Liquid TPU texture processing during and after curing

Abstract

The present invention provides a method for manufacturing a sole structure, preferably for sports shoes. [Solution] A method 100 for manufacturing a sole structure for sports shoes, comprising: a. step 110 of preparing a liquefied polymer and / or a polymer layer or portion thereof; b. step 120 of placing the liquefied polymer and / or polymer layer or portion thereof on a base layer; and c. step 130 of curing the liquefied polymer. Also, a sole structure and outsole manufactured according to this method, and sports shoes.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a sole structure, preferably for sports shoes, to a sole structure and an outsole manufactured according to the method, and to sports shoes.

Background Art

[0002] Various types of sports require specific types of sole structures to guarantee stability. Specifically, sole structures on the outsole of sports shoes, such as protrusions, cleats, or patterned treads, provide various performance advantages depending on the sport. These structures enhance traction, grip, design, stability, and athlete perception, reduce the risk of slipping, and improve exercise efficiency.

[0003] The manufacturing of sole structures on the outsole of sports shoes in the art involves injection molding, which is widely used for sports shoes requiring lightweight and flexible outsoles. In this process, a thermoplastic material such as EVA (ethylene vinyl acetate), TPU (thermoplastic polyurethane), or a rubber compound is melted and injected under high pressure into a steel mold that defines the shape and tread pattern of the sole. One of the main drawbacks is the costly production of molds made of steel that require precision engineering, which makes mold production costly, especially for low-volume production processes or frequent design changes. Furthermore, injection molding may have limited material options, as not all rubber compounds are suitable for this process.

[0004] A different approach includes engraving the final sole, that is, adding the use of laser engraving. Specifically, after the outsole is manufactured, a laser engraving machine burns the desired structure onto the surface. The drawback of this method is that the texture is added only after the sole is manufactured, resulting in inflexible process steps.

[0005] Embossing and debossing, surface roughening, cutting, and other techniques such as grooving can only be performed after the outsole has been manufactured. Therefore, these techniques are commonly used as one of the final steps in the manufacture of the sole structure.

[0006] However, a common drawback of these soles is that conventional soles are heavy and thick, both of which affect an athlete's performance and therefore make them undesirable. A further drawback is that the process for creating the sole structure cannot be flexibly changed or implemented during the overall manufacturing process, making its application rather inflexible. Yet another drawback is the inflexible design of the structure; once prepared, the structure cannot be easily modified or adapted to the specific needs of the sole or the athlete.

[0007] Further prior art is known from International Publication No. 2025 / 045687. [Prior art documents] [Patent Documents]

[0008] [Patent Document 1] International Publication No. 2025 / 045687 [Overview of the initiative]

[0009] Therefore, an object of the present invention is to provide an improved method, sole structure and outsole, and a sports shoe having the sole structure, in order to at least partially overcome the aforementioned defects of the prior art.

[0010] The problems outlined above are addressed by embodiments of the present invention.

[0011] In a first aspect, the present invention relates to a method for manufacturing a sole structure, preferably for sports shoes, a. A step of preparing a liquefied polymer and / or a polymer layer or a portion thereof, b. The step of placing a liquefied polymer and / or a polymer layer or a portion thereof on a base layer, c. A step of curing the liquefied polymer, The method includes a group of first steps and / or a group of second steps, and the group of first steps is d. A step of partially curing the liquefied polymer obtained in step b, e. A step of texture the partially cured polymer before step c, The group in the second step includes, f. The step of placing the cured polymer obtained in step c, and / or the polymer layer or portion thereof obtained in step b, into a mold structure having a textured sole imprint, g. The step of heating the mold structure by applying steam to the mold structure while pressing the cured polymer and / or polymer layer or a portion thereof onto the textured sole imprint, h. The steps of heating the cured polymer and / or polymer layer or a portion thereof in order to at least partially melt the cured polymer and / or polymer layer or a portion thereof, and to substantially form a textured sole imprint on the outer surface of the cured polymer and / or polymer layer or a portion thereof, i. The step of obtaining the sole structure thereafter, This applies to methods that include [specific methods].

[0012] The present invention demonstrates a method that provides a more flexible process for fabricating sole structures. Conventional sole structures, such as structured outsoles for sports shoes, are typically manufactured by, for example, injection molding. The method according to the present invention is based on a different technique, namely, the provision of a liquefied polymer and / or polymer layer or portion thereof to be placed on a base layer. The method of the present invention is more efficient compared to methods known in the prior art because it incorporates a textured step into the fabrication process. Furthermore, textured during or after curing provides flexibility for customizing the sole structure and the overall process. This dual capability helps to improve sole structures and the methods for manufacturing them.

[0013] This method for manufacturing sole structures eliminates the need for additional surface treatment, thereby reducing cycle time and increasing yield. Furthermore, the combination of curing and texturing in a single step avoids the costs of post-processing equipment such as laser or chemical etching systems, and reduces labor costs. Moreover, texturing during and after curing results in fewer processing steps, which leads to reduced energy consumption for heating, handling, or operating additional machinery. The method of the present invention further allows for individual changes or customizations during the process, such as unique branding, part identification, or product differentiation, without the need to change the process or mold. In this way, the processing costs and time required to create new molds or dies when different textures 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, as the texturing process during curing can be incorporated as an automated process, resulting in high reproducibility and high productivity.

[0015] Furthermore, when using the method of the present invention, deposits based on adhesives and injection molding are avoided, for example, while providing a sole structure with enhanced traction and friction performance.

[0016] Therefore, the method of the present invention improves the overall process speed, cost, flexibility of automation (i.e., an automated and scalable method), material efficiency, risk management (as a backup option for process flexibility), and customization for manufacturing sole structures.

[0017] Sole structures can be used in particular 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 and / or polymer layers or portions thereof in specific zones of sports shoes.

[0018] In this way, the liquefied polymer can be positioned more precisely and efficiently, while the sole structure 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 producing 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 a sole structure that reduces the likelihood of slipping while simultaneously enhancing traction on smooth and wet surfaces. When using the sole structure according to the present invention, the running performance of the wearer, for example, an athlete, is substantially improved. For example, by reducing the risk of slipping on wet and smooth surfaces, the sole structure results in an overall improvement in training experience and outcomes. Specifically, the sole structure of the present invention also shows a significant improvement in friction compared to conventional sole structures. Moreover, the sole structure has the advantage that it can be individually designed based on the frictional forces acting on the sole structure. Furthermore, due to the inventive materials and manufacturing methods, the sole structure can be considerably lighter and thinner, making the overall sole structure more desirable. The sole structure can further be individually designed based, for example, on the magnitude and / or direction of forces in various parts of the shoe. In this way, the sole structure can be optimized for various sports and various athletes.

[0020] The “sole structure” according to the present invention is any part of a shoe or footwear that provides structure, texture, and / or traction to the wearer, but is not limited to this. The method may be used, for example, to manufacture the sidewall of a midsole. For example, the sole structure may include, for example, an outsole that overlaps the midsole. In other words, the sole structure may be an outsole that wraps around the midsole. The sole structure may further include any part of the midsole and / or a part of the outsole that overlaps the midsole, for example, a separate sidewall layer of the midsole. The sidewall layer may be based on, for example, liquid TPU. This sidewall layer is advantageous for protecting lightweight foam used, for example, in trail shoes and / or outdoor shoes.

[0021] 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 contacts the ground during, for example, walking movement. Furthermore, the polymer layer provides flexibility, durability, cushioning, and support in a sole structure.

[0022] A polymer layer or a portion thereof includes any polymer film or a portion thereof. For example, the polymer layer may be a thin layer of polymer. The polymer layer may have cutouts. In this regard, portions of the polymer layer include cutouts of the polymer layer. These cutouts from the polymer layer may be referred to as "portions thereof".

[0023] The "base layer" according to the present disclosure is, but not limited to, a basic component of a sole structure and helps maintain the structural integrity of the sole structure. The base layer may be a midsole and / or a shoe upper and / or a portion thereof. The base layer does not necessarily need to be a part of the sports shoe, that is, it is removed when the sole structure is further processed. The base layer may be, for example, a midsole, and may include a material that absorbs impact and reduces stress on joints. The base layer may be made of a durable material to withstand wear and tear during constant use. The base layer can function together with the sole structure and other layers of the sports shoe.

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

[0025] "Curing" according to the present disclosure is to be understood as, but not limited to, a chemical and / or physical process of solidifying, setting, and / or coagulating a polymer. Curing may be performed using radiation.

[0026] The term "mixing" as used in this disclosure should be understood, but is not limited to, a process of combining two or more substances to produce a mixture of the individual substances, preferably in liquid form.

[0027] The “arrangement” as described herein should be understood, but is not limited to, a process of applying and / or depositing a liquefied polymer onto a base layer.

[0028] For example, the liquid material may be applied onto a base layer, which may be a carrier layer. The carrier layer is then attached, for example, to the midsole. In some embodiments, the liquefied polymer may be applied directly to the midsole. In this regard, the liquefied polymer may be partially cured, and the partially cured polymer may be textured.

[0029] In some embodiments, the liquefied polymer may be applied to a base layer (such as a carrier layer). In this regard, the process involves placing the cured polymer obtained in step c and / or the polymer layer or portion thereof obtained in step b into a mold structure having a textured sole imprint, and / or heating the mold structure by applying steam to the mold structure, preferably while pressing the cured polymer and / or polymer layer or portion thereof into the textured sole imprint, in order to at least partially melt the cured polymer and / or polymer layer or portion thereof, and to substantially form the textured sole imprint on the outer surface of the cured polymer and / or polymer layer or portion thereof, and / or thereby obtaining the sole structure.

[0030] In some embodiments, steps f) through h) are taken, i.e., f. A step of placing (160) the cured polymer (232) obtained in step c and / or the polymer layer or a portion thereof obtained in step b into a mold structure (300) having a textured sole imprint (340), g. A step of heating the mold structure (300) (170) by applying steam into the mold structure (300) while pressing the cured polymer (232) and / or the polymer layer or a portion thereof onto the textured sole imprint (340), h. A step of heating (180) the cured polymer (232) and / or polymer layer or a portion thereof in order to at least partially melt the cured polymer and / or polymer layer or a portion thereof, and to substantially form the textured sole imprint (340) on the outer surface of the cured polymer (232) and / or polymer layer or a portion thereof, However, this can be done using a liquefied polymer. In addition, or instead, steps f) through h), i.e., f. A step of placing (160) the cured polymer (232) obtained in step c, and / or the polymer layer or a portion thereof obtained in step b, into a mold structure (300) having a textured sole imprint (340), g. A step of heating the mold structure (300) (170) by applying steam to the mold structure (300) while pressing the cured polymer (232) and / or the polymer layer or a portion thereof onto the textured sole imprint (340), h. A step of heating (180) the cured polymer (232) and / or polymer layer or a portion thereof in order to at least partially melt the cured polymer and / or polymer layer or a portion thereof, and to substantially form the textured sole imprint (340) on the outer surface of the cured polymer (232) and / or polymer layer or a portion thereof, Alternatively, this can preferably be done using a polymer layer based on TPU. The polymer layer may be a polymer film, such as a TPU film. For example, the polymer layer may be inserted into a molded structure.

[0031] A polymer layer or a portion thereof may be placed on a carrier layer. The carrier layer may include any structural and / or support layers. The carrier layer may be placed, for example, in a multilayer material system. The carrier layer provides stability and facilitates processing. Specifically, the carrier layer acts as a base layer for additional processing steps, such as coatings, adhesives, or functional layers. The carrier layer may include materials selected from the group including thermoplastic polyurethane (TPU), rubber, polyester, aramid fibers, carbon fibers, glass fibers, and ultra-high molecular weight polyethylene (e.g., Dyneema), and / or ethylene vinyl acetate (EVA).

[0032] A polymer layer or portion thereof may have one or more cutouts. These cutouts in the polymer layer are, for example, intentionally designed openings, perforations, and / or recesses. Specifically, it is conceivable that a polymer layer may have one or more cutouts in a certain pattern. Therefore, the openings, perforations, and / or recesses, e.g., portions of the polymer layer, may have a pattern. The use of one or more cutouts enhances the flexibility, traction, and cushioning properties of the sole structure. Furthermore, one or more cutouts result in a considerable weight reduction of the sole structure.

[0033] In the step of texture a partially cured polymer, a textured element may be applied on top of the partially cured polymer, and the textured element is preferably air permeable.

[0034] The use of air-permeable textured elements ensures that applied forces are evenly distributed across the entire surface and are not affected by pressure differences caused by trapped air. This results in a more uniform and consistent surface structure across the entire surface of the sole structure. Furthermore, air-permeable textured elements maintain a constant pressure, ensuring that the texture is "fixed" when the material hardens, i.e., solidifies. In this way, defects such as deformation, displacement, or loss of texture accuracy are minimized. Another advantage of using air-permeable textured elements is that the solvent is thus allowed to leave the polymer through evaporation. While we do not wish to be bound by any theory, a partially hardened polymer surface would not harden completely if the textured element were not air-permeable. In other words, drying and / or hardening would take considerably longer. The textured elements may be molds, stamps, embossing tools, and / or textiles, preferably stamps and / or textiles.

[0035] The textured element may be applied to the partially cured polymer for at least 5 minutes. Preferably, the textured element may be applied to the partially cured polymer for at least 1 hour. More preferably, the textured element may be applied to the partially cured polymer for at least 6 hours. Even more preferably, the textured element may be applied to the partially cured polymer for at least 12 hours. Most preferably, the textured element may be applied to the partially cured polymer for at least 24 hours.

[0036] In this way, the partially cured polymer is allowed to harden during the application of the textured element. This one-step process provides a time-efficient and energy-efficient process for textured applications.

[0037] The textured element may be a woven fabric. Woven fabrics exhibit more complex and irregular patterns, such as fibers, waves, and meshes, which are difficult to reproduce with conventional molds. By using woven fabrics in the method of the present invention, a more "natural" and biomimetic surface structure can be obtained in the sole structure. These textures are ideal for sole structures with, for example, soft, organic, or natural designs.

[0038] The curing time in the step of partially curing the liquefied polymer can be 10 to 60 minutes. Preferably, the curing time in the step of partially curing the liquefied polymer can be 15 to 40 minutes. More preferably, the curing time in the step of partially curing the liquefied polymer can be 20 to 35 minutes. Most preferably, the curing time in the step of partially curing the liquefied polymer can be 30 minutes.

[0039] The sole structure may include a surface structure. In this way, the sole structure provides traction and grip when used by the wearer. Furthermore, the surface structure allows for a rougher design, which may be desirable to the user.

[0040] The surface structure may be selected from a group including one or more of rectangles, grids, lattices, lines, helices, honeycombs, dots, waves, or any combination thereof. The sole structure may be designed individually, and multiple surface structures can be provided. It is conceivable that the sole structure may have two or more surface structures. Alternatively, or in addition, the surface structure may include contour lines and / or filled patterns.

[0041] These specific surface structures enhance the traction of the sole structure, which helps the wearer maintain a firm footing on various surfaces. This improved traction allows the wearer to experience greater 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. Specifically, using the patterns of the present invention enables faster turns, crossings, and lateral movements.

[0042] The sole structure can be the outsole of a sports shoe. In this way, the outsole provides improved traction and grip, as well as design elements such as individual surface structures. For example, the sole structure can be used to provide badge branding. In other words, the sole structure has the advantage of providing an outsole that can be used for design purposes.

[0043] 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. 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.

[0044] The liquefied polymer can be placed on one or more predetermined parts of a sports shoe, determined using a traction map. The liquefied polymer can be placed on one or more predetermined parts of a sports shoe, determined using an abrasion map. The liquefied polymer can be placed on one or more predetermined parts of a sports shoe, determined using a pressure map. This has the advantage that the sole structure can be individually adapted to the specific needs of the user.

[0045] The liquefied polymer can be placed on the base layer to a thickness of 1 to 10 mm. Preferably, the liquefied polymer can be placed on the base layer to a thickness of 2 to 4 mm. Most preferably, the liquefied polymer can be placed on the base layer to a thickness of 3 mm.

[0046] The thickness of the sole structure can be 0.3 mm to 0.7 mm. Preferably, the thickness of the sole structure can be 0.5 mm.

[0047] The placement step may be carried out by at least one of the following methods: brushing, coating, dipping, painting, automatic dispensing, automatic printing, or controlled dispensing. The placement step may also be carried out by screen printing.

[0048] Liquid polymers can be placed on a base 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 fused 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.

[0049] The base layer may be the midsole. The base layer may be the shoe upper. The base layer may be a part of it. Thus, the liquefied polymer is placed, for example, on the midsole and thus forms the outsole. In this embodiment, the polymer material may be ethylene vinyl acetate (EVA), thermoplastic polyurethane (TPU), or supercritical foam. These materials are relatively lightweight while providing good cushioning properties.

[0050] The liquefied polymer may be placed in the first section of the sports shoe with a kinematic viscosity coefficient of 30,000 to 50,000 mPa·s, and in the second section of the sports shoe with a kinematic viscosity coefficient of 10,000 to 30,000 mPa·s.

[0051] By varying 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.

[0052] The contact angle θ between the liquefied polymer and the base layer can be 30° to 110°. Preferably, the contact angle θ between the liquefied polymer and the base layer can be 40° to 90°. More preferably, the contact angle θ between the liquefied polymer and the base layer can be 50° to 70°.

[0053] The curing step can be carried out using radiation. In this way, the liquefied component deposited on the second component is cured on the second component at the same time as the solvent is removed and the deposited liquefied component is dried.

[0054] 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.

[0055] The inventors have found that 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).

[0056] These polymers reduce the likelihood of slipping while simultaneously enabling enhanced traction. Furthermore, the use of these particular polymers has been shown to achieve a time-efficient and sustainable process in the production of sole structures, 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.

[0057] 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.

[0058] These solvents allowed for flexible adaptation of the polymer's physical properties to product and process requirements, while also demonstrating optimal compatibility with the methods for fabricating the components.

[0059] The solvent may be one or more of tetrahydrofuran (THF), methyl ethyl ketone (MEK), cyclohexane (CYC), ethyl acetate, butyl acetate, preferably a mixture of THF and / or CYC.

[0060] These solvents can be removed in a time-efficient manner during the curing process, which has the advantage of enabling a fabrication process that can accommodate various physical properties of liquid polymers.

[0061] The ratio of the mixture may be in the range of 10 to 90 vol.%. Preferably, the ratio of the mixture may be in the range of 20 to 80 vol.%. More preferably, the ratio of the mixture may be in the range of 30 to 70 vol.%.

[0062] In this way, the ratio of the solvent mixture indicates the best suitability for both mixing the polymers and modifying / adapting the physical properties of the liquefied polymers to the specific requirements of the product and process.

[0063] The polymer may be characterized by its Shore A value. The polymer may also be characterized by its Shore D value. The Shore A value may be in the range of 20 to 120. Preferably, the Shore A value may be in the range of 40 to 100. More preferably, the Shore A value may be in the range of 60 to 80. The Shore D value may be in the range of 2 to 80. Preferably, the Shore D value may be in the range of 5 to 75. More preferably, the Shore D value may be in the range of 8 to 70.

[0064] 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.

[0065] The ratio of polymer to solvent may be in the range of 2:98 to 40:60 vol.%. Preferably, the ratio of polymer to solvent may be in the range of 5:95 to 30:70 vol.%. More preferably, the ratio of polymer to solvent may be in the range of 10:90 to 20:80 vol.%.

[0066] 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.

[0067] The liquefied polymer may have a kinematic viscosity coefficient of 10,000 to 50,000 mPa·s. Preferably, the liquefied polymer has a kinematic viscosity coefficient of 20,000 to 40,000 mPa·s. The use of liquid polymers with specific kinematic viscosity coefficients enables the use of liquid polymers in automated and / or manual deposition processes.

[0068] In the curing step, a curing temperature between 20°C and 150°C may be used. Preferably, a curing temperature between 30°C and 100°C may be used in the curing step. More preferably, a curing temperature between 40°C and 50°C may be used in the curing step.

[0069] In the step of curing the liquefied polymer, the curing time may be between 2 minutes and 750 minutes. Preferably, the curing time in the step of curing the liquefied polymer may be between 5 minutes and 390 minutes. More preferably, the curing time in the step of curing the liquefied polymer may be between 10 minutes and 180 minutes.

[0070] These curing conditions enable a cost-effective and energy-efficient process for fabricating sole structures.

[0071] In some embodiments, the outsole may be a sole structure according to a first aspect of the present invention. In addition, or instead, the sole structure may be a sole. Using an inventive sole structure as an outsole and / or sole has been shown to improve the traction of sports shoes.

[0072] In a second embodiment, the present invention relates to a sole structure manufactured according to the method of the present invention.

[0073] Sole structures 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.

[0074] The sole structure of the present invention reduces the likelihood of slipping while simultaneously enhancing traction on smooth and wet surfaces. When using the sole structure according to the present invention, the running performance of the wearer, such as an athlete, is substantially improved. For example, by reducing the risk of slipping on wet and smooth surfaces, the sole structure results in an overall improvement in training experience and outcomes. Specifically, the sole structure of the present invention also exhibits a significant improvement in friction compared to conventional sole structures. Moreover, the sole structure has the advantage that it can be individually designed based on the frictional forces acting on the sole structure. Furthermore, due to the inventive materials and manufacturing methods, the sole structure becomes considerably lighter and thinner, making the overall sole structure more desirable.

[0075] 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.

[0076] The outsole of the present invention is considerably thinner and lighter than sole structures 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.

[0077] In a fourth embodiment, the present invention relates to a sports shoe comprising the sole structure of the present invention or an outsole according to the present invention.

[0078] Sports shoes equipped with the outsole according to the present invention are considerably lightweight and thin, making the overall sports shoe more desirable. In addition, the sports shoes exhibit the same and / or even better durability and performance as sports shoes known in the art.

[0079] 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 sole structure, outsole, and sports shoe of the present invention.

[0080] 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 discussion and disclosure of the second aspect, 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.

[0081] 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]

[0082] [Figure 1] This is a flowchart illustrating the process for manufacturing the sole structure. [Figure 2] This is a diagram of a preferred embodiment of a sole structure manufactured using the method according to the present invention. [Figure 3] This is a diagram of a preferred embodiment of a sole structure manufactured using the method according to the present invention. [Figure 4] This is a diagram of a preferred embodiment of a sole structure manufactured using the method according to the present invention. [Figure 5] This is a diagram of a preferred embodiment of an outsole having a sole structure according to the present invention. [Figure 6] This is a diagram illustrating the manufacturing process of the outsole shown in Figure 5, which has the sole structure according to the present invention. [Modes for carrying out the invention]

[0083] 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.

[0084] 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 and / 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. Therefore, in order to avoid redundancy, the descriptions in the preceding sections, which also apply to the detailed descriptions below, are referenced.

[0085] Figure 1 shows a flowchart of a method 100 for manufacturing a sole structure 240, which is preferably for a sports shoe 260.

[0086] 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.%.

[0087] The polymer is characterized by its 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. Furthermore, 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.

[0088] 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 10The solvent is a mixture selected from the group consisting of esters, (C1-C8) ketones, (C1-C8) alkanes, and / or combinations thereof. Specifically, the solvent is one or more of tetrahydrofuran (THF), methyl ethyl ketone (MEK), cyclohexane (CYC), ethyl acetate, butyl acetate, preferably a mixture of THF and / or CYC. The ratio of this mixture may be in the range of 10 to 90 vol.%. The ratio is preferably 20 to 80 vol.%, more preferably 30 to 70 vol.%.

[0089] 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. Furthermore, in step 120, the liquefied polymer is placed on a base layer. The base layer is preferably a midsole, but may be a layer that is not part of the sports shoe. In other words, the base layer may be any layer on which the liquefied polymer is placed.

[0090] In step 110, a polymer layer and its portions are prepared. In this regard, the polymer layer and its portions are provided with cutouts. Specifically, these cutouts are provided with patterns. For example, the polymer layer is provided with cutouts in the shape of a square and / or a rectangular pattern. In this regard, any pattern is possible. In this connection, the polymer layer or its portions are placed on a base layer. The base layer is preferably a midsole, but may be a layer that is not part of the sports shoe. In other words, the base layer may be any layer on which the liquefied polymer is placed.

[0091] The liquefied polymer 230 may be placed on the base layer to a thickness of 1 to 10 mm. The thickness is preferably 2 mm to 4 mm, and most preferably 3 mm. The base layer 250 may be the midsole and / or the shoe upper and / or a portion thereof.

[0092] 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 base layer 250 may be 30° to 110°, preferably 40° to 90°, and more preferably 50° to 70°.

[0093] When placing the liquefied polymer in step 120, at least one of the following methods is applied: brushing, coating, dipping, painting, automated dispensing, automated printing, and controlled dispensing.

[0094] 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 a traction map, abrasion map, and / or pressure map. In this way, the liquefied polymer may be placed based on the individual needs and requirements of the wearer.

[0095] In step 120, the polymer layer and its portion are placed on the carrier layer.

[0096] Method 100 shown in Figure 1 further includes a step 130 of curing the placed liquefied polymer. Curing may be carried out using radiation. The curing temperature is between 20°C and 150°C. Preferably, the curing temperature is between 30°C and 100°C, more preferably between 40°C and 50°C. Furthermore, 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.

[0097] According to one alternative, the liquefied polymer obtained in step 120 (step b) is partially cured and textured in step 140 before step 130 (step c). The curing time is 10 to 60 minutes. The curing time may preferably be 15 to 40 minutes, more preferably 20 to 35 minutes, and most preferably 30 minutes.

[0098] It is preferable that the textured element is applied to a partially cured polymer. The textured element is preferably air-permeable. In this way, the partially cured polymer can be cured while being textured by the textured element.

[0099] Specifically, the textured element is applied to the partially cured polymer for at least 5 minutes. The application of the textured element may be preferably at least 1 hour, more preferably at least 6 hours, even more preferably at least 12 hours, and most preferably at least 24 hours. In some embodiments, the textured element is a fabric. However, the textured element may also be a stamp, an embossing element, and / or a mold.

[0100] According to a second alternative that may be performed in addition to the first alternative, the cured polymer of step 130 (step c) is placed in a mold structure 160. The mold structure comprises a textured sole imprint 340. The mold structure is then heated in step 170. This is preferably done by applying steam, for example, in a steam chamber mold. Simultaneously in step 170, the cured polymer is pressed onto the textured sole imprint of the mold structure. In the subsequent step 180, the cured polymer is heated to at least partially melt it. In this way, the textured sole imprint is substantially formed on the outer surface of the cured polymer.

[0101] Specifically, in steps 160 to 180, the base layer is dried for 2 hours, preferably 3 hours, more preferably 4 hours. Drying is preferably carried out at a temperature of at least 50°C, preferably 60°C, more preferably at least 70°C. Drying may be carried out using heat.

[0102] In this regard, steam chest molding may be preferred. The temperature may be at least 130°C. Preferably, the temperature is at least 150°C. More preferably, the temperature is at least 160°C. The steam treatment may be carried out for at least 30 seconds, preferably 45 seconds, and most preferably 1 minute. The steam treatment may be carried out for a maximum of 6 minutes, preferably 5 minutes, and most preferably 3 minutes.

[0103] A second alternative is also applied to the polymer layer and / or portion thereof. In the second alternative, the polymer layer and / or portion thereof is placed within a mold structure 160. The mold structure comprises a textured sole imprint 340. The mold structure is then heated in step 170. This is preferably done by applying steam, for example, in a steam chamber mold. Simultaneously in step 170, the polymer layer and / or portion thereof is pressed onto the textured sole imprint of the mold structure. In the subsequent step 180, the polymer layer and / or portion thereof is heated to at least partially melt the cured polymer. In this way, the textured sole imprint is substantially formed on the outer surface of the cured polymer.

[0104] Specifically, in steps 160 to 180, the base layer is dried for 2 hours, preferably 3 hours, and more preferably 4 hours. Drying is preferably carried out at a temperature of at least 50°C, preferably 60°C, and more preferably at least 70°C. Drying may be carried out using heat.

[0105] However, it is conceivable that the polymer layer and / or portion thereof may be textured in step 150 of method 100.

[0106] Following the first and / or second alternatives as shown in Figure 1, the sole structure 240 is obtained in step 190. The thickness of the sole structure 240 may be 0.3 mm to 0.7 mm, preferably 0.5 mm. Furthermore, the sole structure 240 may include a surface structure 400. This surface structure may be selected from the group including one or more of rectangles, grids, lattices, lines, helices, honeycombs, dots, waves, or any combination thereof.

[0107] In one embodiment, the sole structure 240 is the outsole 290 of a sports shoe 260. In another embodiment, the outsole 290 having a surface structure 400 is manufactured according to the method 100 shown in Figure 1. In yet another embodiment, the sports shoe 260 comprises the sole structure or outsole of the present invention.

[0108] The textured cured polymer may have a length of at least 0.5 cm, preferably 1 cm, more preferably 1.5 cm, and most preferably 2 cm, and / or a width of at least 0.7 cm, preferably 1.5 cm, more preferably 2.3 cm, and most preferably 3 cm.

[0109] 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 6.

[0110] Figure 2 shows a preferred embodiment of a sole structure 240 manufactured according to the method of the present invention (as described above in relation to Figure 1). The sole structure 240 has a rough texture and a matte design.

[0111] Specifically, the sole structure 240 shown in Figure 2 is obtained by partially curing the liquefied polymer after step d, and then texture the partially cured polymer using a fabric. The partially cured polymer is cured for 10 to 60 minutes. Preferably, the partially cured polymer is cured for 15 to 40 minutes, and more preferably for 20 to 30 minutes.

[0112] However, the sole structure 240 shown in Figure 2 may be obtained by placing a polymer layer within a mold structure having a textured sole imprint, heating the mold structure by applying steam within the mold structure while pressing the polymer layer onto the textured sole imprint, and heating the polymer layer to at least partially melt the polymer layer and to substantially form the textured sole imprint on the outer surface of the polymer layer.

[0113] Pattern 400 is obtained by texturedting a partially cured polymer. Specifically, the fabric is permeable, for example, having a permeable lattice structure, and is applied to a partially cured polymer. A permeable lattice for embossing is a structure that simultaneously applies a pattern to a surface while allowing air, heat, or material to pass through. For example, a perforated or mesh-like surface is used to press a pattern onto a material made of, for example, rubber, silicone, polyester, or nylon, while allowing air to escape.

[0114] As can be seen from Figure 2, pattern 400 is a honeycomb-shaped pattern. Specifically, a honeycomb-shaped pattern comprises multiple hexagonal elements. Pattern 400 can be a grid, lattice, line, spiral, honeycomb, dot, wave, sinusoidal pattern, or any combination thereof. The resulting pattern 400 is shallow.

[0115] In some embodiments, a force is applied to the fabric when it is being applied to a partially cured polymer. Preferably, a force between 5,000 and 15,000 kN is applied during the texturing step. In this way, it is ensured that the texture is applied to the partially cured polymer. Alternatively, a force between 1 and 1,000 N, preferably between 5 and 500 N, more preferably between 10 and 100 N, and even more preferably around 50 N is applied during the texturing step. Since the partially cured polymer may still be quite flexible during the texturing step, such a force may be sufficient to obtain the desired texture.

[0116] During the textured polymer processing time of 5 minutes, preferably at least 1 hour, more preferably at least 6 hours, even more preferably at least 12 hours, and most preferably 24 hours. The textured polymer is then cured 232, thereby providing the sole structure 240. In this way, the partially cured and textured polymer is fully cured.

[0117] Figure 3 shows a preferred embodiment of a sole structure 240 manufactured according to the method of the present invention (as described above in relation to Figure 1). The sole structure 240 has a rough texture and a matte design.

[0118] Specifically, pattern 400 is obtained by partially curing a liquefied polymer and then texture the partially cured polymer using a fabric. In this way, the fabric provides a shallow pattern 400.

[0119] The fabric used to texture the partially cured polymer is permeable and, for example, has a permeable lattice structure. As can be seen from Figure 3, pattern 400 is a grid-like pattern. Specifically, the grid-like pattern comprises two rectangular elements arranged in a repeating manner. Pattern 400 can be a grid, lattice, line, spiral, honeycomb, dot, wave, sinusoidal pattern, or any combination thereof.

[0120] In some embodiments, a force is applied to the fabric while it is being applied to the partially cured polymer during the textured step. Preferably, a force of 5,000 to 15,000 kN is applied during the textured step. In this way, it is ensured that a pattern is applied to the partially cured polymer.

[0121] During the textured polymer processing time of 5 minutes, preferably at least 1 hour, more preferably at least 6 hours, even more preferably at least 12 hours, and most preferably at least 24 hours. The textured polymer is then cured 232, thereby providing the sole structure 240. In this way, the partially cured and textured polymer is fully cured.

[0122] Figure 4 shows a preferred embodiment of the sole structure 204 manufactured according to the method of the present invention (as described above in relation to Figure 1). The sole structure 240 has a rough texture and a matte design.

[0123] Specifically, pattern 400 is obtained by partially curing a liquefied polymer and then textured the partially cured polymer using a stamp. In this way, the fabric provides a shallow pattern 400.

[0124] As can be seen from Figure 4, pattern 400 is a honeycomb-shaped pattern. Specifically, a honeycomb-shaped pattern comprises multiple hexagonal elements. Pattern 400 can be a grid, lattice, line, spiral, honeycomb, dot, wave, sinusoidal pattern, or any combination thereof. In this way, a shallow pattern 400 is obtained.

[0125] In some embodiments, a force is applied to the stamp when it is applied to a partially cured polymer. Preferably, a force of 5,000 to 15,000 kN is applied during the texturing step. In this way, it is ensured that the texture is applied to the partially cured polymer. It is conceivable that the applied force may not be so dependent on the material used.

[0126] The stamp may be a roller or plate with an engraved or etched design that is pressed onto the sole structural material. It is conceivable that heat may be used during the textured process.

[0127] Figure 5 shows a preferred embodiment of an outsole 290 having a sole structure 240. The sole structure 240 is manufactured according to the method of the present invention. The sole structure 240 has a rough texture and a matte finish.

[0128] Specifically, pattern 400 is obtained by placing a cured polymer within a mold structure containing a sole imprint. Specifically, the mold structure is heated by applying steam within the mold structure while indirectly pressing the cured polymer into the sole imprint. The cured polymer is then heated to at least partially melt the cured polymer and substantially form the sole imprint on the outer surface of the cured polymer.

[0129] However, the pattern 400 shown in Figure 5 may also be obtained by placing a polymer layer within a mold structure having a textured sole imprint, heating the mold structure by applying steam within the mold structure while pressing the polymer layer onto the textured sole imprint, and heating the polymer layer to at least partially melt the polymer layer and to substantially form the textured sole imprint on the outer surface of the polymer layer.

[0130] The outsole 290 shown in Figure 5 may be obtained in a similar manner by using a hot press. Specifically, the pattern 400 is obtained by placing a cured polymer within a mold structure including a sole imprint, the mold structure being heated while pressing the cured polymer into the sole imprint. As can be seen from Figure 5, the outsole 290 has a pattern 400 with a moss-like structure.

[0131] Figure 6 shows the process for manufacturing the outsole shown in Figure 5. As can be seen from Figure 6, the outsole 290 is made from a cured polymer 232. Specifically, a fibrous material 500, such as ultra-high molecular weight polyethylene (UHMWPE) fibers like Dyneema, is layered between the cured polymer and the sole imprint. Other fibrous materials such as (para)aramid, polybenzoxazole, liquid crystal polymer, metharamid, or any combination thereof may be used. However, it is conceivable that the cured polymer be pressed directly into the sole imprint.

[0132] Pattern 400 can be a grid, lattice, line, spiral, honeycomb, dot, wave, sinusoidal pattern, or any combination thereof. The cured polymer 232 is placed between the fibrous material 500 (shown as a transparent sheet) and the molded structure having a sole imprint 340.

[0133] 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.

[0134] Furthermore, this application discloses the following embodiments. [1] A method (100) for manufacturing a sole structure (240) which is preferably for sports shoes (260), a. A step of preparing (110) a liquefied polymer (230) and / or a polymer layer or portion thereof, b. The step of placing the liquefied polymer and / or the polymer layer or portion thereof on the base layer (250) (120), c. A step of curing the liquefied polymer (130), The method includes a group of first steps and / or a group of second steps, and the group of first steps is d. A step of partially curing (140) the liquefied polymer (230) obtained in step b, e. A step of texture the partially cured polymer (231) before step c (150), The group of the second step includes, f. A step of placing (160) the cured polymer (232) obtained in step c, and / or the polymer layer or portion thereof obtained in step b, into a mold structure (300) having a textured sole imprint (340), g. A step of heating the mold structure (300) by applying steam to the mold structure (300) while pressing the cured polymer (232) and / or the polymer layer or portion thereof onto the textured sole imprint (340) (170), h. A step of heating (180) the cured polymer (232) and / or the polymer layer or portion thereof in order to at least partially melt the cured polymer and / or the polymer layer or portion thereof, and to substantially form the textured sole imprint (340) on the outer surface of the cured polymer (232) and / or the polymer layer or portion thereof, i. The step of obtaining the sole structure (240) thereby (190), Method (100), including the method (100). [2] The method according to [1], wherein the polymer layer or portion thereof is placed on the carrier layer. [3] The method according to [1] or [2], wherein the polymer layer or portion thereof comprises one or more cutouts. [4] The method according to any one of [1] to [3], wherein in the step of texture the partially cured polymer (150), a textured element is applied to the partially cured polymer, and the textured element is preferably air permeable. [5] The method according to [4], wherein the textured element is applied to the partially cured polymer for at least 5 minutes, preferably at least 1 hour, more preferably at least 6 hours, even more preferably at least 12 hours, and most preferably at least 24 hours. [6] The method according to any one of [5] to [6] (100), wherein the textured element is a woven fabric. [7] The method according to any one of [1] to [6] (100), wherein the curing time in the step of partially curing the liquefied polymer (230) (140) is 10 to 60 minutes, preferably 15 to 40 minutes, more preferably 20 to 35 minutes, and most preferably 30 minutes. [8] The method (100) according to any one of [1] to [7], wherein the sole structure (240) comprises a surface structure (400). [9] The method (100) according to [8], wherein the surface structure (400) is selected from the group including one or more of rectangles, grids, lattices, lines, helices, honeycombs, dots, waves, or any combination thereof.

[10] The method according to any one of [1] to [9] (100), wherein the sole structure (240) is the outsole (290) of the sports shoe (260).

[11] The method (100) according to any one of [1] to

[10] , wherein the liquefied polymer (230) and / or the polymer layer or portion thereof is placed on one or more sections 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.

[12] The method (100) of any one of [1] to

[11] , wherein the liquefied polymer (230) and / or the polymer layer or portion thereof is placed on one or more predetermined portions of the sports shoe (260) determined using a traction map, abrasion map, and / or pressure map.

[13] The method (100) according to any one of [1] to

[12] , wherein the liquefied polymer (230) and / or the polymer layer or portion thereof is disposed on the base layer to a thickness of 1 to 10 mm, preferably 2 to 4 mm, most preferably 3 mm.

[14] The method according to any one of [1] to

[13] (100), wherein the thickness of the sole structure (240) is 0.3 mm to 0.7 mm, preferably 0.5 mm.

[15] The method(100) of any one of [1] to

[14] , wherein the setting (120) step is performed by at least one of the following methods: brushing, coating, dipping, painting, automatic dispensing, automatic printing, and controlled dispensing.

[16] The method (100) of any one of [1] to

[15] , wherein the base layer (250) is the midsole and / or the shoe upper and / or a portion thereof.

[17] The method (100) according to any one of [1] to

[16] , wherein the liquefied polymer (230) is 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.

[18] The method according to any one of [1] to

[17] (100), wherein the contact angle θ between the liquefied polymer (230) and the base layer (250) is 30° to 110°, preferably 40° to 90°, and more preferably 50° to 70°.

[19] The method according to any one of [1] to

[18] (100), wherein the curing step (130, 140) is performed using radiation.

[20] The method according to any one of [1] to

[19] (100), wherein 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.

[21] The method according to

[18] (100), wherein the solvent is a mixture selected from the group of solvent-based solvents and / or aqueous solvents, preferably from the group of solvent-based solvents, more preferably from the group of (C1-C6) ethers, (C1-C10) esters, (C1-C8) ketones, (C1-C8) alkanes, and / or combinations thereof.

[22] The method according to

[18] or

[19] (100), wherein the solvent is a mixture of one or more of tetrahydrofuran (THF), methyl ethyl ketone (MEK), cyclohexane (CYC), ethyl acetate, butyl acetate, preferably THF and / or CYC.

[23] The method according to any one of

[18] to

[20] (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.%.

[24] The method according to

[18] (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, 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.

[25] The method according to any one of

[18] to

[22] (100), wherein 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.%.

[26] The method according to any one of [1] to

[25] (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.

[27] The method according to any one of [1] to

[26] (100), wherein in the curing step (130, 140), a curing temperature between 20°C and 150°C, preferably between 30°C and 100°C, more preferably between 40°C and 50°C, and in the step of curing the liquefied polymer (130), 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.

[28] A sole structure (240) manufactured according to the method described in any one of paragraphs [1] to

[27] . An outsole (290) manufactured in accordance with the method described in any one of paragraphs [1] through

[27] .

[30] The outsole (290) described in

[29] , having a surface structure (400). Sports shoes (260) having the sole structure described in

[31]

[28] or the outsole described in any one of

[29] to

[30] . [Explanation of symbols]

[0135] 100 ways 160 mold structure 230 Liquefied Polymer 232 Cured polymer 240 Sole Structure 250 base layer 260 Sports Shoes 290 Outsole 340 Textured sole imprint 400 Surface structure 500 Fiber Materials

Claims

1. A method for manufacturing a sole structure, preferably for sports shoes, a. A step of preparing a liquefied polymer and / or a polymer layer or portion thereof, b. The step of placing the liquefied polymer and / or the polymer layer or portion thereof on the base layer, c. A step of curing the liquefied polymer, The method includes a group of first steps and / or a group of second steps, and the group of first steps is d. A step of partially curing the liquefied polymer obtained in step b, e. A step of texture the partially cured polymer before step c, The group of the second step includes, f. A step of placing the cured polymer obtained in step c, and / or the polymer layer or portion thereof obtained in step b, into a mold structure having a textured sole imprint, g. The step of heating the mold structure by applying steam to the mold structure while pressing the cured polymer and / or the polymer layer or portion thereof onto the textured sole imprint, h. The steps of heating the cured polymer and / or the polymer layer or portion thereof in order to at least partially melt the cured polymer and / or the polymer layer or portion thereof, and to substantially form the textured sole imprint on the outer surface of the cured polymer and / or the polymer layer or portion thereof, i. The step of obtaining the sole structure thereby, Methods that include...

2. The method according to claim 1, wherein the polymer layer or a portion thereof is disposed on a carrier layer.

3. The method according to claim 1, wherein the polymer layer or portion thereof comprises one or more cutouts.

4. The method according to claim 1, wherein in the step of texture-forming the partially cured polymer, a texture-forming element is applied to the partially cured polymer, and the texture-forming element is preferably air-permeable.

5. The method according to claim 4, wherein the textured element is applied to the partially cured polymer for at least 5 minutes, preferably at least 1 hour, more preferably at least 6 hours, even more preferably at least 12 hours, and most preferably at least 24 hours.

6. The method according to claim 4, wherein the textured element is a woven fabric.

7. The method according to claim 1, wherein the curing time in the step of partially curing the liquefied polymer is 10 to 60 minutes, preferably 15 to 40 minutes, more preferably 20 to 35 minutes, and most preferably 30 minutes.

8. The method according to claim 1, wherein the sole structure comprises a surface structure.

9. The method according to claim 8, wherein the surface structure is selected from the group including one or more of rectangles, grids, lattices, lines, helices, honeycombs, dots, waves, or any combination thereof.

10. The method according to claim 1, wherein the sole structure is the outsole of the sports shoe.

11. The method according to claim 1, wherein the liquefied polymer and / or the polymer layer or portion thereof is placed on one or more sections of the sports shoe, including a toe section, a forefoot section, a heel section, a midsole section, a sidewall section, and / or an upper section.

12. The method according to claim 1, wherein the liquefied polymer and / or the polymer layer or portion thereof is placed on one or more predetermined portions of the sports shoe determined using a traction map, abrasion map, and / or pressure map.

13. The method according to claim 1, wherein the liquefied polymer and / or the polymer layer or portion thereof is disposed on the base layer to a thickness of 1 to 10 mm, preferably 2 mm to 4 mm, most preferably 3 mm.

14. The method according to claim 1, wherein the thickness of the sole structure is 0.3 mm to 0.7 mm, preferably 0.5 mm.

15. The method according to claim 1, wherein the placement step is performed by at least one of the following methods: brushing, coating, immersion, painting, automatic dispensing, automatic printing, and controlled dispensing.

16. The method according to claim 1, wherein the base layer is the midsole and / or the shoe upper and / or a portion thereof.

17. The method according to claim 1, wherein the liquefied polymer is disposed in a first section of the sports shoe with a kinematic viscosity coefficient of 30,000 to 50,000 mPa·s and in a second section of the sports shoe with a kinematic viscosity coefficient of 10,000 to 30,000 mPa·s.

18. The method according to claim 1, wherein the contact angle θ between the liquefied polymer and the base layer is 30° to 110°, preferably 40° to 90°, and more preferably 50° to 70°.

19. The method according to claim 1, wherein the curing step is performed using radiation.

20. The method according to claim 1, 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), preferably thermoplastic polyurethane (TPE-U or TPU), and / or combinations thereof.

21. The method according to claim 18, wherein the solvent is a mixture selected from the group of solvent-based solvents and / or aqueous solvents, preferably from the group of solvent-based solvents, more preferably from the group of (C1-C6) ethers, (C1-C10) esters, (C1-C8) ketones, (C1-C8) alkanes, and / or combinations thereof.

22. The method according to claim 18, wherein the solvent is a mixture of one or more of tetrahydrofuran (THF), methyl ethyl ketone (MEK), cyclohexane (CYC), ethyl acetate, butyl acetate, and preferably THF and / or CYC.

23. The method according to claim 18, 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.%.

24. The method according to claim 18, 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, 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.

25. The method according to claim 18, wherein 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.%.

26. The method according to claim 1, wherein the liquefied polymer has a kinematic viscosity coefficient of 10,000 to 50,000 mPa·s, preferably 20,000 to 40,000 mPa·s.

27. The method according to claim 1, wherein in the curing step, a curing temperature between 20°C and 150°C, preferably between 30°C and 100°C, more preferably between 40°C and 50°C, is used, and in the step of curing the liquefied polymer, 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.

28. A sole structure manufactured according to the method described in any one of claims 1 to 27.

29. An outsole manufactured according to the method described in any one of claims 1 to 27.

30. An outsole according to claim 29, having a surface structure.

31. A sports shoe comprising the sole structure described in claim 28, or the outsole described in claim 29.

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