consistency of the foam's cushioning and support properties, leading to more predictable and reliable performance in footwear. The fine and uniform cellular structure of foams produced by supercritical foaming often results in excellent thermal insulation properties. This helps maintain a comfortable temperature inside the shoe, contributing to improved wearer comfort across different environments. The supercritical foaming process allows for the creation of foams with improved breathability because a uniform pore structure promotes better air circulation. This helps regulate humidity and temperature inside the shoe, keeping feet dry and comfortable. In summary, using materials manufactured by the supercritical foaming process in the midlayer offers several advantages, including improved mechanical properties, a uniform cellular structure, lightweight properties, and enhanced breathability, all of which contribute to superior performance, comfort, and sustainability in footwear.

[0043] In a preferred embodiment of the shoe upper described herein, the shoe upper further comprises a foil layer on a second layer adapted to provide a coating for the shoe upper. Adding a foil layer to the second layer of the shoe upper brings various benefits, including improved durability, water resistance, aesthetics, and ease of maintenance, while also improving the overall functionality and performance of the shoe. The foil layer acts as a protective coating, increasing the overall durability of the shoe upper. It protects the underlying fibers from fraying, as well as environmental factors such as moisture, ultraviolet rays, and abrasion. Furthermore, the foil layer provides effective water resistance, preventing water from penetrating through the shoe upper. This keeps the wearer's feet dry and comfortable, especially in humid conditions. In addition, the foil coating can enhance the visual appeal of the shoe upper by adding a glossy, lustrous finish or a distinctive texture. This can improve the quality of the design and give the shoe a more luxurious or fashionable look. Furthermore, the foil layer can make the shoe upper easier to clean and maintain. Its smooth surface repels dirt and stains, allowing for easier wiping or cleaning compared to the surface of untreated fibers. Furthermore, depending on the type of foil used, it can be processed to maintain or improve the breathability of the shoe upper. Advanced foil materials can strike a balance between protection and ventilation, ensuring comfort. In addition, the latest foil materials are designed to be flexible, allowing the shoe upper to retain its suppleness and not compromise the comfort or fit of the shoe.

[0044] In preferred embodiments of the shoe uppers described herein, the foil layer comprises thermoplastic polyurethane (TPU) material. TPU is known for its high durability and abrasion resistance. The foil layer provides improved protection against fraying, extending the service life of the product. TPU also maintains flexibility even at low temperatures, thereby contributing to overall comfort. The foil layer can bend and stretch with the movement of the shoe, providing a comfortable fit without compromising durability. TPU has excellent resistance to chemicals and oils. This makes the foil layer more robust in environments where the shoe may be exposed to such substances, ensuring the long life and maintenance of the shoe's appearance. TPU is also inherently water-resistant, thereby preventing water from entering and helping to keep the internal materials of the shoe dry. This is particularly advantageous for footwear used in humid conditions. TPU has high elasticity and resilience, thereby contributing to improved shock absorption and impact resistance. This enhances the performance characteristics of the shoe, especially in high-impact or athletic use. Furthermore, TPU is stable across a wide temperature range, maintaining its properties and performance under various environmental conditions. This ensures that the shoes perform consistently in both high and cold conditions.

[0045] In preferred embodiments of the shoe uppers described herein, the foil layer has a thickness of 0.01 mm to 0.1 mm, preferably 0.02 mm to 0.07 mm, and more preferably about 0.05 mm. This range of foil thickness allows the material to be sufficiently flexible to conform to different shapes and surfaces without becoming too rigid or difficult to handle. This is particularly advantageous in applications where the foil needs to conform to complex geometric shapes or movements. A specific thickness range provides a balance between durability and weight. Foil that is too thin may tear or puncture easily, while foil that is too thick may be unnecessarily heavy or rigid. The selected thickness range ensures that the foil has adequate strength while being practical for its intended use. Furthermore, at a particular thickness, the foil can effectively function as a barrier against various environmental factors such as moisture, gases, or chemicals, depending on the material. This level of thickness is typically sufficient to provide effective protection while maintaining lightness. The selected thickness also ensures effective thermal or electrical insulation where needed, without compromising the overall design and functionality of the product.

[0046] In preferred embodiments of the shoe uppers described herein, the foil layer is extruded. Extrusion allows for the creation of a foil layer with uniform thickness and consistent material properties throughout the layer. This ensures that the foil layer exhibits consistent performance and avoids weaknesses or thickness variations that could affect the overall quality and functionality of the product. The extrusion process can provide the foil layer with a smooth, high-quality surface finish. This can be advantageous in applications where appearance and surface texture are important, such as consumer products or components with high visibility. Extruded foil layers can be manufactured in a variety of shapes and dimensions, including complex geometric shapes. This versatility allows for the design of components that are precisely adapted to the desired application or product, providing more design options.

[0047] In preferred embodiments of the shoe uppers described herein, the foil layer has a hardness of 40 to 90 Shore A, preferably 50 to 70 Shore A, and more preferably about 65 Shore A. A foil layer within this hardness range provides a desirable combination of flexibility, durability, impact resistance, and aesthetic quality, making it suitable for a wide range of applications while ensuring consistent and reliable performance. For example, foil within this hardness range provides good abrasion resistance without being too hard. This level of hardness allows the foil to withstand wear and physical stress over a long period, contributing to the long lifespan of the product.

[0048] In a preferred embodiment of the shoe upper described herein, the shoe upper further comprises a resin layer as the outermost layer having polyurethane material. A resin layer made from polyurethane as the outermost layer provides a combination of durability, flexibility, water resistance, and ease of maintenance, making it an excellent choice for improving the performance and longevity of the product. For example, PU is known for its high durability and resistance to abrasion. As the outermost layer, PU resin provides a robust protective barrier that can withstand everyday use and harsh environmental conditions, extending the service life of the product. Furthermore, PU resin provides excellent abrasion resistance, which is important for applications where the surface is exposed to friction and rough surfaces. This helps prevent the outer layer from deteriorating or showing signs of wear, maintaining the aesthetic and functional integrity of the product. In addition, PU resin can be formulated to provide a flexible yet supportive layer. This flexibility helps the product conform to the shape of the foot or other parts, improving comfort and reducing the possibility of discomfort or pressure points. Furthermore, by using PU resin as the outermost layer, a variety of different colors and various further visual effects can be achieved. For example, surface texture can be provided, for example, by debossing the PU resin layer. More preferably, the resin layer can be applied in a liquid state by rolling the polyurethane material onto adjacent layers of the layer structure.

[0049] In a preferred embodiment of the shoe upper described herein, the first layer and / or second layer is a resin layer made of polyurethane. Due to its durability, flexibility, and abrasion resistance, the resin layer made of PU as the first layer and / or second layer provides sufficient protection and comfort.

[0050] In preferred embodiments of the shoe uppers described herein, the resin layer has a thickness of 0.01 mm to 0.1 mm, preferably 0.02 mm to 0.07 mm, and more preferably approximately 0.05 mm. A resin layer with a carefully controlled thickness offers numerous technical advantages, including precise control, improved bonding, minimal weight increase, improved flexibility, cost-effectiveness, optimal curing time, and consistent performance. For example, a resin layer with a controlled thickness, such as the thickness range described above, allows for precise application and ensures uniform coverage. This level of control helps achieve consistent performance across the entire surface, which is crucial in applications where a uniform distribution of material properties is essential. Furthermore, a resin layer of this thickness can result in optimal bonding between different layers or components. It ensures strong adhesion without excessive bulk, thereby improving the overall structural integrity and durability of the final product. Optimizing the thickness of the resin layer minimizes material usage, leading to cost reductions in resin procurement and processing. This also contributes to a more efficient production process. Furthermore, thinner resin layers often cure faster compared to thicker resin layers, reducing overall processing time and improving production efficiency. This can be advantageous in manufacturing environments where time is a critical factor.

[0051] In preferred embodiments of the shoe uppers described herein, one or more of the layers are joined by an adhesive film, preferably a polyamide (PA) hot-melt adhesive film. Using a polyamide hot-melt adhesive film to join the layers provides a combination of strong, durable bonding, a lightweight structure, and efficient manufacturing, while maintaining aesthetic quality and resistance to environmental factors. For example, PA hot-melt adhesive films provide strong, durable bonding between layers, ensuring that the layers remain stably bonded throughout the entire product lifecycle, even under stress or strain. Furthermore, the use of polyamide adhesives contributes to the overall durability of the product. Polyamides are known for their high mechanical strength and abrasion resistance, thereby helping to maintain the integrity of the layer structure. Additionally, hot-melt adhesives, including polyamide-based ones, are flexible and can adapt to the shape of the layers they join. This flexibility is beneficial in applications where the layers being joined need to move or bend without damaging the bond.

[0052] In preferred embodiments of the shoe uppers described herein, the layered structure is positioned in the midfoot and / or tongue regions of the shoe upper. Placing the layered structure with polyamide foam in the midfoot and / or tongue regions of the shoe upper provides various benefits, including improved support, enhanced comfort, reduced pressure points, and improved durability. This strategically placed layered structure addresses key areas of the foot that experience significant stress and abrasion, contributing to a better overall footwear experience. For example, the layered structure in the midfoot region provides additional support and stability to the arch and midfoot area. This helps to evenly distribute the pressure applied during exercise, reducing foot fatigue and the risk of injury. Furthermore, by incorporating foam layers in these areas, the shoe provides enhanced cushioning where it is most needed. The midfoot region experiences significant stress during activity, and the cushioning helps absorb shock, resulting in a more comfortable feel. In the tongue region, the layered structure can improve the shoe's fit by providing additional padding. This helps reduce pressure points and discomfort caused by laces or the internal structure of the shoe, improving overall comfort. The foam layer acts as a cushion, minimizing common pressure points in the midfoot and tongue areas. This is particularly beneficial in preventing blisters and other foot ailments resulting from friction or pressure. In sports and athletic footwear, improved support and cushioning in the midfoot area contribute to better performance by improving foot control and reducing the impact of high-intensity activities.

[0053] In preferred embodiments of shoe uppers described herein, the layered structure further preferably includes debossed morphological elements. Including morphological elements such as debossed morphological elements in the layered structure brings several advantages, including improved grip, enhanced structural integrity, functional design benefits, and durability. These benefits contribute to both the performance and appeal of the product. For example, debossing allows complex and precise patterns or logos to be persistently embedded in the material. This not only adds a unique and visually appealing design element to the product but also improves its overall appearance and promotes branding opportunities. Furthermore, debossed morphological elements can provide additional grip and traction. The raised or recessed patterns created by debossing can increase surface contact and friction with the ground, improving stability and reducing the risk of slipping. In addition, debossed morphs can contribute to the structural strength and stability of the layered material. By creating raised or recessed areas, the external elements can help distribute stress and force more evenly, reducing the likelihood of deformation or breakage of the material under pressure. The debossing process often involves compressing the material, thereby increasing its density and resistance to abrasion. This added durability helps maintain the integrity of the design element over long periods, even with regular use. Debossed elements can also serve as functional decorations, such as indicators or guides for the user. For example, in shoes, debossed patterns can guide the foot's position for optimal comfort or indicate pressure points.

[0054] In some embodiments, there are several types of morphological elements, preferably arranged in the outermost layer. For example, there are rubber protrusions and / or printed protrusions. Also, to achieve the advantages mentioned above, there are several different types of morphological elements.

[0055] Furthermore, external elements such as rubber protrusions are placed on the outermost layer and preferably bonded to the outermost layer. Another example is printed protrusions.

[0056] In a preferred embodiment of the shoe upper described herein, the shoe upper further comprises multiple openings in the intermediate foam layer. Multiple openings in the intermediate foam layer provide several benefits, including improved breathability, reduced weight, improved flexibility, optimized cushioning, better thermal regulation, and effective humidity control, all of which contribute to a more comfortable, effective, and sustainable product. For example, openings in the foam layer promote airflow and improve ventilation within the shoe. This helps reduce moisture and heat buildup, keeping the feet cooler and drier, thereby being particularly beneficial for athletic and everyday footwear. Furthermore, by including openings, the overall weight of the foam layer can be reduced by eliminating excess material. This lightweight design can improve comfort and performance, especially in high-performance athletic footwear where minimizing weight is important. In addition, openings can improve the flexibility of the foam layer by allowing it to bend and adapt more easily to the shape of the foot. This results in a more comfortable and conforming fit, reduces pressure points, and improves overall wearability. Furthermore, by strategically placing the openings, the foam layer can provide targeted cushioning and support. The design can be optimized to provide better shock absorption and impact protection to specific areas of the foot, improving overall comfort and performance. By using openings to reduce the amount of foam required, manufacturers can achieve cost reductions and decrease material consumption. This can contribute to implementing more sustainable production and lower production costs.

[0057] "Multiple" can refer to a number greater than one, and often indicates a larger or unspecified number in order to achieve the stated technical effect.

[0058] In preferred embodiments of the shoe uppers described herein, multiple openings are also provided in the first and / or second layers. Incorporating multiple openings into the layers of the shoe upper offers several advantages, including improved breathability, moisture control, weight reduction, flexibility, and overall comfort, while also offering the potential for innovative designs. For example, incorporating openings into the layers improves airflow and ventilation within the shoe. This helps maintain a comfortable internal temperature by allowing heat and moisture to escape, reducing the possibility of overheating and excessive sweating. Furthermore, the openings promote better evaporation of moisture from the feet. This helps keep the feet dry and contributes to improved hygiene and comfort by reducing the risk of bacterial growth and odor. Incorporating openings directly into the layers can lead to a reduction in the overall weight of the shoe. Fewer or smaller material compartments are required to achieve the same structural support, thereby improving the performance of the shoe, especially in athletic applications. Planned placement of openings can reduce the amount of fiber material needed, potentially leading to cost savings in material usage without compromising the structural integrity of the shoe upper.

[0059] In preferred embodiments of the shoe upper described herein, the first layer, the second layer, and the intermediate layer form a single integrated structure extending from the top surface to the bottom surface of the shoe upper. The integrated structure can completely enclose the wearer's foot when in use. The integrated structure can be positioned in the forefoot region of the shoe upper. All of these embodiments allow the PA foam material to provide cushioning under the foot and especially between the foot and a stiffer sole and / or soleplate, without adding excessive compressibility and material that could be detrimental to stability in soccer, such as ease of handling a soccer ball. Furthermore, the integrated structure can completely enclose the foot and thus provide a sock-like fit. This design minimizes pressure points, creates a snug and stable fit, and improves overall comfort for the wearer. By completely enclosing the foot, the structure provides a uniform pressure distribution, reducing high-temperature areas or inflammation. By positioning the integrated structure in the forefoot region, flexibility and responsiveness are ensured where they are most needed. This can improve athletic performance in competition by resulting in better energy transfer and natural movement.

[0060] In further embodiments of the present disclosure, the object is at least partially solved by a shoe upper, particularly for athletic shoes, comprising a polyamide (PA) foam layer extending from the top surface of the shoe upper to the bottom surface of the shoe upper and surrounding the wearer's foot. In other words, the PA foam layer extends along the sides and top of the wearer's foot.

[0061] In preferred embodiments of the shoe upper described herein, the PA foam layer has a thickness of 1.0 mm to 7 mm, preferably 2.5 mm to 6.0 mm, and more preferably about 4.5 mm or about 6.0 mm.

[0062] In a preferred embodiment of the shoe upper described herein, the PA foam layer includes a first portion in the forefoot area of ​​the shoe upper and a second portion in the heel area. The second portion may be thicker than the first portion.

[0063] In a preferred embodiment of the shoe upper described herein, the first portion may have a thickness of 1.0 mm to 5.0 mm, preferably about 4.5 mm. The second portion may have a thickness of 1.0 mm to 7 mm, preferably about 6.0 mm.

[0064] Thinning the first portion of the forefoot improves flexibility, breathability, weight reduction, and ground feel, making it ideal for both performance and comfort. For example, the forefoot is the most active part of the foot during walking, running, and other movements; therefore, a thinner upper layer allows for greater flexibility, enabling the shoe to move and bend naturally with the foot, improving overall performance. Furthermore, thinner materials contribute to lighter shoes, which is especially important in sports and athletic footwear where weight reduction improves speed and endurance.

[0065] The advantage of the thicker second section is the greater cushioning effect in the side walls of the heel area and the bottom of the heel, resulting in a greater damping effect in the heel area during running, and the corresponding rearfoot and ankle portions of the foot being comfortably wrapped by the shoe upper.

[0066] In a preferred embodiment of the shoe upper described herein, the first and second parts are joined by heat or adhesive bonding. In this way, an unpleasant seam inside the shoe upper in the heel area can be avoided. Alternatively, the first and second parts may be joined by stitching, preferably zigzag stitching.

[0067] In a preferred embodiment of the shoe upper described herein, the first part includes at least two parts that are joined or connected as previously stated.

[0068] In a preferred embodiment of the shoe upper described herein, the PA foam layer is a portion that is debossed, for example, hot-pressed, to give a thinner thickness, as previously stated for the first portion. This reduces the manufacturing effort required to join / connect the PA foam layer and the two (or more) portions of the shoe upper.

[0069] In this way, an integrated (or continuum) structure can be provided in this embodiment, as previously described with respect to the aforementioned embodiments.

[0070] The shoe upper of this embodiment may also be combined with one or more of the aforementioned features of a shoe upper, comprising a layered structure having a first layer, a second layer, and an intermediate foamed layer between the first and second layers containing a polyamide (PA) foamed material, where the intermediate foamed layer is the same as the PA foamed layer described.

[0071] In further embodiments of the present disclosure, the object is at least partially solved by a shoe upper, particularly for athletic shoes, comprising a polyamide (PA) foam layer. The shoe upper may be combined with a first layer and / or a second layer, as defined in one or more of the embodiments described above. It is also conceivable that the shoe upper comprises only the PA foam layer and no further layers. The shoe upper of this embodiment may also be combined with one or more of the features of the shoe upper described above, comprising a layered structure having a first layer, a second layer, and an intermediate foamed layer between the first and second layers, comprising a polyamide (PA) foam material.

[0072] The PA foam layer provides the advantages described in relation to the previously stated embodiments. In particular, the PA foam layer provides excellent cushioning properties while providing sufficient structural support to the shoe upper, contributing to wearer comfort by absorbing shocks and impacts during exercise. Furthermore, the stretchable nature of the foam allows for better conformity and flexibility during active movements, as well as better conformity of the upper to the shape of the wearer's foot, resulting in a snug fit and comfortable wear for the wearer.

[0073] In a preferred embodiment of the shoe upper described herein, the PA foam layer is positioned in the forefoot and / or midfoot region of the shoe upper. The forefoot and midfoot regions are subjected to greater pressure and movement. The cushioning of the PA foam layer provides additional comfort by more evenly distributing pressure across the foot. Furthermore, the forefoot and midfoot regions need to accommodate a variety of foot shapes and dimensions. The PA foam layer allows the material to conform better to the contours of the foot, resulting in a snug, stable, and comfortable fit that conforms to the individual foot shape.

[0074] In preferred embodiments of the shoe uppers described herein, the material for the PA foam layer is manufactured by a supercritical foaming process as previously stated. The supercritical foaming process allows for precise control of the structure and properties of the foam, resulting in a material with improved mechanical properties, such as a higher strength-to-weight ratio and better impact resistance. This contributes to the overall durability and performance of the PA foam layer. Furthermore, supercritical foaming typically produces a more uniform cellular structure compared to conventional foaming methods. This uniformity improves the consistency of the foam's cushioning and support properties, resulting in more predictable and reliable performance in footwear. The fine and uniform cellular structure of foams produced by supercritical foaming often results in excellent thermal insulation properties. This helps maintain a comfortable temperature inside the shoe, contributing to improved wearer comfort across different environments. The supercritical foaming process can produce foams with improved breathability, as the uniform pore structure promotes better air circulation. This helps manage humidity and temperature inside the shoe, keeping feet dry and comfortable. In summary, using materials manufactured by a supercritical foaming process in the PA foam layer offers several advantages, including improved mechanical properties, a uniform cellular structure, lightweight properties, and enhanced breathability, all of which contribute to superior performance, comfort, and sustainability in footwear.

[0075] In a preferred embodiment, the PA foam layer comprises polyamide 11 (PA11), polyamide 12 (PA12), and / or polyether block amide (PEBA).

[0076] In further embodiments of this disclosure, the object is at least partially solved by athletic shoes having a shoe upper as described in any one of the embodiments herein.

[0077] Since the athletic shoes of this embodiment have an upper as described elsewhere, it is understood that the technical characteristics, advantages and improvements over the existing art shown or described with respect to the upper are also applicable to athletic shoes, and vice versa.

[0078] In a preferred embodiment of the footwear described herein, the athletic footwear is soccer footwear. The upper portion of the soccer footwear is constructed to provide improved ball handling. Features such as textured surfaces or materials that enhance grip help the player better handle and control the ball, enabling more accurate passes, dribbles, and shots.

[0079] In a preferred embodiment of the footwear described herein, the soccer shoe is laceless. By eliminating laces, the shoe can provide a more orderly and consistent striking surface against the ball. This can improve accuracy and handling when kicking, passing, or shooting, as there are no laces to interfere with contact with the ball. The absence of laces also reduces the risk of injury due to lace-related problems, such as laces coming undone and causing tripping, or laces compressing the foot. Additionally, the laceless design minimizes the risk of lace-related abrasion or discomfort. Overall, laceless soccer shoes offer a combination of functional and performance benefits, making them an attractive option for players seeking a fusion of comfort, style, and improved athletic performance on the field.

[0080] In a preferred embodiment of athletic shoes described herein, the intermediate foam layer is placed only in the throat area of ​​the shoe upper. By placing the foam layer only in the throat area, which is the area around the opening of the shoe into which the foot enters, cushioning is concentrated where it is most needed. This can improve comfort when first putting the foot in, while also securing the shoe and providing a soft, supportive feel. The throat area is often subjected to the greatest stress due to foot movement and adjustment. The foam layer can help adapt to the changing shape of the foot and provide a snug, fitted feel, thereby reducing pressure points and improving overall comfort. Furthermore, limiting the foam layer to the throat area helps keep the overall weight of the shoe lower compared to having foam throughout the entire upper. This can improve the performance of athletic or running shoes, in particular, where weight reduction is important.

[0081] The present invention includes the following embodiments.

[0082] 1.a. The first layer, b. The second layer, and c. Intermediate foam layer containing polyamide (PA) foam material between the first and second layers A shoe upper, particularly for athletic shoes, having a layered structure.

[0083] 2. The first layer is fitted so that it is on the inside of the shoe upper; The second layer is fitted so that it is on the outside of the shoe upper; The intermediate foam layer is adapted to provide elasticity and cushioning during ball contact; A shoe upper of Embodiment 1 to which at least one of the following is applied.

[0084] 3. A shoe upper according to embodiment 1 or 2, wherein the first layer forms the innermost surface of the shoe upper.

[0085] 4. A shoe upper from one of the embodiments described above, wherein the second layer forms the outermost surface of the shoe upper.

[0086] 5. A shoe upper according to one of the embodiments described above, wherein the layer structure is arranged in the vamp area of ​​the shoe upper.

[0087] 6. The shoe upper of the above embodiment, wherein the layered structure is arranged in the forefoot region of the shoe upper.

[0088] 7. A shoe upper of embodiment 5 or 6, wherein the layered structure is positioned in the toe area of ​​the shoe upper.

[0089] 8. A shoe upper according to one of the embodiments described above, wherein the first layer is the first fiber layer.

[0090] 9. A shoe upper according to one of embodiments 1 to 7, wherein the first layer includes a coating, film, synthetic leather, or leather.

[0091] 10. A shoe upper according to one of the embodiments described above, wherein the second layer is a second fiber layer.

[0092] 11. A shoe upper from one of embodiments 1 to 9, wherein the second layer includes a coating, film, synthetic leather, or leather.

[0093] 12. A shoe upper according to one of the embodiments described above, wherein one or more of the first and second layers include a fabric, preferably a knitted fabric.

[0094] 13. A shoe upper according to one of the embodiments described above, wherein one or more of the first and second layers include a polyamide (PA) material, a polyurethane (PU) material, and / or a thermoplastic polyurethane (TPU) material.

[0095] 14. A shoe upper according to one of the embodiments described above, wherein one or more of the first and second layers have a thickness of 0.05 mm to 1.0 mm, preferably 0.1 mm to 0.8 mm, more preferably 0.2 mm to 0.6 mm, and most preferably about 0.3 mm.

[0096] 15. A shoe upper according to one of the embodiments described above, wherein the intermediate foam layer has a thickness of 0.5 mm to 1.5 mm, preferably 0.7 mm to 1.2 mm, and more preferably about 1.0 mm.

[0097] 16. A shoe upper according to one of the embodiments described above, wherein the material of the intermediate foam layer is manufactured by a supercritical foaming process.

[0098] 17. A shoe upper from one of the aforementioned embodiments, further comprising a foil layer on a second layer adapted to provide a coating for the shoe upper.

[0099] 18. A shoe upper according to the above embodiment, wherein the foil layer comprises a thermoplastic polyurethane (TPU) material.

[0100] 19. A shoe upper according to Embodiment 17 or 18, wherein the foil layer has a thickness of 0.01 mm to 0.1 mm, preferably 0.02 mm to 0.07 mm, and more preferably approximately 0.05 mm.

[0101] 20. A shoe upper from one of embodiments 17 to 19, wherein a foil layer is extruded.

[0102] 21. A shoe upper from one of embodiments 17 to 20, wherein the foil layer has a hardness of 40 to 90 Shore A, preferably 50 to 70 Shore A, and more preferably about 65 Shore A.

[0103] 22. A shoe upper from one of the above embodiments, further comprising a resin layer as the outermost layer having polyurethane (PU) material.

[0104] 23. The shoe upper of the above embodiment, wherein the resin layer has a thickness of 0.01 mm to 0.1 mm, preferably 0.02 mm to 0.07 mm, and more preferably about 0.05 mm.

[0105] 24. A shoe upper according to one of the embodiments described above, wherein one or more of the layers are joined by an adhesive film, preferably a polyamide (PA) hot melt adhesive film.

[0106] 25. A shoe upper according to one of the embodiments described above, wherein the layer structure is arranged in the midfoot region and / or tongue region of the shoe upper.

[0107] 26. A shoe upper according to one of the embodiments described above, wherein the layer structure further includes, preferably, external morphological elements formed by debossing.

[0108] 27. A shoe upper from one of the above embodiments, further comprising multiple openings in the intermediate foam layer.

[0109] 28. A shoe upper of the preceding embodiment, wherein multiple openings are also provided in the first layer and / or the second layer.

[0110] 29. A shoe upper according to one of the embodiments described above, wherein the first layer, the second layer, and the intermediate layer form an integrated structure extending from the upper surface of the shoe upper to the lower surface of the shoe upper.

[0111] 30. The shoe upper of the aforementioned embodiment, in which the one-piece structure completely surrounds the wearer's foot when in use.

[0112] 31. A shoe upper of embodiment 29 or 30, wherein the integrated structure is positioned in the forefoot region of the shoe upper.

[0113] 32. An athletic shoe having a shoe upper from one of the embodiments described above.

[0114] 33. The athletic shoes of the previously described embodiment, wherein the athletic shoes are soccer shoes.

[0115] 34. A running shoe of the aforementioned embodiment, in which the soccer shoe is laceless.

[0116] 35. An athletic shoe from one of embodiments 32 to 34, wherein the intermediate foam layer is located only in the throat area of ​​the shoe upper.

[0117] The present invention will be described in more detail below with reference to the following figures. [Brief explanation of the drawing]

[0118] [Figure 1] This figure shows a layered structure for a shoe upper, particularly for athletic shoes, according to an embodiment of the present disclosure. [Figure 2] This is a side view of a soccer shoe with a laceless upper according to an embodiment of the disclosure. [Figure 3] This is a side view of a soccer shoe with a laceless upper, according to another embodiment of the present disclosure. [Figure 4] This is a top view of a shoe upper according to another embodiment of the present disclosure. [Modes for carrying out the invention]

[0119] In the following, only some possible embodiments of the present invention will be described in detail. However, the present invention is not limited thereto, and numerous other embodiments are applicable without departing from the scope of the invention. The embodiments presented can be modified in several ways and can always be combined with each other if compatible, and certain features can be omitted insofar as they are not considered necessary. In particular, the disclosed embodiments can be modified by combining certain features of one embodiment with one or more features of another embodiment.

[0120] It should be understood that not all features of the described aspects / embodiments must be present in order to realize the technical benefits provided by the disclosure as defined by the subject matter of the claims. The disclosed aspects / embodiments may be modified by combining certain features of one aspect / embodiment with one or more features of another aspect / embodiment. Specifically, a person skilled in the art will understand that features and / or functional elements of one aspect / embodiment may be combined with technically compatible features and / or functional elements of any other aspect / embodiment of the disclosure, provided that the resulting combination falls within the definition of the disclosure.

[0121] The following embodiments primarily describe shoe uppers for athletic shoes such as soccer shoes, but those skilled in the art will recognize that the disclosures according to the present invention may be equally applicable to several different technical fields and / or use cases. For example, athletic shoes for basketball, football, tennis, golf, cross-training, hiking, cycling, trail running, or snowboarding are also envisioned. The phrase "athletic shoes such as soccer shoes" means that athletic shoes are described excluding use cases not intended for athletic use, such as business shoes, chess shoes, or household slippers.

[0122] Throughout the drawings and specification of this invention, the same reference numerals refer to the same elements. For clarity and brevity, certain features, parts, elements, aspects, components and / or steps of a particular embodiment are presented without excessive detail where such detail would be obvious to those skilled in the art in consideration of the teachings herein, and / or where such detail would obscure a more suitable understanding of the embodiment.

[0123] For the sake of understanding by those skilled in the art, and / or to avoid redundancy, the descriptions in the preceding section, which also apply to the detailed descriptions below, are also referenced. Furthermore, for the sake of brevity and clarity, not all features, parts, elements, aspects, components and / or steps are explicitly indicated by reference numerals. This is especially true when those skilled in the art will recognize that there are multiple such features, parts, elements, aspects, components and / or steps.

[0124] definition As used herein, the term “forefoot region” of the shoe upper may refer to the front part of the shoe upper, for example, the forefoot portion of the shoe upper that encloses the area from the ball of the foot to the toes. It is the part of the shoe upper that contacts the foot during the propulsion and toe-off phases of the gait cycle.

[0125] As used herein, the term “toe area” of a shoe upper may refer to the front portion of the shoe upper that covers and protects the wearer’s toes. This area is typically designed to provide space and comfort to the toes while also offering protection from external elements.

[0126] As used herein, the term “midfoot region” of a shoe upper may refer to the central portion of the shoe upper that encloses the area between the ball of the foot (forefoot) and the heel. It is located approximately in the center of the longitudinal axis of the foot.

[0127] As used herein, the term “vump area” of the shoe upper may refer to a portion of the shoe upper that covers the top of the foot and includes the area that covers the toes.

[0128] As used herein, the term “supercritical foaming process” may refer to a technique used to create foams having specific properties by utilizing a supercritical fluid, in which case the supercritical fluid is a substance at a temperature and pressure above its critical point.

[0129] As used herein, the term “outer” of a shoe or shoe upper may refer to the outer side of the shoe or shoe upper. This outer side may be further from the midline of the wearer’s body when the shoe with the shoe upper is worn, compared to the inner side, which is the inside of the shoe. This outer side may extend from the toe area to the heel area.

[0130] Unless otherwise stated, the term “approximately” as used in the context of this invention may be understood to mean a large or significant degree, relating to the maximum part, or being essential. In particular, manufacturing tolerances are included by this term. Accordingly, any value or arrangement described by using the term “approximately” may deviate slightly from the value or arrangement described.

[0131] The term "and / or" is merely a relational relationship that describes the objects being related, indicating that three relationships are possible. For example, A and / or B could represent three conditions: the independent existence of A, the existence of both A and B, or the independent existence of B. In addition, the symbol " / " in this disclosure typically indicates that the objects being related before and after it form an "or" relationship.

[0132] Terms such as “upper,” “higher,” “lower,” and “below” used in this invention to indicate relative positions in space are used for the purpose of facilitating explanation in order to describe soles, shoes, elements, parts, objects and / or features shown in the drawings in relation to other shoes, elements, parts, objects and / or features.

[0133] Explanation of the diagram Figure 1 shows a layered structure 105 according to an embodiment of the present disclosure, particularly for a shoe upper (not shown) for athletic shoes.

[0134] The layered structure 105 is described from the inside out of the shoe upper. The layered structure 105 has (or includes) a first layer 110, which is a first fiber layer 110, but other materials such as coatings, films, synthetic leather or leather are also conceivable. This first fiber layer 110 may be adapted to be on the inside of the shoe upper. The first fiber layer 110 may form the innermost surface of the shoe upper, i.e., this surface refers to the inner side of the shoe upper that comes into direct contact with the foot when the shoe is worn.

[0135] The layered structure 105 also has a second layer 120, which is a second fiber layer 120, but other materials such as coatings, films, synthetic leather, or leather are also conceivable. In some embodiments, the second fiber layer 120 may be adapted to be on the outside of the shoe upper. The second fiber layer 120 may form the outermost surface of the shoe upper, i.e., this surface refers to the positive outer layer or outer surface of the shoe upper portion, and thus further layers are then placed on top of it.

[0136] The first fiber layer 110 and the second fiber layer 120 may include polyamide (PA) material. As previously described, using PA in layers such as the fiber layers improves the overall durability of the shoe upper, making it more resistant to abrasion and thereby extending the life of the footwear. Other (specific) materials may be polyamide (PA) material, polyurethane (PU) material, and / or thermoplastic polyurethane (TPU) material.

[0137] The first fiber layer 110 and the second fiber layer 120 may have a thickness of 0.05 mm to 1.0 mm, preferably 0.1 mm to 0.8 mm, more preferably 0.2 mm to 0.6 mm, and most preferably about 0.3 mm. These values ​​contribute to effective breathability, thereby aiding in humidity control and temperature regulation, and providing an optimal balance of flexibility and support. Both the first fiber layer 110 and the second fiber layer 120 may have a thickness of about 0.3 mm.

[0138] The first fiber layer 110 and the second fiber layer 120 may also include fabric, preferably knitted fabric. As described above, the first fiber layer 110 and / or the second fiber layer 120 may also include woven fabric and / or nonwoven fabric. Other (specific) materials may be as described above.

[0139] The layered structure 105 also has an intermediate foamed layer 130 containing PA foamed material between the first fiber layer 110 and the second fiber layer 120. As described above, high tensile strength and abrasion resistance, as well as additional structural support, are provided to the shoe upper. For example, polyamide 11 (PA11) can be used as a raw material in the foaming process of the PA foamed material. In another embodiment, PA12 can be used. In another embodiment, polyether block amide (PEBA) can be used. Another (specific) material can be TPEE (thermoplastic polyester elastomer) foam.

[0140] Alternatively or additionally, the intermediate foam layer may include thermoplastic polyurethane (TPU) foam instead of or in conjunction with the PA foam.

[0141] The intermediate foam layer 130 may have a thickness of 0.5 mm to 1.5 mm, preferably 0.7 mm to 1.2 mm, and more preferably about 1.0 mm.

[0142] The material for the intermediate foam layer 130 may be manufactured by a supercritical foaming process, and the foam is created with specific properties by utilizing a supercritical fluid. Thus, the overall durability and performance of the intermediate layer are improved. For example, polyamide 11 (PA11) can be used as a raw material. PA11 is a type of nylon, and Rilsan® is a trademark name used by Arkema. In another embodiment, PA12 can be used. In another embodiment, polyether block amide (PEBA) can be used.

[0143] Furthermore, the three layers, namely the first fiber layer 110, the second fiber layer 120, and the intermediate foam layer 130, can be laminated together on a sheet roll.

[0144] The layer structure 105 further comprises a foil layer 140 on a second fiber layer 120. The foil layer 140 may be adapted to provide a coating for the shoe upper, especially when applied as the outermost layer. "Coating" may refer to a thin layer of material applied to the surface of the shoe upper to improve its properties, or to give it specific characteristics, such as waterproofing, durability, breathability, protection from deterioration due to exposure to sunlight (ultraviolet rays), or prevention of dirt and stains.

[0145] The foil layer 140 comprises a thermoplastic polyurethane (TPU) material having high durability and abrasion resistance. An advantage of the TPU foil layer 140 is that dissimilar coatings, such as printed layers or some kind of protrusions, can be applied on it. Furthermore, the TPU foil layer 140, as the outermost layer, can be beneficial for bonding the shoe upper to the sole, which is typically a relatively stiff sole for soccer shoes. Another (specific) material for the foil layer 140 may be PA (polyamide).

[0146] The foil layer 140 has a thickness of 0.01 mm to 0.1 mm, preferably 0.02 mm to 0.07 mm, and more preferably about 0.05 mm.

[0147] The foil layer 140 can be extruded. Other (specific) manufacturing processes, such as coating, are also conceivable.

[0148] The foil layer 140 has a hardness of 40 to 90 Shore A, preferably 50 to 70 Shore A, and more preferably about 65 Shore A.

[0149] The layered structure 105 further comprises a resin layer as the outermost layer having polyurethane (PU) material. As stated, the PU resin provides excellent abrasion resistance.

[0150] The resin layer may have a thickness of 0.01 mm to 0.1 mm, preferably 0.02 mm to 0.07 mm, and more preferably about 0.05 mm.

[0151] The five layers 110, 120, 130, 140, and 150 are each joined by an adhesive film, such as a PA hot melt adhesive film. Other (specific) materials may be a TPU hot melt adhesive film or a PU hot melt adhesive film.

[0152] Figure 2 shows a side view of a soccer shoe 200 with a laceless shoe upper 201 according to an embodiment of the present disclosure.

[0153] The shoe upper 201 comprises a layered structure 205 having a first layer 210, a second layer 220, and an intermediate foamed layer 230 containing PA foam material between the first layer 210 and the second layer 220. These layers may be similar to the first layer 110, second layer 120, and intermediate foamed layer 130 in Figure 1.

[0154] The first layer 210 is a first fiber layer 210, but other materials such as coatings, films, synthetic leather, or leather are also conceivable.

[0155] The second layer 220 is a second fiber layer 220, but other materials such as coatings, films, synthetic leather, or leather are also conceivable.

[0156] The layer structure 205 also includes a foil layer 240 similar to the foil layer 140 in Figure 1.

[0157] The layer structure 205 may also include a resin layer similar to the resin layer 150 in Figure 1.

[0158] The layered structure 205 is positioned in the bump area 201a, forefoot area 201b, and toe area 201c of the shoe upper 201 and is covered by the foil layer 140. Alternatively, the foil layer 140 may also be omitted in these areas. As described above, the layered structure 205 in these specific areas of the shoe upper 201 provides additional cushioning and impact protection, reducing the risk of injury from impacts or external forces.

[0159] When the shoe upper 201 is laceless, the layer structure 205 having the foil layer 140 is also positioned in the throat region 201d of the shoe upper 201. With respect to the shoe upper with laces, the layer structure 205 having the foil layer 140 is further positioned in the tongue region of the shoe upper 201. As previously stated, the foil layer 140 may also be omitted in these regions with respect to the shoe upper with laces.

[0160] On the outer surface of the midfoot region of the shoe upper 201, there are multiple openings 260 in the intermediate foam layer 230. These can result in improved breathability, reduced weight, improved flexibility, optimized cushioning, better thermal regulation, and effective humidity control. "Multiple" may refer to a number greater than one, and often indicates a larger or unspecified number to achieve the stated technical effects.

[0161] Further openings 260 are provided in the first fiber layer 210 and / or the second fiber layer 220. However, the openings 260 are also provided only in the intermediate foam layer 230.

[0162] Alternatively or additionally, the opening 260 may also be located on the inner surface of the shoe upper 201.

[0163] Figure 3 shows a side view of an athletic shoe 300 according to an embodiment of the present disclosure, in which the shoe upper 301 is laceless.

[0164] The shoe upper 301 comprises a layered structure 305 having a first layer 310, a second layer 320, and an intermediate foamed layer 330 containing PA foam material between the first layer 310 and the second layer 320. These layers may be similar to the first layer 110, second layer 120 and intermediate foamed layer 130 in Figure 1, and the first layer 210, second layer 220 and intermediate foamed layer 230 in Figure 2.

[0165] The first layer 310 is a first fiber layer 310, but other materials such as coatings, films, synthetic leather, or leather are also conceivable.

[0166] The second layer 320 is a second fiber layer 320, but other materials such as coatings, films, synthetic leather, or leather are also conceivable.

[0167] The layer structure 305 may also include a foil layer similar to the foil layer 240 in Figure 2. The layer structure 305 may also include a resin layer similar to the resin layer 150 in Figure 1.

[0168] The layered structure 305 is positioned in the forefoot region 301b, the toe region 301c, and the midfoot region 301e of the shoe upper 201.

[0169] The layered structure 205 further includes one or more debossed contour elements 370 for providing a specific pattern in the toe area 301c and the forefoot area 301b. As previously mentioned, there may be several types of contour elements 370, such as rubber protrusions and / or printed protrusions.

[0170] Figure 4 shows a top view of the shoe upper 401 according to an embodiment of the present disclosure.

[0171] The shoe upper 401 is in a two-dimensional form before it takes on and maintains its three-dimensional form.

[0172] The shoe upper 401 comprises a polyamide (PA) foam layer 430 extending from the top surface of the shoe upper 401 to the bottom surface of the shoe upper 401, surrounding the wearer's foot. As described, the PA foam layer extends along the sides and top of the wearer's foot, if it has its three-dimensional shape.

[0173] The PA foam layer 430 has a thickness of 1.0 mm to 7.0 mm, preferably 2.5 mm to 6.0 mm, and more preferably about 4.5 mm or about 6.0 mm.

[0174] The PA foam layer 430 includes a first portion 440 in the forefoot area and a second portion 450 in the heel area of ​​the shoe upper 400.

[0175] The first portion 440 has a thickness of 1.0 mm to 5.0 mm, or approximately 4.5 mm.

[0176] The second portion 450 has a thickness of 1.0 mm to 7 mm, or approximately 6.0 mm.

[0177] As stated, the different thicknesses result in advantages such as flexibility in the forefoot area and cushioning in the heel area of ​​the shoe upper 401.

[0178] The first part 440 and the second part 450 are partially joined by heat or adhesive bonding. This can be applied to be "seamless from end to end" so that an unpleasant seam inside the shoe upper 400 in the heel area can be avoided. Below them, the first part 440 and the second part 450 are joined by suture, i.e., zigzag suture. Other suture techniques are also conceivable.

[0179] In this way, a single (or continuous) body for the shoe upper 401 can be provided from the PA foam layer 430.

[0180] The shoe upper 401 may also have a foil layer (not shown) similar to the foil layer 240 in Figure 2.

[0181] A method for manufacturing such a shoe upper 400 may include the steps of wrapping a shoe upper 401 having a PA foam layer 430 and a first portion 440 and a second portion 450 around a shoe last (not shown), and joining the lower portion of the two parts directly to the upper portion of the two parts along the rim. The joining is preferably done by stitching.

[0182] The sole can then be bonded to the lower part of the two sections with adhesive. Other bonding techniques for the sole to the shoe upper 401 are also conceivable. [Explanation of Symbols]

[0183] 105 layer structure 110 First fiber layer 120 Second fiber layer 130 Intermediate foam layer 140 TPU foil layer 150 resin layer 200 soccer shoes 201 Shoe Upper 201a Bump area 201b Forefoot area 201c Toe Area 201d Throat region 205 layer structure 210 First fiber layer 220 Second fiber layer 230 Intermediate foam layer 240 foil layer 260 opening 300 athletic shoes 301 Shoe Upper 301b Forefoot area 301c Toe Area 301e Midfoot area 305 layer structure 310 First fiber layer 320 Second fiber layer 330 Intermediate foam layer 370 External Elements 400 shoe upper 401 Shoe Upper 430 Polyamide (PA) foam layer 440 Part 1 450 Part 2

Claims

1. a. The first layer, b. The second layer, and c. An intermediate foamed layer between the first layer and the second layer, comprising a polyamide (PA) foamed material. A shoe upper having a layered structure.

2. The first layer is fitted so as to be on the inside of the shoe upper; The second layer is fitted so as to be on the outside of the shoe upper; The aforementioned intermediate foam layer is adapted to provide elasticity and cushioning when the ball is in contact with it; The shoe upper according to claim 1, wherein at least one of the following is applied.

3. The shoe upper according to claim 1, wherein the first layer forms the innermost surface of the shoe upper.

4. The shoe upper according to claim 1, wherein the second layer forms the outermost surface of the shoe upper.

5. The shoe upper according to claim 1, wherein the layer structure is arranged in the bump region of the shoe upper.

6. The shoe upper according to claim 1, wherein the layer structure is arranged in the forefoot region of the shoe upper.

7. The shoe upper according to claim 5 or 6, wherein the layer structure is arranged in the toe area of ​​the shoe upper.

8. The shoe upper according to claim 1, wherein the first layer is a first fiber layer.

9. The shoe upper according to claim 1, wherein the first layer includes a coating, a film, synthetic leather, or leather.

10. The shoe upper according to claim 1, wherein the second layer is a second fiber layer.

11. The shoe upper according to claim 1, wherein the second layer includes a coating, a film, synthetic leather, or leather.

12. The shoe upper according to claim 1, wherein one or more of the first layer and the second layer include fabric.

13. The shoe upper according to claim 1, wherein one or more of the first layer and the second layer comprises a polyamide (PA) material, a polyurethane (PU) material, and / or a thermoplastic polyurethane (TPU) material.

14. The shoe upper according to claim 1, wherein one or more of the first layer and the second layer have a thickness of 0.05 mm to 1.0 mm.

15. The shoe upper according to claim 1, wherein the intermediate foam layer has a thickness of 0.5 mm to 1.5 mm.

16. The shoe upper according to claim 1, wherein the material of the intermediate foam layer is manufactured by a supercritical foaming process.

17. The shoe upper according to claim 1, further comprising a foil layer on the second layer adapted to provide a coating for the shoe upper.

18. The shoe upper according to claim 17, wherein the foil layer comprises a thermoplastic polyurethane (TPU) material.

19. The shoe upper according to claim 17 or 18, wherein the foil layer has a thickness of 0.01 mm to 0.1 mm.

20. The shoe upper according to claim 17 or 18, wherein the foil layer is extruded.

21. The shoe upper according to claim 17 or 18, wherein the foil layer has a hardness of 40 to 90 Shore A.

22. The shoe upper according to claim 1, further comprising a resin layer as the outermost layer having polyurethane (PU) material.

23. The shoe upper according to claim 22, wherein the resin layer has a thickness of 0.01 mm to 0.1 mm.

24. The shoe upper according to claim 1, wherein one or more of the aforementioned layers are joined by an adhesive film.

25. The shoe upper according to claim 1, wherein the layer structure is arranged in the midfoot region and / or tongue region of the shoe upper.

26. The shoe upper according to claim 1, wherein the layer structure further includes external morphological elements.

27. The shoe upper according to claim 1, further comprising a plurality of openings in the intermediate foam layer.

28. The shoe upper according to claim 27, wherein the plurality of openings are also provided in the first layer and / or the second layer.

29. The shoe upper according to claim 1, wherein the first layer, the second layer, and the intermediate layer form an integrated structure extending from the upper surface of the shoe upper to the lower surface of the shoe upper.

30. The shoe upper according to claim 29, wherein the integrated structure completely surrounds the wearer's foot when in use.

31. The shoe upper according to claim 29 or 30, wherein the integrated structure is disposed in the forefoot region of the shoe upper.

32. An athletic shoe comprising the shoe upper described in claim 1.

33. The athletic shoe according to claim 32, wherein the athletic shoe is a soccer shoe.

34. The athletic shoe according to claim 32 or 33, wherein the soccer shoe is laceless.

35. The athletic shoe according to claim 32 or 33, wherein the intermediate foam layer is disposed only in the throat region of the shoe upper.

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