Shoe and method for producing same

Abstract

The invention relates to a shoe with an upper, an insole secured thereto, and an outsole connected to the upper and the insole, wherein the insole comprises a foam material, and the outsole is connected to the upper and the insole secured thereto by means of an additional foam material which is provided at least between the upper with the insole secured thereto and the outsole and is in contact with an end portion of the upper and with part of the insole secured thereto.

Description

[0001] Late registration

[0002] Hero GmbH & Co. KG H34575WO

[0003] Shoe and manufacturing process

[0004] The invention relates to a shoe and a corresponding manufacturing process. Traditionally, shoes are manufactured by joining a pre-made upper made of a top material to an insole, for example made of leather, by last stitching or lasting. The shoe and insole are then joined to a sole using expandable polyurethane. A functional midsole can also be arranged in the sole, providing the shoe with, for example, cushioning properties. The arrangement of the midsole represents an additional manufacturing step.

[0005] The object of the present invention is to provide a shoe and a corresponding manufacturing method in which a midsole is not required, but the shoe nevertheless has the function of a midsole. This object is achieved by a shoe having the features of claim 1 and a manufacturing method having the features of claim 9.

[0006] The shoe according to the invention has an upper with an attached insole and an outsole connected to the upper and the insole, wherein the insole comprises a foam material and the outsole is connected to the upper and the attached insole by a further foam material, which is arranged at least between the upper with the attached insole and the outsole and is in contact with both an end section of the upper and with a part of the attached insole.

[0007] An insole made entirely of foam material has the advantage that it can also possess a functional property based on the foam material, such as cushioning. This eliminates the need for an additional midsole with this property, allowing for a simplified shoe manufacturing process.

[0008] According to one design, the insole is shaped in one or more areas to fulfill a specific function of the shoe. A functional area may be located on the underside of the insole. Additionally or alternatively, one or more areas may be formed on the upper side of the insole, giving it another specific property or function, such as a footbed that supports the wearer's foot in certain areas, provides better support, or one or more areas that stimulate the foot.

[0009] The insole can be given one or more desired functions through a special shaping. For example, a cushioning function can be achieved by molding a midsole from foam material in a specific area on the underside of the insole, such as the heel or midfoot area, or along the entire length of the insole.

[0010] According to one embodiment, the insole has increased thickness at least in one area, which includes the heel, midfoot, or forefoot area, or a combination thereof. This area is designed to fulfill a specific function of the insole, such as providing cushioning for the shoe. The insole may be wider in its upper area, which is designed to accommodate the foot, than in its lower area, which faces the outsole and has increased thickness. The rim formed between the upper and lower areas of the insole may be designed to secure the insole to the upper.

[0011] The foam material, which is arranged in the finished shoe between the upper with the attached insole and the outsole and is in contact with both an end section of the upper and with a part of the attached insole, preferably surrounds the area of ​​the insole with the increased thickness from all sides, is in contact with it and is thus firmly connected.

[0012] According to one embodiment, the insole has at least one or more recesses or depressions in at least one area, which are designed to fulfill a specific function of the insole. The recesses or depressions may be provided on the underside or the top side of the insole and may extend in a substantially vertical or horizontal direction relative to the longitudinal section plane of the insole. The recesses or depressions may be adapted to the anatomy of a wearer's foot or may have a cushioning function.

[0013] According to one embodiment, the foam material of the insole is connected to the upper by Strobel bonding. In this process, the upper material of the upper is not directly attached to the

[0014] The insole is not glued or sewn, but rather connected to the outer edge of the insole with a special thread around the edge of the lower end of the upper material. According to one embodiment, the foam material of the insole is attached to the upper by crimping. In crimping, the upper material of the upper is stretched over a form (last) at its lower end and attached to the insole. The upper material is pulled and fixed with nails, staples, or glue.

[0015] Alternatively, the foam material of the insole can also be attached to the upper using a combination of Strobel and lasting stitches. For example, lasting stitches can be used in the front of the shoe and Strobel stitching in the middle and rear of the insole.

[0016] According to one embodiment, the insole is coated or covered with a woven or knitted fabric, such as a microfiber material or Alcantara. This allows moisture-regulating properties similar to those of a conventional insole to be achieved, thus increasing the wearing comfort of the shoe.

[0017] According to one embodiment, the foam material comprises or consists of a foamed polymer material, polystyrene, polyurethane, in particular expanded thermoplastic polyurethane. Preferably, a foamed polymer material, such as polystyrene, is used for the insole, and expanded thermoplastic polyurethane is used for the outsole. Expanded thermoplastic styrene, expanded polystyrene, expanded polypropylene, expanded thermoplastic polyamide, expanded thermoplastic copolyester, expanded thermoplastic polyolefin, or other materials not mentioned are also conceivable as foam materials that can be used for both the insole and the outsole. The material's softness is preferably at a density of 200–350 kg / m³. 3 The melting point of the materials is preferably greater than 230°C.

[0018] According to the invention, a method for manufacturing a shoe with an upper and an attached insole is also provided. It comprises attaching the upper to an insole comprising a foam material, inserting the upper with the attached insole into a mold, and inserting further foam material into the mold below the upper with the attached insole to produce the outsole.

[0019] According to one embodiment, the method further comprises inserting a sole, which is made of, for example, rubber or latex, into the mold at a distance from the upper with the insole attached to it, wherein the foam material is inserted between the upper with the insole attached to it and the rubber sole and connects the upper with the insole attached to it and the rubber sole in the mold, and the outsole is produced after the foam material has hardened and cooled.

[0020] The inventive method enables the simplified production of shoes with special functions, for which a midsole made of a material suitable for the function is usually required. The special function, or even several special functions, can be formed directly from the foam material of the insole according to the invention. The foam material used for the insole can, for example, be a foamed polymer material such as polystyrene or polyurethane.

[0021] According to one embodiment, the foam material injected into the mold on the underside of the shaft with the associated insole comprises expandable thermoplastic polyurethane.

[0022] According to one embodiment, the method involves joining the upper to an insole containing a foam material by strobbing, pinching, or a combination thereof. Combinations of both methods can also be used to join the upper to the insole.

[0023] According to one embodiment, the method involves coating or covering the insole with a woven or knitted fabric. This can create moisture-regulating conditions and increased wearing comfort for the wearer's foot.

[0024] Further features, properties and advantages of the invention will become apparent from the following drawing of a preferred embodiment of the invention, according to the

[0025] Fig. 1 shows a shoe with an insole made of foam material and an upper attached to it in a top view of an embodiment;

[0026] Fig. 2 shows the shoe according to the embodiment in cross-section; and

[0027] Figure 3 shows a sequence of a manufacturing process according to one embodiment of the invention. One embodiment of the invention is described below with reference to the figures.

[0028] According to the embodiment shown in Figures 1 and 2, a shoe 2 has an insole 1 made of a foam material on the underside of an upper 3. The foam material can, for example, be a foamed polymer material. The insole 1 is firmly connected to the upper 3 above it. In particular, the insole 1 is attached to the lower edge of the upper 3 in the midfoot area and in the heel 4 area by a Strobel seam 5. The Strobel seam 5 is formed by a thread sewn spirally around the contact area between the insole 1 and the edge of the upper 3. In the front area of ​​the shoe 2, the upper 3 is attached to the insole 1 by a last 7.

[0029] The insole 1, made of foamed polymer material, exhibits cushioning properties due to the inclusion of air bubbles within it. As can be seen in Figures 1 and 2, the insole 1 has a substantially flat surface on the side facing the interior of the shoe 2. The insole 1 is thickened on its underside in the area of ​​the heel 4. This thickening of the insole 1 provides improved cushioning properties for the shoe 2 at the heel 4 without the need for a separate midsole. The insole 1 can have a thickness in the heel area that is, for example, two, three, four, or five times the thickness of the insole 1 in the forefoot area. The thickened area on the underside of the insole 1 can have a reduced width compared to the width of the insole 1 above the thickened area.The insole 1 has an edge on its side facing the interior of the shoe 2, to which the lower edge of the upper 3 can be attached using the Strobel seam 5 or the last 7. To form this edge, the lower cushioning area of ​​the insole 1 is set back from the upper area of ​​the insole 1. The insole 1 can be given a variety of different shapes during manufacturing.

[0030] As shown in Fig. 2, the insole 1, prefabricated from a foam material, can have a thickened or reinforced area in a specific region, such as the heel 4. This thickened area provides cushioning to the finished shoe 2 and is formed as a single unit with the insole 1. This thickened area can also have a special shape, such as a wedge shape, which further enhances the cushioning function. Additionally, recesses, such as holes or indentations, can be provided in the thickened area or in other areas of the insole 1. Depending on their size and shape, these recesses can also contribute to the cushioning function in a predefined manner. These recesses can also be filled with a different material.The insole 1 may also have a special shape on the upper side, such as a footbed or one or more raised areas at the edge, for example at the arch of the foot, to support a foot.

[0031] Beneath the upper 3, with the attached insole 1, is a sole 9 made of thermoplastic polyurethane. The sole 9 is produced by injecting the polyurethane into a mold 11, which is positioned beneath the upper 3 and the attached insole 1. During the injection of the polyurethane, the mold 11 seals the space beneath the upper 3. The mold 11 also defines the outer shape of the sole 9 beneath the upper 3. The sole 9 may also have a layer 13 of rubber or latex on its underside, which is bonded to the sole 9, as well as to the upper 3 and the attached insole 1, during the injection of the polyurethane.

[0032] A method for manufacturing a shoe 2 according to the embodiment shown in Fig. 1 and Fig. 2 can comprise the steps shown in Fig. 3. First, in a first step 1010, an upper 3 for a shoe 2, made from an upper material, is joined to an insole 1. The upper 3 can be attached to the insole 1 by means of a Strobel seam 5, a lasting seam 7, or a combination of these two fastening methods, as described above.

[0033] In a further step 1020, the upper 3 with the attached insole 1 is placed in a mold 11 and thus sealed at the bottom. Optionally, in a step 1030, a sole 13, such as a rubber sole, is inserted into the mold 11. Finally, in step 1040, the upper 3 with the attached insole 1 and the rubber sole 13 are joined by injecting a foam material into the mold 11 on the underside of the upper 3, i.e., between the upper 3 and the rubber sole 13. The foam material can be thermoformable polyurethane. The outsole 9 can also be produced without inserting a rubber sole 13, simply by injecting the foam material into the otherwise empty mold 11 beneath the upper 3.

[0034] Numerous modifications can be made to the preferred embodiment without departing from the scope of the invention. Reference numerals:

[0035] 1 insole

[0036] 3 shaft

[0037] Paragraph 4

[0038] 5 Strobel seam

[0039] 7 pinch connection

[0040] 9 Outsole shape

[0041] 13 Rubber sole

Claims

Late registration Hero GmbH & Co. KG H34575WO Claims 1. Shoe (2) comprising an upper (3), an insole (1) attached thereto, and an outsole (9) connected to the upper (3) and the insole (1), wherein the insole (1) comprises a foam material and the outsole (9) is connected to the upper (3) and the insole attached thereto by a further foam material which is arranged at least between the upper (3) with the insole (1) attached thereto and the outsole (9) and is in contact with both an end section of the upper (3) and with a part of the insole (1) attached thereto.

2. Shoe (2) according to claim, wherein the insole (1) is designed at least in one area such that a special function of the shoe (2) is thereby realized.

3. Shoe (2) according to claim 1 or 2, wherein the insole (1) has an increased thickness at least in an area comprising the heel area, midfoot area or forefoot area or a combination of these areas, and this area is designed to fulfill a specific function of the insole (1).

4. Shoe (2) according to one of claims 1-3, wherein the insole (1) has at least in one area one or more recesses or depressions which are arranged to fulfill a specific function of the insole.

5. Shoe (2) according to one of claims 1-4, wherein the foam material of the insole (1) is connected to the upper (3) by a Strobel seam (5).

6. Shoe (2) according to one of claims 1-5, wherein the foam material of the insole (1) is connected to the upper (3) by a gusset connection (7).

7. Shoe (2) according to one of claims 1-6, wherein the insole (1) is coated or covered with a woven or knitted fabric, such as a microfiber material or Alcantara.

8. Shoe (2) according to one of claims 1-7, wherein the foam material comprises a foamed polymer material, polystyrene, polyurethane, in particular expanded thermoplastic polyurethane or a combination thereof. 9- Method for manufacturing a shoe (2) with an upper (3) and an insole (1) attached thereto, comprising: - Attaching (1010) the shaft (3) to an insole (1) comprising a foam material; - Inserting (1020) the shaft (3) with the insole (1) attached to it into a mold (11); - Imports (1040) of another foam material into the mold (11) under the shaft (3) with the insole (1) attached to it, to produce the outsole (9).

10. Method according to claim 9, which further comprises inserting (1030) a rubber sole (13) into the mold, wherein the foam material is inserted between the upper (3) with the insole (1) attached thereto and the rubber sole (13) and connects the upper (3) with the insole (1) attached thereto and the rubber sole (13).

11. Method according to claim 9 or 10, wherein the foam material comprises expandable thermoplastic polyurethane which is injected into the mold at the bottom of the shaft (3) with the insole (1) associated therewith.

12. Method according to any one of claims 9 to 11, wherein fastening the shaft (3) to the insole (1) comprising a foam material comprises strobbing, pinching or a combination thereof.

13. Method according to any one of claims 9 to 12, comprising coating or covering the insole (1) with a woven or knitted fabric.

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