Liquid TPU stencil printing

Abstract

The present invention provides a method for manufacturing apparel or footwear, preferably sports shoes. [Solution] The method includes (a) preparing a liquefied polymer (110), (b) placing the liquefied polymer on a support layer via a stencil including one or more cutouts (120), wherein the liquefied polymer is applied through one or more cutouts of the stencil, thereby printing the liquefied polymer on the support layer in a certain pattern, (c) optionally removing the stencil (130), and (d) curing the printed liquefied polymer on the support layer (140), thereby obtaining apparel or footwear, or at least a part thereof (150).

Description

[Technical Field]

[0001] The present invention relates to a method for manufacturing apparel or footwear, preferably sports shoes; apparel or footwear and outsoles manufactured according to this method; and sports shoes comprising apparel or footwear or outsoles. [Background technology]

[0002] Various types of sports require specific types of footwear to ensure performance and functionality. Current technologies for manufacturing footwear or apparel, such as sports shoes, typically require a combination of advanced materials and precision manufacturing techniques to improve durability, performance, comfort, and sustainability.

[0003] Injection molding is widely used in sole manufacturing. Specifically, injection molding is precise and has the ability to bond materials such as ethylene vinyl acetate (EVA), thermoplastic polyurethane (TPU), and rubber into a single outsole. This allows for complex designs and various levels of stiffness. However, injection molding comes with high initial setup costs, limited material compatibility, and concerns about the environmental impact of petroleum-based thermoplastics. Direct injection molding or direct attachment techniques provide a strong bond between the outsole and upper, eliminating the need for adhesives, but require expensive machinery and limit the design of complex outsoles.

[0004] Another method is compression molding, which is cost-effective for mass production and results in a very durable outsole. However, compression molding has the disadvantage of lacking the design flexibility of injection molding. Moreover, this method generates even more waste during the process, which is not ecologically beneficial.

[0005] Vulcanization is another common method for creating durable and resilient rubber outsoles, particularly for high-performance sports, but it is energy-intensive, environmentally burdensome due to the use of chemicals, and not well-suited for complex, flexible patterns. Laser cutting and laser engraving allow for precision in outsole design and add functional texture or aesthetic detail, but are limited to certain materials and may leave surface imperfections that require additional finishing.

[0006] However, a common drawback of these soles is that the sole manufacturing process cannot be flexibly modified or implemented during the overall manufacturing process, making their application rather inflexible. Furthermore, another drawback is the inflexible design of the sole material; once prepared, the sole material cannot be easily modified or adapted to the specific needs of the sole.

[0007] Furthermore, another drawback of conventional technology is the use of hazardous and harmful liquids in the manufacture of lightweight footwear. Typically, vapor-type solvents that can be quickly removed are used during the manufacturing process of lightweight sportswear or footwear. However, the use of these hazardous solvents requires expert handling and specific means of transport. Moreover, this use results in the generation of chemical waste, and the removal and transport of such chemical waste is costly and complex, and furthermore, undesirable from an environmental perspective, so the generation of such chemical waste is undesirable throughout the overall process. [Overview of the Initiative]

[0008] Therefore, an object of the present invention is to provide an improved method and outsole, as well as a sports shoe comprising apparel or footwear, in order to overcome at least partially the aforementioned defects of the prior art.

[0009] The problems outlined above are addressed by aspects of the present invention.

[0010] In a first aspect, the present invention relates to a method for manufacturing apparel or footwear, preferably for sports shoes, a. A step of preparing a liquefied polymer, b. A step of placing a liquefied polymer onto a support layer via a stencil and / or screen containing one or more cutouts, wherein the liquefied polymer is applied through one or more cutouts of the stencil, thereby printing the liquefied polymer onto the support layer in a specific pattern. c. Optional step of removing the stencil, d. A step of curing a printed liquefied polymer onto a support layer to obtain apparel or footwear, or at least a portion thereof (150), This applies to methods that include [specific methods].

[0011] The present invention demonstrates a method that provides a more beneficial and flexible process for manufacturing apparel or footwear. Conventional sole structures, such as outsoles for sports shoes, are typically manufactured by, for example, injection molding. The present invention is based on a different method, namely, the preparation of a liquefied polymer by mixing a polymer with a solvent and / or additives, and the liquefied polymer is printed onto a support layer via a stencil. The present invention is more efficient than methods known in the prior art because it incorporates the step of placing and printing the liquefied polymer onto the support layer into the manufacturing process. Furthermore, the application of the liquefied polymer via a stencil provides flexibility for customizing apparel or footwear and the overall process. This dual capability helps improve apparel or footwear and the methods for manufacturing them. Additives may affect stability, viscosity, curability, and / or solubility.

[0012] The method of the present invention may be used for the manufacture of accessories and / or clothing. For example, the method may be used for the back of a football glove or the upper of a football boot. In this regard, for example, silicone may be used in the method of the present invention and may be stencil printed, for example.

[0013] This method for manufacturing apparel or footwear eliminates the need for additional process steps to generate patterns, thereby reducing cycle times and increasing output. Furthermore, the combination of liquefied polymer placement, application, and printing in a single step avoids the costs of post-processing equipment such as laser or chemical etching systems, and also reduces labor costs. For example, when printing on a structured support layer, the structure is also transferred onto the apparel and / or footwear. Moreover, patterns obtained by the application and curing of liquefied polymer via stencils result in fewer processing steps overall, which leads to a reduction in the overall process energy consumption for heating, handling, or operating additional machinery. The method of the present invention further enables individual changes or customizations during the process, such as unique branding, part identification, or product differentiation, by adapting stencils without the need to change the process. In this way, the processing costs and time required to create new molds or dies when different patterns and / or surface structures are needed are avoided, resulting in a more cost-effective method.

[0014] Furthermore, using the method of the present invention provides a more scalable process. When increasing production volume, the method of the present invention remains efficient. Specifically, the attachment of parts and / or apparel or footwear can be performed during the curing step, which can be incorporated as an automated process, resulting in high repeatability and high productivity.

[0015] Furthermore, when using the method of the present invention, deposition based on adhesives and injection molding is avoided, for example, and less material is required, thus providing apparel or footwear in a cost-effective and time-efficient manner. Moreover, the present invention provides a support layer that is advantageous in terms of transfer and flexibility for subsequent steps such as direct attachment processes.

[0016] Therefore, the method of the present invention improves the overall process speed, cost, flexibility through automation (automated and scalable methods), material efficiency, risk management (backup options for process flexibility, reduced handling of hazardous materials), and customization for manufacturing apparel or footwear.

[0017] Apparel or footwear can be used in particular to create lighter and thinner, for example, outsoles, but apparel or footwear can also be used to enhance the design and visual appeal of sports shoes for specific sports, for example, by placing liquefied polymers in specific zones of footwear and / or sportswear. Specifically, finer and more elegant apparel and / or footwear that cannot be achieved by conventional processes such as molding can be obtained by the method of the present invention.

[0018] In this way, liquefied polymers can be positioned more precisely and efficiently, and apparel or footwear can be manufactured more efficiently. This eliminates material waste, for example, from cutting off excess material. Thus, the method according to the present invention provides an improved method for creating inventive sole structures, for example, for sports shoes, by consuming only the amount of material required and avoiding the generation of any waste.

[0019] The present invention demonstrates the provision of apparel or footwear that reduces the overall weight of the apparel or footwear while simultaneously enhancing the performance of athletes. When using apparel or footwear according to the present invention, its lightweight properties substantially improve the running performance of the wearer, such as an athlete. The reduced weight results in an overall improvement in the training experience and outcomes of the apparel or footwear. Specifically, the apparel or footwear of the present invention also exhibits a significant weight improvement compared to conventional apparel or footwear. Furthermore, the apparel or footwear has the advantage of being individually designed based on the needs and requirements of athletes, for example. In addition, due to the inventive materials and manufacturing methods, the apparel or footwear becomes considerably thinner, and the apparel or footwear as a whole becomes more desirable and visually appealing.

[0020] "Apparel" as used in this disclosure refers to any part of clothing or garments designed to be worn, but is not limited to these. Apparel encompasses a broad range of items, including outerwear, underwear, footwear, and accessories, made for a variety of purposes, such as fashion, functionality, or cultural expression. Apparel also includes any part of sportswear.

[0021] "Footwear" as used in this disclosure is any garment worn on the feet for protection, comfort, and / or style. Footwear includes a broad range of articles, such as shoes, sandals, boots, slippers, athletic shoes and / or sports shoes in particular. Footwear provides support, cushioning, and / or traction. Footwear also includes any part of shoes or footwear or sportswear that provides structure, texture, and / or traction to the wearer.

[0022] The "polymer" according to the present disclosure is, but not limited to, preferably a polymer made of a durable and long-lasting material. Specifically, the polymer material provides a contact zone that comes into contact with the ground, for example, during walking. Furthermore, the polymer layer provides flexibility, durability, cushioning and support in apparel or footwear.

[0023] The "support layer" according to the present disclosure is, but not limited to, a structural or functional component in a system designed to provide stability, protection, or additional functions to the polymer layer. The support layer may be a thin film such as a film layer used for disposing the polymer on the aforementioned support layer. The liquefied polymer can be flexibly and easily further processed in an attachment process such as hot-pressing the disposed polymer onto an additional component (e.g., a midsole and / or an outsole) via the support layer, or can be transported, stored on the support layer and subjected to another process step. The support layer may help maintain the structural integrity of apparel or footwear, or a portion thereof. The support layer does not necessarily need to be a part of sports shoes, and may for example be removed when further processing apparel or footwear. The support layer may for example be a midsole, and may include a material that absorbs impact to reduce the load on joints. The support layer is made of a durable material to withstand wear and tear during regular use. The support layer functions together with apparel or footwear and other layers of sports shoes. For example, the support layer may include woven fabric, fibers, polyester-based materials, nylon, and the like.

[0024] "Liquefied polymer" should be understood as, but not limited to, a polymer having semi-solid or liquid physical properties. The liquefied polymer includes a polymer and a liquifying element such as a solvent.

[0025] "Curing" according to the present disclosure should be understood as, but not limited to, chemical and / or physical processes of solidification, setting, and / or coagulation of a polymer. Curing may be performed using radiation.

[0026] "Mixing" according to the present disclosure should be understood as, but not limited to, a process of combining one or more substances to obtain a mixture of individual substances, preferably in liquid form.

[0027] "Placing / Disposing" according to the present disclosure should be understood as, but not limited to, for example a process of applying and / or depositing a liquefied polymer onto a support layer.

[0028] "Printing" according to the present disclosure should be understood as, but not limited to, any process used for applying, for example, design elements, pattern elements, branding elements, or functional elements to a shoe component such as an upper, a sole, or an insole. Printing may serve aesthetic, functional, or branding purposes.

[0029] The apparel or footwear may be an outsole of sports shoes. The liquefied polymer may comprise a polymer and a solvent. The polymer may be a mixture of one or more types of polymers. The mixture may comprise pigments, colorants, and / or additives. The solvent may be a water-soluble solvent selected from the group comprising ethanol, acetone, isopropyl alcohol, methanol, glycerol, propylene glycol, and / or dimethyl sulfoxide (DMSO), and is preferably DMSO.

[0030] These solvents have been shown to emit fewer volatile organic compounds (VOCs) compared to conventional organic solvents, making them more environmentally friendly and compliant with environmental regulations. Furthermore, the solvents of the present invention decompose more readily in the environment, reducing long-term environmental impacts. Moreover, these particular solvents are less toxic and hazardous than solvents commonly used in the prior art, reducing health risks such as respiratory problems or skin irritation when handling them. The solvents of the present invention are also non-flammable, enhancing workplace safety by minimizing the risk of fire.

[0031] The solvents of this invention offer cost-effectiveness as another significant advantage, resulting from simpler waste treatment, lower processing costs, and economical dilution with water, reducing reliance on expensive chemicals. These solvents also simplify equipment cleaning—often requiring water specifically for residue removal—and allow for flexible formulation adjustments through easy mixing and dilution, thus increasing process efficiency. Furthermore, they contribute to better product quality, such as smoother and more uniform coatings or adhesives. These advantages are therefore even more apparent in applications such as water-based solutions.

[0032] When a water-soluble solvent is used, the step of curing the printed liquefied polymer may include treating the printed liquefied polymer with an extractant, preferably water.

[0033] For example, to extract a solvent, such as DMSO, from a printed liquefied polymer placed on a support layer, an extractant, such as water, may be applied by spraying the extractant onto the printed liquefied polymer. In this way, the extractant is applied to the printed polymer, which is still liquid. In this manner, the extractant extracts the solvent from the liquefied polymer, causing the printed polymer on the support layer to solidify. Another method involves, for example, immersing the printed liquefied polymer in a solution tank containing an extractant, such as water. For example, the printed liquefied polymer remains in contact with the water for several minutes. In this way, the solvent in the liquefied polymer is removed by the extractant present in the solution tank. Specifically, the longer the contact time, the more solvent may be removed.

[0034] Specifically, after extracting the solvent from the printed liquefied material, the solvent / extractant phase can be removed from the printed liquefied polymer, for example, by wiping. While we do not wish to be bound by any theory, it is conceivable that the extractant may evaporate more rapidly than the solvent, for example, during the curing step. In this way, the solvent remains on the surface of the printed liquefied polymer. This remaining solvent can then liquefy the printed polymer. The extraction step may be performed two or more times. In this way, it is ensured that the solvent is sufficiently removed.

[0035] The immersion step (for example, in a tank) may be carried out for at least 1 hour. Preferably, the immersion step (for example, in a tank) may be carried out for 2 hours. More preferably, the immersion step (for example, in a tank) may be carried out for 4 hours. Even more preferably, the immersion step (for example, in a tank) may be carried out for 8 hours. Most preferably, the immersion step (for example, in a tank) may be carried out for 12 hours. The immersion step may be carried out for 10 days, preferably 7 days.

[0036] The method is, e. The step of removing the cured printed polymer from the support layer, thereby obtaining at least a portion of the apparel or footwear, f. The step of attaching the apparel or footwear portion to the base layer, This may further include:

[0037] The method is, g. The step of attaching a support layer containing a cured printed polymer layer to the base layer, specifically to the underside of the midsole, h. The step of removing the support layer from a portion of the apparel or footwear, thereby obtaining at least a portion of the apparel or footwear attached to the base layer, This may further include:

[0038] The method steps of the present invention provide apparel or footwear in a cost-effective and time-efficient manner because they require less material while avoiding deposition based on adhesives and injection molding, for example. Furthermore, the method uses a support layer which is advantageous in terms of transport and flexibility during the process and in subsequent steps such as direct attachment processes.

[0039] Specifically, the attachment involves bringing the portion / base layer of the apparel or footwear to be attached (or both) into contact with a solvent, such as DMSO. In this way, the solvent may redissolve the material in contact.

[0040] Specifically, the solvent must be at least 0.0001 ml / cm³ 2 It can be used in an amount of . According to some embodiments, the solvent is preferably at least 0.001 ml / cm³. 2 It can be used in an amount of . According to some embodiments, the solvent is more preferably at least 0.01 ml / cm³. 2 It can be used in an amount of . According to some embodiments, the solvent is more preferably at least 0.1 ml / cm³. 2It can be used in an amount of . According to some embodiments, the solvent is most preferably at least 1 ml / cm³. 2 Can be used in that quantity

[0041] In this regard, the solvent can be applied by various means such as brushing, spraying, and / or immersion. Specifically, the amount of solvent may depend on the type of polymer used.

[0042] According to some embodiments, installation may be carried out at a temperature between 30 and 300°C. According to some embodiments, installation may preferably be carried out at a temperature between 50 and 280°C. According to some embodiments, installation may most preferably be carried out at a temperature between 70 and 260°C.

[0043] For example, when heating and compressing a portion of apparel, the temperature may be adjusted to be sufficient to at least soften the components and, for example, the midsole material. The temperature may differ from these specific temperature ranges.

[0044] In addition, or instead, installation may be completed within a maximum of 12 minutes. Preferably, installation may be completed within a maximum of 10 minutes. More preferably, installation may be completed within a maximum of 6 minutes. Even more preferably, installation may be completed within a maximum of 4 minutes. Even more preferably, installation may be completed within a maximum of 2 minutes. Most preferably, installation may be completed within a maximum of 1 minute.

[0045] The step of attaching a portion of the apparel or footwear to the base layer may include one or more of the following: bonding, lamination, press heating, compression, and / or injection molding.

[0046] In addition, or instead, the step of attaching a part of the apparel or footwear is, i. A step of melting the part, j. A step of sintering the molten portion, k. A step of melting the sintered portion again, l. The step of welding the melted portion again, m. A step of pressing the welded portion against the base layer, It may include.

[0047] In this regard, the base layer may be the midsole. Specifically, the support layer of a portion of the apparel or footwear may be removed. However, it is conceivable that the support layer of a portion of the apparel or footwear may be left and removed in a later step. Specifically, also, if DMSO is used to redissolve, for example, a portion and / or the base layer, for example, the midsole, each or both components are brought into contact with the solvent, i.e., DMSO. Then, a portion of the apparel, including a stencil-printed pattern that is placed on a support layer, for example, a film layer, is placed on the midsole. The film layer may be removed after the portion has been placed on the midsole.

[0048] The midsole may be placed on a support structure to prevent deformation, for example, when subjected to pressure. Specifically, components including a negative of the pattern of the midsole / outsole surface structure are placed on a support layer, for example, a film layer. Subsequently, the portion placed on the base layer undergoes a drying step. During the drying step, weights are applied. The method may further include a step of drying the base layer together with the welded portion.

[0049] In the drying step, a weight of at least 100g is applied. In some embodiments, a weight of at least 1kg is applied in the drying step. In some embodiments, a weight of at least 10kg is applied in the drying step. In some embodiments, a weight of at least 100kg is applied in the drying step.

[0050] In this way, to ensure a sufficient and complete bond, it is made that all parts of the apparel are in contact with the base layer, for example, the midsole surface.

[0051] For example, when a portion is heated and pressed onto a base layer, and when DMSO is used to remelt the portion and / or the base layer, which is, for example, the midsole, each or both are brought into contact with the solvent, i.e., DMSO. Subsequently, a portion of the apparel, including a stencil-printed pattern, which is placed on a support layer, for example, a film, is placed on the midsole.

[0052] Specifically, the midsole may be placed on a support structure to prevent deformation, for example, when subjected to pressure. Then, a top piece showing a negative of the pattern of the midsole / outsole structure is placed on a transfer film. The portion then placed on the base layer undergoes a compression step. The method may further include a step of compressing the base layer containing the portion, preferably using heat. During the compression step, weights are applied.

[0053] In the compression / drying step, a weight of at least 10g is applied. In some embodiments, a weight of at least 100g is applied in the drying step. In some embodiments, a weight of at least 1kg is applied in the drying step. In some embodiments, a weight of at least 10kg is applied in the drying step. It is also conceivable that a weight of at least 50kg, preferably 80kg, and more preferably at least 100kg is applied in the compression / drying step.

[0054] It is conceivable that a combination of attachment and heat compression may be possible. Specifically, attachment / bonding via a solvent, such as DMSO, may be applied, followed by a heat compression step. In this way, it is ensured that a strengthened and sufficient bond occurs, particularly at the edges of the apparel and / or parts and / or base layers.

[0055] Partial welding can be performed using infrared (IR), high-frequency (HF) radiation, and / or ultrasonic radiation.

[0056] The placement of liquefied polymers may include one or more additive manufacturing methods such as dispensing, spraying, spraying, printing, coating, spin coating, casting, deposition, dipping, brushing, roller coating, injection, and / or stereolithography (SLA) and / or selective laser sintering (SLS).

[0057] Liquid polymers can be placed on a support layer by 3D printing. 3D printing includes additive manufacturing methods such as stereolithography and laser sintering. According to stereolithography, light cross-bonds chemical monomers and oligomers to form a layer-wise polymer, creating a 3D-printed object. According to laser sintering, a laser heats and sintersects powdered material. By directing the laser to positions in space defined by a 3D model, the materials are bonded together to create a solid structure. Another example of additive manufacturing is molten deposition modeling, where parts are fabricated by extruding small beads or flows of material that solidify instantly to form layers. When both the midsole and upper are manufactured using a 3D printing process, the midsole and upper may be manufactured in separate 3D printing processes and then joined together, for example, by bonding, welding, or sewing. Alternatively, the midsole and upper may be manufactured together in a single manufacturing step.

[0058] The footwear portion may be the outsole of a sports shoe. The support layer may be the midsole and / or shoe upper, and / or parts thereof. The support layer may be a film.

[0059] Therefore, the liquefied polymer is placed, for example, on the midsole to form the outsole. In preferred embodiments, the polymer material of the midsole may be ethylene vinyl acetate (EVA), thermoplastic polyurethane (TPU), or supercritical foam. These materials are relatively lightweight while providing good cushioning properties.

[0060] The midsole may contain polymers selected from the group including thermoplastic polyurethane (TPU), polyether block amide (PEBA), ethylene vinyl acetate (EVA), and / or thermoplastic elastomers, preferably polyurethane and / or expandable thermoplastic polyurethane (eTPU).

[0061] The liquefied polymer may be placed on one or more sections of a sports shoe, including the toe section, forefoot section, heel section, midsole section, sidewall section, and / or upper section.

[0062] The liquefied polymer may be placed on one or more predetermined parts of apparel or footwear, determined using a torsion map, an abrasion map, and / or a pressure map. The liquefied polymer may be applied to various sections and individually textured in subsequent steps. Furthermore, the liquefied polymer may be placed on multiple sections.

[0063] The liquefied polymer can be placed on one or more predetermined parts of a sports shoe, determined using torsion maps, abrasion maps, and / or pressure maps. This has the advantage that the apparel or footwear can be individually tailored to the specific needs of the user.

[0064] The liquefied polymer can be placed on the support layer with a thickness of 0.1 to 10 mm. Preferably, the liquefied polymer can be placed on the support layer with a thickness of 0.12 to 4 mm. More preferably, the liquefied polymer can be placed on the support layer with a thickness of 0.15 to 2 mm. Even more preferably, the liquefied polymer can be placed on the support layer with a thickness of 0.17 to 1 mm. Most preferably, the liquefied polymer can be placed on the support layer with a thickness of 0.2 to 0.8 mm.

[0065] The thickness of the apparel or footwear, or at least a portion thereof, may be 0.3 to 0.7 mm. Preferably, the thickness of the apparel or footwear, or at least a portion thereof, may be 0.5 mm.

[0066] The stencil may be a screen, and preferably a mesh.

[0067] The liquefied polymer may be placed in a first section of apparel or footwear with a kinematic viscosity coefficient of 50,000 to 200,000 mPa·s, and in a second section of apparel or footwear with a kinematic viscosity coefficient of 10,000 to 50,000 mPa·s.

[0068] The contact angle θ between the liquefied polymer and the support layer may be 30° to 110°, preferably 40° to 90°, and more preferably 50° to 70°.

[0069] The curing step can be carried out using radiation.

[0070] The liquefied polymer may comprise a polymer and a solvent. The polymer may be selected from the group consisting of polyurethane (PU), thermoplastic polyamide (TPE-A or TPA), thermoplastic polyester (TPE-E or TPE), thermoplastic styrene block copolymer (TPE-S or TPS), thermoplastic polyurethane (TPE-U or TPU), thermoplastic vulcanized material (TPE-V or TPV), rubber or ethylene vinyl copolymer (EVA), preferably thermoplastic polyurethane (TPE-U or TPU), and / or combinations thereof.

[0071] These polymers enable enhanced fit. Furthermore, the use of these particular polymers has been shown to achieve a time-efficient and sustainable process in apparel or footwear production, while providing a more durable and long-lasting sole structure. Suitable polymer materials may be elastic foam materials such as thermoplastic elastomers and / or elastomers. The preferred material used in this disclosure is a thermoplastic elastomer.

[0072] The liquefied polymer and the support layer (which is not a film layer) may be soluble in a solvent, and it is preferable that the solvent is the same.

[0073] The polymers of the support layer and the liquefied polymer may be TPU.

[0074] The pattern may be a grid, lattice, line, spiral, honeycomb, dot, wave, sinusoidal pattern, or any combination thereof. Specifically, the pattern may be selected from the group including one or more of rectangles, grids, lattices, lines, spirals, honeycomb, dots, waves, or any combination thereof. Apparel or footwear may be individually designed and may offer multiple patterns. It is conceivable that apparel or footwear may have two or more surface structures. Alternatively, or in addition, the pattern may be a contour line and / or a filled pattern.

[0075] These specific patterns further enhance the traction of apparel or footwear, helping the wearer maintain a firm foothold on various surfaces. This improved traction results in a greater sense of stability, reducing the likelihood of slipping or losing balance. This is particularly important in sports requiring sudden stops, lateral movements, and sharp turns, such as running, football, basketball, and tennis.

[0076] The solvent is from the group of solvent-based solvents and / or aqueous solvents, preferably from the group of solvent-based solvents, more preferably (C1-C6) ethers, (C1-C 10 ) may be a mixture selected from the group consisting of esters, (C1-C8) ketones, (C1-C8) alkanes, and / or combinations thereof.

[0077] Specifically, the use of these polymers enables a time-efficient and sustainable process in the fabrication of components. Suitable polymer materials may be elastic foam materials such as thermoplastic elastomers and / or elastomers. The preferred material used in this disclosure is a thermoplastic elastomer. More preferred materials used in this disclosure are urethane-based thermoplastic elastomers (TPU), polyester-based thermoplastic elastomers (TPE), and / or polyamide-based thermoplastic elastomers (TPA).

[0078] These solvents allowed for flexible adaptation of the polymer's physical properties to product and process requirements, while also demonstrating optimal compatibility with apparel or footwear manufacturing methods.

[0079] The solvent may be one or more of the following: tetrahydrofuran (THF), methyl ethyl ketone (MEK), cyclohexane (CYC), ethyl acetate, butyl acetate, acetone, acetonitrile, benzyl alcohol, chlorobenzene, dichloromethane, dimethyl sulfoxide (DMSO), methyl t-butyl ether (MTBE), N-methyl-2-pyrrolidone (NMP), dimethylacetamide (DMAC), dimethylformamide (DMF), pyridine, toluene, preferably a mixture of THF and / or CYC. The solvent may also be cyclohexanone.

[0080] These solvents have the advantage of being removable in a time-efficient manner during the curing process and enabling a fabrication process that can accommodate various physical properties of liquid polymers.

[0081] The ratio of the mixture may be in the range of 10 to 90 vol.%, preferably 20 to 80 vol.%, and more preferably 30 to 70 vol.%.

[0082] In this way, the ratio of the solvent mixture provides the best suitability for both mixing the polymers and modifying / adapting the physical properties of the liquefied polymers to meet the specific requirements of the product and process.

[0083] Therefore, the specific ratio of solvent to polymer allows for easy use in the deposition process, as well as flexible adaptation to product and / or process requirements.

[0084] The polymer may also be characterized by a Shore A value and / or a Shore D value, where the Shore A value may be in the range of 20 to 120, preferably 40 to 100, more preferably 60 to 80, and the Shore D value may be in the range of 2 to 80, preferably 5 to 75, more preferably 8 to 70.

[0085] The use of polymers containing these Shore A and / or Shore D values ​​provides durable properties for the polymer layer and the entire sole structure.

[0086] The polymer concentration may be in the range of 5 to 60 wt.%, preferably 7 to 50 wt.%, more preferably 10 to 40 wt.%, and most preferably 15 to 30 wt.%.

[0087] The liquefied polymer may have a kinematic viscosity coefficient of 10,000 to 50,000 mPa·s, preferably 20,000 to 40,000 mPa·s. The liquefied polymer may have a kinematic viscosity coefficient of 100,000 to 500,000 mPa·s, preferably 100,000 to 300,000 mPa·s.

[0088] By changing the mixing ratio of the solvent and polymer, various viscosities can be obtained. In this way, it is possible to deposit materials of varying viscosities onto a second component using a single work step. The method allows for flexible adaptation of the work step based on the product needs.

[0089] In the curing step, a curing temperature between 20°C and 250°C, preferably between 30°C and 150°C, and more preferably between 40°C and 50°C may be used, and in the step of curing the liquefied polymer, the curing time may be between 2 minutes and 750 minutes, preferably between 5 minutes and 390 minutes, and more preferably between 10 minutes and 180 minutes.

[0090] Specifically, in the curing step, a curing temperature between 20°C and 150°C, preferably between 40°C and 100°C, more preferably between 60°C and 80°C, and most preferably between 72°C and 78°C may be used, and in the step of curing the liquefied polymer, the curing time may be between 2 minutes and 24 hours, preferably between 5 minutes and 12 hours, more preferably between 10 minutes and 6 hours, and most preferably between 20 minutes and 3 hours. Alternatively, in the step of curing the liquefied polymer, the curing time may be between 2 minutes and 750 minutes, preferably between 5 minutes and 390 minutes, and more preferably between 10 minutes and 180 minutes.

[0091] These curing conditions enable cost-effective and energy-efficient processes for the manufacture of apparel or footwear.

[0092] In a second embodiment, the present invention relates to apparel or footwear, or at least a portion thereof, manufactured according to the method of the present invention. The apparel or footwear has the advantage that it can be individually designed based on the needs of the wearer / user by adapting the shape of a stencil during the process. Furthermore, the apparel or footwear is considerably lighter and thinner due to inventive materials and manufacturing methods that make the entire apparel or footwear or a portion thereof more desirable.

[0093] In a third aspect, the present invention relates to an outsole manufactured according to the method of the present invention. The outsole may have a surface structure formed by a cured polymer. Specifically, the surface structure is influenced by the support layer. For example, if a support layer having a smooth and uniform surface is used, the cured polymer will have a smooth and uniform surface structure. If a support layer including a non-uniform, rough surface is used, the cured polymer will have a non-uniform, rough surface structure.

[0094] The outsole of the present invention is considerably thinner and lighter than outsoles known in the art. Furthermore, the outsole can be individually designed and adapted to the specific needs of the user. The outsole may have one or more surface structures. It is conceivable that the outsole may have various surface structures intended to provide the outsole with various functions. However, it is also conceivable that the outsole may have multiple surface structures that are identical in pattern but differ in depth, thickness, etc.

[0095] Outsoles are designed to provide traction and grip when used by the wearer. Furthermore, surface structures allow for smooth and / or rough designs, which may be desirable to the user. Apparel or footwear can be used specifically to create lighter and thinner outsoles, for example, but they can also be used to enhance the grip of sports shoes for specific training, for example, by placing liquefied polymers in specific zones of sports shoes.

[0096] In a fourth embodiment, the present invention relates to apparel or footwear according to a second aspect of the present invention, or sports shoes comprising at least a part thereof or an outsole according to a third aspect of the present invention.

[0097] Sports shoes equipped with the outsole according to the present invention are considerably lighter and thinner, making the overall sports shoe more desirable. In addition, the sports shoes exhibit enhanced durability and performance compared to sports shoes known in the art, due to the use of the inventive outsole.

[0098] Many of the advantages discussed in relation to the first aspect of the present invention also apply to further aspects of the present invention; that is, the advantages discussed in relation to the method of the present invention apply to the apparel or footwear, outsoles, and sports shoes of the present invention.

[0099] The inventors emphasize that all aspects, features, and options discussed and disclosed above in the context of the first aspect may apply to or be combined with the descriptions and disclosures of the second, third, and fourth aspects, and vice versa, unless physically or technically excluded, even if any possible combination or partial combination of features is not explicitly stated below. Accordingly, the technical advantages of such options and features already discussed above will not be repeated, at least to the same degree of detail, but rather, for the sake of brevity, the corresponding descriptions above will be referenced.

[0100] The present invention includes the following embodiments.

[0101] 1. A method (100) for manufacturing apparel or footwear (240), preferably sports shoes (260), (a) A step of preparing a liquefied polymer (230) (110), (b) A step of placing (120) a liquefied polymer onto a support layer (250) via a stencil including one or more cutouts, wherein the liquefied polymer is applied through one or more cutouts of the stencil, thereby printing the liquefied polymer onto the support layer in a specific pattern, (c) Optional step of removing the stencil (130), (d) The step of curing the printed liquefied polymer on a support layer (250) (140) to obtain apparel or footwear (240) or at least a part thereof (150), Method (100), including the method (100).

[0102] 2. The method according to Embodiment 1, wherein the liquefied polymer comprises a polymer and a solvent.

[0103] 3. The method according to Embodiment 1 or 2, wherein the solvent is a water-soluble solvent selected from the group comprising ethanol, acetone, isopropyl alcohol, methanol, glycerol, propylene glycol, and / or dimethyl sulfoxide (DMSO), preferably DMSO.

[0104] 4. The method according to any one of Embodiments 1 to 3, wherein, when a water-soluble solvent is used, the step of curing the printed liquefied polymer (140) includes the step of treating the printed liquefied polymer with an extractant which is preferably water (155).

[0105] 5.n. The step of removing the cured printed polymer from the support layer (250) (160) to obtain at least a portion of the apparel or footwear (240), o. A step of attaching a portion of the apparel or footwear (240) to the base layer (165), Methods of embodiments further include the following.

[0106] 6.p. Step (162) of attaching a support layer containing a cured printed polymer to the base layer, specifically to the underside of the midsole, q. The steps of removing the support layer from the apparel or footwear (240) (167) to obtain at least a portion of the apparel or footwear (240) attached to the base layer, Methods of embodiments further include the following.

[0107] 7. The method according to Embodiment 5 or 6, wherein the installation is performed at a temperature between 30 and 300°C, preferably between 50 and 280°C, most preferably between 70 and 260°C, and / or the installation is performed within a maximum of 12 minutes, preferably within 10 minutes, more preferably within 6 minutes, even more preferably within 4 minutes, even more preferably within 2 minutes, most preferably within 1 minute.

[0108] 8. The method according to any one of Embodiments 1 to 7 (100), wherein the step of attaching a portion of apparel or footwear (240) to a base layer (165) includes one or more of bonding, laminating, press-heating, compression, and / or injection molding.

[0109] 9. The step of attaching (165) a part of apparel or footwear (240), or, The step of melting part (240) (170), s. The step of sintering the molten portion (175), t. The step of melting the sintered portion again (180), u. The step of welding the melted portion again (185), v. The step of pressing the welded portion against the base layer (190), The method according to any one of Embodiments 1 to 8, including (100).

[0110] 10. The method according to any one of Embodiments 1 to 9 (100), wherein the welding of the portion is performed using infrared (IR), high frequency (HF), and / or ultrasound.

[0111] 11. The method (100) according to any one of Embodiments 1 to 10, wherein the placement (120) of the liquefied polymer (230) is carried out by one or more of the following additive manufacturing methods: dispensing, spraying, spraying, printing, coating, spin coating, casting, deposition, dipping, brushing, roller coating, injection, and / or stereolithography (SLA) and / or selective laser sintering (SLS).

[0112] 12. The method according to any one of Embodiments 1 to 11 (100), wherein the footwear portion (240) is the outsole (290) of a sports shoe (260).

[0113] 13. The method (100) according to any one of embodiments 1 to 12, wherein the support layer (250) is the midsole and / or shoe upper, and / or a portion thereof.

[0114] 14. The method (100) according to any one of Embodiments 1 to 13, wherein the support layer (250) is a film.

[0115] 15. The method according to Embodiment 13, wherein the midsole comprises a polymer selected from the group comprising thermoplastic polyurethane (TPU), polyether block amide (PEBA), ethylene vinyl acetate (EVA), and / or thermoplastic elastomer, preferably polyurethane and / or expanded thermoplastic polyurethane (eTPU).

[0116] 16. The method according to any one of embodiments 1 to 15 (100), wherein a liquefied polymer (230) is placed (120) on one or more sections (120) of a sports shoe (260), including a toe section, a forefoot section, a heel section, a midsole section, a sidewall section, and / or an upper section.

[0117] 17. The method according to any one of Embodiments 1 to 16 (100), wherein a liquefied polymer (230) is placed on one or more predetermined portions of apparel or footwear determined using a torsion map, abrasion map, and / or pressure map (120).

[0118] 18. The method according to any one of Embodiments 1 to 17 (100), wherein a liquefied polymer (230) is placed on a support layer (120) to a thickness of 0.1 to 10 mm, preferably 0.12 to 4 mm, more preferably 0.15 to 2 mm, even more preferably 0.17 to 1 mm, and most preferably 0.2 to 0.8 mm.

[0119] 19. The method (100) according to any one of Embodiments 1 to 18, wherein the thickness of the apparel or footwear (240) or at least a portion thereof is 0.3 to 0.7 mm, preferably 0.5 mm.

[0120] 20. The method according to any one of Embodiments 1 to 19 (100), wherein the stencil is a screen, preferably a mesh.

[0121] 21. The method according to any one of Embodiments 1 to 20 (100), wherein a liquefied polymer (230) is placed in a first section of apparel or footwear with a kinematic viscosity coefficient of 50,000 to 200,000 mPa·s and in a second section of apparel or footwear with a kinematic viscosity coefficient of 10,000 to 50,000 mPa·s.

[0122] 22. The method according to any one of Embodiments 1 to 21 (100), wherein the contact angle θ between the liquefied polymer (230) and the support layer (250) is 30° to 110°, preferably 40° to 90°, and more preferably 50° to 70°.

[0123] 23. The method according to any one of Embodiments 1 to 22 (100), wherein the curing step (140) is performed using radiation.

[0124] 24. The method according to any one of Embodiments 1 to 23 (100), wherein the liquefied polymer comprises a polymer and a solvent, and the polymer is selected from the group consisting of polyurethane (PU), thermoplastic polyamide (TPE-A or TPA), thermoplastic polyester (TPE-E or TPE), thermoplastic styrene block copolymer (TPE-S or TPS), thermoplastic polyurethane (TPE-U or TPU), thermoplastic vulcanized material (TPE-V or TPV), rubber or ethylene vinyl copolymer (EVA), preferably thermoplastic polyurethane (TPE-U or TPU), and / or combinations thereof.

[0125] 25. The method according to any one of Embodiments 1 to 24 (100), wherein the liquefied polymer and the support layer, preferably the midsole, are soluble in a solvent, and the solvent is preferably the same.

[0126] 26. The method according to any one of Embodiments 1 to 25 (100), wherein the polymer of the support layer, which is preferably the midsole, and the liquefied polymer is TPU.

[0127] 27. The method according to any one of Embodiments 1 to 26 (100), wherein the pattern is a grid, lattice, line, spiral, honeycomb, dot, wave, sinusoidal pattern, or any combination thereof.

[0128] 28. The solvent is preferably from the group of solvent-based solvents and / or aqueous solvents, more preferably from the group of solvent-based solvents, (C1-C6) ether, (C1-C 10 The method according to any one of Embodiments 2 to 27 (100), wherein the mixture is selected from the group consisting of esters, (C1-C8) ketones, (C1-C8) alkanes, and / or combinations thereof.

[0129] 29. The method according to any one of Embodiments 2 to 28 (100), wherein the solvent is one or more of the following: tetrahydrofuran (THF), methyl ethyl ketone (MEK), cyclohexane (CYC), ethyl acetate, butyl acetate, acetone, acetonitrile, benzyl alcohol, chlorobenzene, dichloromethane, dimethyl sulfoxide (DMSO), methyl t-butyl ether (MTBE), N-methyl-2-pyrrolidone (NMP), dimethylacetamide (DMAC), dimethylacetamide (DMF), pyridine, toluene, preferably a mixture of THF and / or CYC.

[0130] 30. The method according to Embodiment 28 or 29 (100), wherein the ratio of the mixture is in the range of 10 to 90 vol.%, preferably 20 to 80 vol.%, and more preferably 30 to 70 vol.%.

[0131] 31. The method according to any one of Embodiments 2 to 30 (100), wherein the polymer is characterized by a Shore A value and / or Shore D value, the Shore A value being in the range of 20 to 120, preferably 40 to 100, more preferably 60 to 80, and the Shore D value being in the range of 2 to 80, preferably 5 to 75, more preferably 8 to 70.

[0132] 32. The method according to any one of Embodiments 2 to 31 (100), wherein the polymer concentration is in the range of 5 to 60 wt.%, preferably 7 to 50 wt.%, more preferably 10 to 40 wt.%, and most preferably 15 to 30 wt.%.

[0133] 33. The method according to any one of Embodiments 1 to 32 (100), wherein the liquefied polymer (230) has a kinematic viscosity coefficient of 10,000 to 50,000 mPa·s, preferably 20,000 to 40,000 mPa·s.

[0134] 34. The method (100) according to any one of Embodiments 1 to 33, wherein in the curing step (140), a curing temperature between 20°C and 250°C, preferably between 30°C and 150°C, more preferably between 40°C and 50°C, and in the step of curing the liquefied polymer (230), the curing time is between 2 minutes and 750 minutes, preferably between 5 minutes and 390 minutes, more preferably between 10 minutes and 180 minutes.

[0135] 35. The method (100) according to any one of claims 1 to 34, as dependent on any one of claims 2 to 4, wherein in the curing step (140), a curing temperature between 20°C and 150°C, preferably between 40°C and 100°C, more preferably between 60°C and 80°C, most preferably between 72°C and 78°C, and in the step of curing the liquefied polymer (230), the curing time is between 2 minutes and 24 hours, preferably between 5 minutes and 12 hours, more preferably between 10 minutes and 6 hours, most preferably between 20 minutes and 3 hours.

[0136] 36. Apparel or footwear (240), or at least a part thereof, manufactured according to the method (100) described in any one of Embodiments 1 to 35.

[0137] 37. An outsole (290) manufactured according to the method (100) described in any one of Embodiments 1 to 35.

[0138] 38. An outsole (290) according to any one of embodiments 1 to 37, having a surface structure (400) formed by a cured polymer.

[0139] 39. An apparel or footwear (240) according to claim 37, or at least a part thereof, or a sports shoe (260) comprising an outsole according to embodiment 37 or 38.

[0140] Possible embodiments of the present invention will be further described in the following detailed description with reference to the following figures. [Brief explanation of the drawing]

[0141] [Figure 1] This is a flowchart illustrating the process for manufacturing apparel or footwear. [Figure 2] This is a diagram of a preferred embodiment of apparel or footwear manufactured using the method according to the present invention. [Figure 3] This is a diagram of a preferred embodiment of apparel or footwear manufactured using the method according to the present invention. [Figure 4] This is a diagram of a preferred embodiment of apparel or footwear manufactured using the method according to the present invention. [Modes for carrying out the invention]

[0142] Possible embodiments of the present invention and various aspects of this disclosure are described below, primarily with respect to sports shoes. However, it is again emphasized that various embodiments can also be practiced in various types of soles and shoes, and are not limited to the specific embodiments described below.

[0143] It should be further noted that only individual embodiments may be described in more detail below. Those skilled in the art will understand that the features and possible modifications described with respect to those particular embodiments may be further modified in different ways or combined with each other in different partial combinations without departing from the scope of the present invention and disclosure. Individual or partial features may also be omitted if they are not so necessary to obtain the desired result. Accordingly, in order to avoid redundancy, the descriptions in the preceding sections, which also apply to the detailed descriptions below, are referenced.

[0144] Figure 1 shows a flowchart for a method 100 for manufacturing apparel or footwear 240, which is preferably for sports shoes 260.

[0145] In step 110, a liquefied polymer is prepared. The liquefied polymer comprises the polymer and a solvent. The ratio of the polymer to the solvent is in the range of 2:98 to 40:60 vol.%, preferably 5:95 to 30:70 vol.%, and more preferably 10:90 to 20:80 vol.%.

[0146] The liquefied polymer 230 is placed in the first section of the apparel or footwear with a kinematic viscosity coefficient of 50,000 to 200,000 mPa·s. In the second section of the apparel or footwear, the liquefied polymer 230 is placed with a kinematic viscosity coefficient of 10,000 to 50,000 mPa·s.

[0147] Alternatively, the liquefied polymer 230 may have a kinematic viscosity coefficient of 10,000 to 50,000 mPa·s. Preferably, the liquefied polymer 230 has a kinematic viscosity coefficient of 20,000 to 40,000 mPa·s. The liquefied polymer may also have a kinematic viscosity coefficient of 100,000 to 500,000 mPa·s, preferably 100,000 to 300,000 mPa·s.

[0148] The contact angle θ between the liquefied polymer 230 and the support layer 250 is 30° to 110°. Preferably, the contact angle θ between the liquefied polymer 230 and the support layer is 40° to 90°. More preferably, the contact angle θ between the liquefied polymer 230 and the support layer is 50° to 70°.

[0149] The liquefied polymer comprises a polymer and a solvent, the polymer being selected from the group consisting of polyurethane (PU), thermoplastic polyamide (TPE-A or TPA), thermoplastic polyester (TPE-E or TPE), thermoplastic styrene block copolymer (TPE-S or TPS), thermoplastic polyurethane (TPE-U or TPU), thermoplastic vulcanized material (TPE-V or TPV), rubber or ethylene vinyl copolymer (EVA), preferably thermoplastic polyurethane (TPE-U or TPU), and / or combinations thereof.

[0150] The solvent is from the group of solvent-based solvents and / or aqueous solvents, preferably from the group of solvent-based solvents, more preferably (C1-C6) ethers, (C1-C 10 ) may be a mixture selected from the group consisting of esters, (C1-C8) ketones, (C1-C8) alkanes, and / or combinations thereof.

[0151] The solvent may be a mixture of one or more of the following: tetrahydrofuran (THF), methyl ethyl ketone (MEK), cyclohexane (CYC), ethyl acetate, butyl acetate, acetone, acetonitrile, benzyl alcohol, chlorobenzene, dichloromethane, dimethyl sulfoxide (DMSO), methyl t-butyl ether (MTBE), N-methyl-2-pyrrolidone (NMP), dimethylacetamide (DMAC), dimethylformamide (DMF), pyridine, toluene, and preferably THF and / or CYC.

[0152] The solvent may be cyclohexanone.

[0153] The ratio of the mixture may be in the range of 10 to 90 vol.%, preferably 20 to 80 vol.%, and more preferably 30 to 70 vol.%. The concentration of the polymer may be in the range of 5 to 60 wt.%, preferably 7 to 50 wt.%, more preferably 10 to 40 wt.%, and most preferably 15 to 30 wt.%.

[0154] The polymer may also be characterized by a Shore A value and / or Shore D value, where the Shore A value is in the range of 20 to 120, preferably 40 to 100, more preferably 60 to 80, and the Shore D value is in the range of 2 to 80, preferably 5 to 75, more preferably 8 to 70.

[0155] Furthermore, as can be seen from Figure 1, the liquefied polymer is placed on a support layer in step 120. The support layer is preferably a film and / or midsole, and therefore may be a layer that is not a component of the sports shoe. In other words, the support layer may be any layer on which the liquefied polymer is placed.

[0156] In step 120, the liquefied polymer is placed on the support layer via a stencil containing one or more cutouts, and the liquefied polymer is applied through one or more cutouts in the stencil. In this way, the liquefied polymer is printed on the support layer in a specific pattern.

[0157] The stencil is preferably made from alumina and / or steel. Any stencil material is possible, but any material that is non-reactive and / or insoluble with respect to the liquefied polymer and / or the solvent used in the preparation of the support layer may be used.

[0158] The placement of the liquefied polymer 230 in step 120 may be carried out by additive manufacturing such as dispensing, spraying, spraying, printing, coating, spin coating, casting, deposition, dipping, brushing, roller coating, injection, and / or stereolithography (SLA) and / or selective laser sintering (SLS).

[0159] The liquefied polymer 230 may be placed on the support layer to a thickness of 1 to 10 mm. Preferably, the liquefied polymer may be placed on the support layer to a thickness of 0.17 to 1 mm. The support layer 250 may be the midsole and / or shoe upper, and / or a part thereof. Preferably, the liquefied polymer may be placed on the support layer to a thickness of 0.17 to 1 mm.

[0160] It is conceivable that the liquefied polymer 230 may be placed in a first section of the sports shoe 260 with a kinematic viscosity coefficient of 30,000 to 50,000 mPa·s and in a second section of the sports shoe 260 with a kinematic viscosity coefficient of 10,000 to 30,000 mPa·s. The contact angle θ between the liquefied polymer 230 and the support layer 250 may be 30° to 110°, preferably 40° to 90°, and more preferably 50° to 70°.

[0161] In step 120, the liquefied polymer is placed by brushing, coating, dipping, printing, automated dispensing, automated printing, and / or controlled dispensing.

[0162] The liquefied polymer may be placed on one or more sections of the sports shoe 260. These sections may be the toe section, forefoot section, heel section, midsole section, sidewall section, and / or upper section. The liquefied polymer 230 may also be placed on one or more predetermined parts of the sports shoe 260, determined using torsion maps, abrasion maps, and / or pressure maps. In this way, the liquefied polymer may be placed based on the individual needs and requirements of the wearer.

[0163] In step 120, the liquefied polymer 230 is placed on the support layer with a thickness of 0.1 to 10 mm. Preferably, the liquefied polymer 230 can be placed on the support layer with a thickness of 0.12 to 4 mm. More preferably, the liquefied polymer 230 can be placed on the support layer with a thickness of 0.15 to 2 mm. Even more preferably, the liquefied polymer 230 can be placed on the support layer with a thickness of 0.17 to 1 mm. Most preferably, the liquefied polymer 230 can be placed on the support layer with a thickness of 0.2 to 0.8 mm.

[0164] The thickness of the apparel or footwear 240 or at least a portion thereof is 0.3 to 0.7 mm. Preferably, the thickness of the apparel or footwear may be 0.5 mm. In relation to sports shoes, this thickness may not include the midsole. However, in some embodiments, the thickness may include the midsole.

[0165] In step 120, the liquefied polymer is applied through one or more cutouts of the stencil. In this way, the liquefied polymer is printed on the support layer in a specific pattern. The pattern may be a grid, lattice, line, spiral, honeycomb, dot, wave, sinusoidal pattern, or any combination thereof.

[0166] In some embodiments, the stencil is a screen. In some embodiments, the stencil is preferably a mesh. The mesh size is 1 cm.2 at least 12 yarns per cm, preferably 1 cm 2 at least 24 yarns per cm, and / or 1 cm 2 comprises 32 yarns per cm. The mesh size further comprises a diameter of at least 50 μm per yarn, preferably 80 μm, more preferably at least 100 μm.

[0167] In some embodiments, a force is applied to the stainless steel when the liquefied polymer is applied. In this way, it is ensured that the liquefied polymer is sufficiently printed to obtain a pattern.

[0168] In optional step 130 shown by the dashed line in Figure 1, the stencil is removed after printing the liquefied polymer in a predetermined pattern. However, the stencil comprising the liquefied polymer throughout the one or more cutouts thereof may remain on the support layer 250 without being removed.

[0169] In step 140, the printed liquefied polymer is cured on the support layer 250. In this way, an article of apparel or footwear 240 or at least a portion thereof is obtained. Curing may be performed using radiation. The stencil may remain on the support layer 250 during the step of curing the polymer.

[0170] In one embodiment, the solvent is an aqueous solvent selected from the group comprising ethanol, acetone, isopropyl alcohol, methanol, glycerol, propylene glycol, and / or dimethyl sulfoxide (DMSO), and is preferably DMSO. According to this embodiment, the step of curing the printed liquefied polymer comprises the step of treating the printed liquefied polymer with an extractant that is preferably water.

[0171] In one embodiment, the cured printed polymer is removed from the support layer 250 in step 160, thereby obtaining at least a portion of the apparel or footwear 240. In addition, the portion of the apparel or footwear 240 is attached to a base layer in step 165. In this regard, the base layer may be a midsole.

[0172] Alternatively, a support layer containing a cured printed polymer is attached to the base layer, specifically to the underside of the midsole. In addition, the support layer 250 is removed from the portion of the apparel or footwear 240. In this way, at least a portion of the apparel or footwear 240 attached to the base layer is obtained.

[0173] Specifically, the installation step 165 is performed at a temperature between 30 and 300°C. Preferably, the installation step 165 is performed at a temperature between 50 and 280°C. Most preferably, the installation step 165 is performed at a temperature between 70 and 260°C. In addition, or instead, the installation step is performed within a maximum of 12 minutes. Preferably, the installation step 165 is performed within a maximum of 10 minutes. More preferably, the installation step 165 is performed within a maximum of 6 minutes. Even more preferably, the installation step 165 is performed within a maximum of 4 minutes. Even more preferably, the installation step is performed within a maximum of 2 minutes. Most preferably, the installation step is performed within a maximum of 1 minute.

[0174] Specifically, step 165, which involves attaching a portion of the apparel or footwear 240 to the base layer, includes one or more of the following: bonding, lamination, press heating, compression, and / or injection molding.

[0175] According to one embodiment, when DMSO is used to redissolve the portion and / or midsole, the portion and / or midsole is brought into contact with a solvent such as DMSO. A stencil-printed pattern is placed on a support layer, such as a film which is a transport film, and then the midsole is placed on a support structure, for example, to prevent deformation when subjected to load.

[0176] Specifically, components including negatives of the midsole and / or outsole structure patterns are placed on the support layer 250. In a subsequent step, this arrangement is moved and left to dry. During drying, the parts and / or midsoles and / or films are weighted between 100g and 100kg. In this way, complete bonding is ensured.

[0177] According to another embodiment, when the part of the present invention is heated and compressed, drying does not occur. Specifically, bonding is established through the application of heat. Specifically, heat may be applied during bonding. The part and / or midsole and / or film are subjected to weights between 100g and 100kg. In this way, complete bonding is ensured. However, it is conceivable that the weights may be changed. It is even more conceivable that no weights are applied.

[0178] A combination of both embodiments described above is conceivable. For example, the first bonding is achieved via DMSO, followed by a heating and compressing step to ensure better bonding, for example, on the edges of the structure.

[0179] Alternatively, step 165 of attaching a portion of apparel or footwear 240 may include melting the portion 240 170. The melted portion 240 may then be sintered 175, and the sintered portion may be melted again 180. The melted portion may then be welded 185. Finally, the welded portion may be pressed into a base layer 190.

[0180] Specifically, welding of the parts is carried out using infrared (IR), high-frequency (HF) radiation, and / or ultrasonic radiation. In this regard, the footwear part 240 is preferably the outsole 290 of a sports shoe 260. The support layer 250 is the midsole. The support layer 250 may also be the shoe upper. Specifically, the support layer may be a part of it.

[0181] Specifically, the support layer 250 may be a film. Any film material that does not dissolve in the extractant or solvent used in the preparation of the liquefied polymer is considered to be used. For example, if water is used as the extractant, the film material is not water-soluble and may be, for example, a woven fabric, fiber, polyester-based material, nylon, etc.

[0182] The midsole contains a polymer based on expandable thermoplastic polyurethane. The midsole may contain a polymer selected from the group including thermoplastic polyurethane (TPU), polyether block amide (PEBA), ethylene vinyl acetate (EVA), and / or thermoplastic elastomer, preferably polyurethane and / or expandable thermoplastic polyurethane (eTPU).

[0183] Specifically, the liquefied polymer and the midsole are soluble in a solvent, and preferably the same solvent. The polymer of the support layer, when it is a midsole, and the liquefied polymer are based on the same polymer, preferably TPU.

[0184] In curing step 140, a curing temperature between 20°C and 250°C is used. Preferably, a curing temperature between 30°C and 150°C is used. More preferably, a curing temperature between 40°C and 50°C is used. In curing step 140 of the liquefied polymer 230, the curing time is between 2 minutes and 750 minutes. Preferably, the curing time can be between 5 minutes and 390 minutes. More preferably, the curing time can be between 10 minutes and 180 minutes.

[0185] Alternatively, in curing step 140, a curing temperature between 20°C and 150°C is used. Preferably, a curing temperature between 40°C and 100°C is used. More preferably, a curing temperature between 60°C and 80°C is used. Most preferably, a curing temperature between 72°C and 78°C is used. In curing step 140 of the liquefied polymer 230, the curing time may be between 2 minutes and 24 hours. Preferably, the curing time may be between 5 minutes and 12 hours. More preferably, the curing time may be between 10 minutes and 6 hours. Most preferably, the curing time may be between 20 minutes and 3 hours.

[0186] To avoid unnecessary redundancy, only differences or additions to the method described in Figure 1 will be discussed with respect to the various embodiments shown in Figures 2 to 4.

[0187] Figure 2 shows an apparel or footwear 240 or at least a portion thereof manufactured according to the method 100 of the present invention discussed above in relation to Figure 1. Specifically, Figure 2 shows a preferred embodiment of the apparel or footwear 240 manufactured according to the method of the present invention (described above in relation to Figure 1). As can be seen from Figure 2, the apparel or footwear 240 has a matte design. The stencil used to print the liquefied polymer is made of alumina and / or steel material. Specifically, also as shown in Figure 2, the stencil has not been removed (yet) from the support layer (not shown in Figure 2). It is conceivable that the printed polymer be cured on the support layer without removing the stencil. However, it may also be desirable to remove the stencil in a later step.

[0188] Figures 3 and 4 show two different embodiments of an outsole 290 manufactured according to method 100 of the present invention. As can be seen from Figure 3, the outsole 290 has a surface structure 400 formed by a pattern and arrangement of cured polymers. Specifically, the surface structure 400 as shown in Figure 3 is a linear continuous pattern with diagonal parallel arrangements. The cured polymers are arranged in one or more stripes with substantially constant spacing between them. However, as can be seen from Figure 3, the one or more stripes do not have substantially constant spacing. It is conceivable that the one or more stripes have constant spacing. To do so, a stencil including cutouts with constant spacing can be used. Specifically, a support layer 250 is visible between the arrangement of cured polymers in Figure 3. As can be seen from Figure 3, the support layer 250 is a film layer.

[0189] The outsole 290 shown in Figure 4 has a linear discontinuous pattern. Specifically, the surface structure 400 of the outsole 290 is arranged perpendicularly along the longitudinal axis of the outsole 290. Specifically, the outsole has a pattern comprising one or more bars made of arranged cured polymer. The one or more bars are arranged at continuous intervals from one another. Specifically, the one or more bars are arranged in multiple rows. As in Figure 3, in Figure 4, the support layer 250 is a film layer.

[0190] It should be noted that the embodiments and / or examples described above may be combined with further embodiments described herein, as will be understood by those skilled in the art, and that details of the embodiments and / or examples may be omitted. The scope of protection is defined by the claims and is not limited by the embodiments and / or examples disclosed in the above figures. [Explanation of Symbols]

[0191] 100 ways 230 Liquefied Polymer 240 Footwear, Partial 250 Supporters 260 Sports Shoes 290 Outsole 400 Surface structure

Claims

1. A method (100) for manufacturing apparel or footwear (240), a. A step (110) of preparing a liquefied polymer (230), b. A step (120) of placing the liquefied polymer onto a support layer (250) via a stencil including one or more cutouts, wherein the liquefied polymer is applied through one or more cutouts of the stencil, thereby printing the liquefied polymer onto the support layer in a specific pattern, c. A step of optionally removing the stencil (130), d. The steps of curing the printed liquefied polymer on the support layer (250) (140) to obtain the apparel or footwear (240) or at least a part thereof (150), Method (100), including the method (100).

2. The method according to claim 1, wherein the liquefied polymer comprises a polymer and a solvent.

3. The method according to claim 2, wherein the solvent is a water-soluble solvent selected from the group comprising ethanol, acetone, isopropyl alcohol, methanol, glycerol, propylene glycol, and / or dimethyl sulfoxide (DMSO).

4. The method according to claim 1, wherein, when a water-soluble solvent is used, the step of curing the printed liquefied polymer (140) includes the step of treating the printed liquefied polymer with an extractant (155).

5. w. The steps of removing the cured printed polymer from the support layer (250) (160) to obtain at least a portion of the apparel or footwear (240), x. The step of attaching the portion of the apparel or footwear (240) to the base layer (165), The method according to claim 1, further comprising:

6. y. The step of attaching the support layer containing the cured printed polymer to the base layer, particularly to the lower part of the midsole (162), z. The steps of removing the support layer from the portion of the apparel or footwear (240) (167), thereby obtaining at least a portion of the apparel or footwear (240) attached to the base layer, The method according to claim 1, further comprising:

7. The method according to claim 5, wherein the installation is performed at a temperature between 30 and 300°C, and / or the installation is performed within a maximum of 12 minutes.

8. The method of claim 5 (100), wherein the step of attaching the portion of the apparel or footwear (240) to the base layer (165) includes one or more of bonding, laminating, press-heating, compression, and / or injection molding.

9. The step of attaching (165) the part of the apparel or footwear (240) may be, aa. A step of melting the aforementioned portion (240) (170), bb. The step of sintering the molten portion (175), cc. The step of melting the sintered portion again (180), dd. The step of welding the melted portion again (185), ee. The step of pressing the welded portion against the base layer (190), The method according to claim 1 (100), including the method according to claim 1.

10. The method according to claim 1 (100), wherein the welding of the portion is performed using infrared (IR), radio frequency (HF), and / or ultrasound.

11. The method according to claim 1 (100), wherein the placement (120) of the liquefied polymer (230) is carried out by one or more additive manufacturing methods such as dispensing, spraying, spraying, printing, coating, spin coating, casting, deposition, dipping, brushing, roller coating, injection, and / or stereolithography (SLA) and / or selective laser sintering (SLS).

12. The method according to claim 1 (100), wherein the portion (240) of the footwear is the outsole (290) of a sports shoe (260).

13. The method according to claim 1 (100), wherein the support layer (250) is the midsole and / or shoe upper, and / or a portion thereof.

14. The method according to claim 1 (100), wherein the support layer (250) is a film.

15. The method according to claim 13, wherein the midsole comprises a polymer selected from the group comprising thermoplastic polyurethane (TPU), polyether block amide (PEBA), ethylene vinyl acetate (EVA), and / or thermoplastic elastomer and / or expandable thermoplastic polyurethane (eTPU).

16. The method according to claim 1 (100), wherein the liquefied polymer (230) is placed on one or more sections (120) of the sports shoe (260), including a toe section, a forefoot section, a heel section, a midsole section, a sidewall section, and / or an upper section.

17. The method according to claim 1 (100), wherein the liquefied polymer (230) is placed on one or more predetermined portions of the apparel or footwear determined using a torsion map, abrasion map, and / or pressure map (120).

18. The method according to claim 1 (100), wherein the liquefied polymer (230) is disposed on the support layer (120) to a thickness of 0.1 to 10 mm.

19. The method according to claim 1 (100), wherein the thickness of the apparel or footwear (240), or at least a portion thereof, is 0.3 to 0.7 mm.

20. The method according to claim 1 (100), wherein the stencil is a screen.

21. The method according to claim 1 (100), wherein the liquefied polymer (230) is disposed in a first section of the apparel or footwear with a kinematic viscosity coefficient of 50,000 to 200,000 mPa·s and in a second section of the apparel or footwear with a kinematic viscosity coefficient of 10,000 to 50,000 mPa·s.

22. The method according to claim 1 (100), wherein the contact angle θ between the liquefied polymer (230) and the support layer (250) is 30° to 110°.

23. The method according to claim 1 (100), wherein the curing step (140) is performed using radiation.

24. The method according to claim 1 (100), wherein the liquefied polymer comprises a polymer and a solvent, and the polymer is selected from the group consisting of polyurethane (PU), thermoplastic polyamide (TPE-A or TPA), thermoplastic polyester (TPE-E or TPE), thermoplastic styrene block copolymer (TPE-S or TPS), thermoplastic polyurethane (TPE-U or TPU), thermoplastic vulcanized product (TPE-V or TPV), rubber or ethylene vinyl copolymer (EVA), and / or combinations thereof.

25. The method according to claim 1 (100), wherein the liquefied polymer and the support layer are soluble in the solvent.

26. The method according to claim 1 (100), wherein the polymer in the support layer and the liquefied polymer is TPU.

27. The method according to claim 1 (100), wherein the pattern is a grid, lattice, line, spiral, honeycomb, dot, wave, sinusoidal pattern, or any combination thereof.

28. The method according to claim 2 (100), wherein the solvent is a mixture selected from the group consisting of solvent-based solvents and / or aqueous solvents.

29. The method according to claim 2 (100), wherein the solvent is a mixture of one or more of the following: tetrahydrofuran (THF), methyl ethyl ketone (MEK), cyclohexane (CYC), ethyl acetate, butyl acetate, acetone, acetonitrile, benzyl alcohol, chlorobenzene, dichloromethane, dimethyl sulfoxide (DMSO), methyl t-butyl ether (MTBE), N-methyl-2-pyrrolidone (NMP), dimethylacetamide (DMAC), dimethylformamide (DMF), pyridine, and toluene.

30. The method according to claim 28 (100), wherein the ratio of the mixture is in the range of 10 to 90 vol.%.

31. The method according to claim 2 (100), wherein the polymer is characterized by a Shore A value and / or a Shore D value, the Shore A value being in the range of 20 to 120.

32. The method according to claim 2 (100), wherein the concentration of the polymer is in the range of 5 to 60 wt.%.

33. The method according to claim 1 (100), wherein the liquefied polymer (230) has a kinematic viscosity coefficient of 10,000 to 50,000 mPa·s.

34. The method according to claim 1 (100), wherein in the curing step (140), the curing temperature is between 20°C and 250°C, and in the step of curing the liquefied polymer (230), the curing time is between 2 minutes and 750 minutes.

35. The method according to claim 2 (100), wherein in the curing step (140), the curing temperature is between 20°C and 150°C, and in the step of curing the liquefied polymer (230), the curing time is between 2 minutes and 24 hours.

36. Apparel or footwear (240), or at least a part thereof, manufactured according to the method (100) of claim 1.

37. An outsole (290) manufactured according to the method (100) of claim 1.

38. The outsole (290) according to claim 37, having a surface structure (400) formed by the cured polymer.

39. Apparel or footwear (240) according to claim 37, or at least a part thereof, or a sports shoe (260) comprising an outsole according to claim 37 or 38.

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