Recyclable article of footwear

Abstract

The present invention relates to a recyclable article of footwear designed for complete recycling The footwear comprises an outsole layer made of a first type of recyclable thermoplastic polyurethane (TPU) and a midsole layer directly bonded to the outsole layer, forming a dual-layer sole construction. The midsole, made of a softer second type of recyclable TPU. The upper features a plurality of straps, also made of recyclable material, either mechanically attached to the midsole layer using a recyclable adhesive. In another example, the plurality of straps are integrally formed with buttons for secure attachment. The entire footwear, including a customizable TPU film for aesthetic purposes, can be processed as a whole in an extruder, converting it into TPU granules without prior disassembly which can further be used in making of the new footwear. This innovation addresses the need for sustainable, fully recyclable and circular footwear.

Description

RECYCLABLE ARTICLE OF FOOTWEARFIELD OF THE INVENTION

[0001] The present invention relates generally to a recyclable article of footwear and more specifically to a footwear which is designed to be processed as a whole into granules for recycling without the need for prior disassembly.BACKGROUND

[0002] In recent years, there has been a growing awareness of the environmental impact caused by non-recyclable footwear. Traditional footwear is typically made from a combination of synthetic materials, rubber, and adhesives that are not easily recyclable and can persist in landfills for many years. Consequently, there is an increasing demand for sustainable and environmentally friendly alternatives that minimize waste and reduce the ecological footprint of footwear products.

[0003] Several attempts have been made to develop recyclable footwear. For example, some designs have focused on using recyclable materials for specific components of the footwear, while others have explored modular designs that allow for easier disassembly and recycling of individual parts. However, these approaches often come with significant drawbacks. Modular designs can be complex and costly to manufacture, while partial use of recyclable materials does not fully address the issue of non-recyclability.

[0004] Existing recyclable footwear solutions suffer from several limitations. One major limitation is the complexity in disassembly; many designs require the user to disassemble the footwear into its constituent parts before recycling, which can be time-consuming and impractical. Additionally, some footwear only incorporates recyclable materials in select components, leaving other parts non-recyclable andenvironmentally harmful. Manufacturing challenges are also prevalent, as modular designs and multi-material constructions can be complex and expensive to produce, limiting their widespread adoption. Furthermore, current recyclable footwear often lacks options for aesthetic customization, which can limit consumer appeal.

[0005] In light of above, there exists a need for an easily recyclable article of footwear.

[0006] Thus, it is an object of the present invention to provide an easily recyclable article of footwear and use of the recycled material in the further making of footwear and footwear parts ensuring a complete circularity.SUMMARY OF THE INVENTION

[0007] The object of the present invention is achieved by a recyclable article of footwear. The recyclable article of footwear comprises an outsole layer configured for ground contact. The outsole layer is made of a first type of recyclable material.

[0008] The recyclable article of footwear further comprises a midsole layer directly bonded to an interior face of the outsole layer, forming a dual-layer sole construction. The midsole layer is made of a second type of recyclable material.

[0009] The second type of recyclable material is softer than the first type of recyclable material. The first type of recyclable material and the second type of recyclable material comprises thermoplastic polyurethane (TPU).

[0010] The recyclable article further comprises an upper comprising a plurality of straps, made of the recyclable material, mechanically attached to an interior face of the midsole layer. The outsole layer, the midsole layer, and the plurality of straps are made of the recyclable material.

[0011] The plurality of straps are mechanically attached to the interior face of the midsole layer via a recyclable adhesive. The plurality of straps are moulded straps by using recyclable material. The article of footwear is recyclable as a whole through direct conversion into granules for recycling without a need for prior disassembly.

[0012] The plurality of straps are also made with buttons for mechanically attaching to the sole. This is also recyclable as a whole and can be converted to granules which can be used for further making of footwear.

[0013] The recyclable article of footwear further comprising a customizable layer which is directly bonded onto the interior face of the midsole layer. The customizable layer is customizable based on a plurality of designs. The midsole layer comprises a layer of printed TPU sheets.

[0014] In one example, a top layer may comprise Expanded TPU (ETPU).

[0015] The recyclable article of footwear is configured to be processed as a whole in an extruder, and thereby converted into TPU granules.BRIEF DESCRIPTION OF FIGURES

[0016] FIG 1 is a diagram of perspective view of a recyclable article of footwear, according to an embodiment of the present invention; and

[0017] FIG 2 is a diagram of a side view of a recyclable article of footwear, in which an embodiment of the present invention can be implemented.DETAILED DESCRIPTION

[0018] FIG 1 is a diagram of perspective view of a recyclable article of footwear 100, according to an embodiment of the present invention.

[0019] Referring to FIG. 2, the recyclable article of footwear 100 comprises an outsole layer 102, a midsole layer 104, and an upper 106. The outsole layer 102 comprises an interior face 102A and an exterior face 102B. The midsole layer 104 comprises an interior face 104A and an exterior face 104B. The recyclable article of footwear 100 further comprises a customizable layer 108. The upper 106 comprises a plurality of straps 112. The plurality of straps 112 are attached to the midsole layer 104 via a recyclable adhesive 114 or plugs.

[0020] The outsole layer 102 is made of a first type of a recyclable material. The midsole layer 104 is directly bonded to the interior face 102A of the outsole layer 102, forming a dual -layer sole construction.

[0021] The outsole layer 102, being in direct contact with ground, provides durability and resistance against wear and tear, which ensures a longer lifespan for the recyclable article of footwear 100. The recycled granules by recycling the footwear is used to make the outsole layer 102 of the footwear 100.

[0022] The midsole layer 104, which is directly bonded to the interior face 102A of the outsole layer 102, adds a layer of comfort and cushioning for a user of the recyclable article of footwear 100. The second type of recyclable material used in the midsole layer 104 is softer than the material in the outsole layer 102, which enhances shock absorption and reduces strain on a wearer's feet during prolonged use. By forming a dual-layer sole construction, the footwear 100 achieves a balance between durability and comfort, catering to both a structural integrity required for ground contact and ergonomic needs of the user.

[0023] The dual-layer sole construction ensures that the recyclable article of footwear 100 maintains shape and support overtime while providing a comfortableexperience for the wearer. A seamless bonding of the midsole layer 104 to the outsole layer 102 eliminates the need for additional adhesives or components, which simplifies manufacturing process and makes the entire recyclable article of footwear 100 easier to recycle. Integration of the midsole layer 104 and the outsole layer 102 into a single construction creates a fully recyclable product without compromising on performance or comfort. By using recyclable materials in both the outsole layer 102 and the midsole layer 104, the recyclable article of footwear 100 supports environmental sustainability and reduces waste. The first type of recyclable material and the second type of recyclable material comprise thermoplastic polyurethane TPU.

[0024] The outsole layer 102, the midsole layer 104, and the plurality of straps 112 are made of the recyclable material.

[0025] The upper 106 is a crucial component of the recyclable article of footwear 100, providing essential support and securing the recyclable article of footwear 100 to the wearer's foot. The plurality of straps 112, is strategically designed to ensure a comfortable and secure fit. The plurality of straps 112 are made of the recyclable material, which aligns with the overall sustainable design of the footwear 100.

[0026] Mechanically attaching the plurality of straps 112 to the interior face 104A of the midsole layer 104 enhances a structural integrity and durability of the recyclable article of footwear 100. A mechanical attachment method, such as using integrally formed buttons, ensures that the plurality of straps 112 remain securely in place during use. Thus, a manufacturing process of the recyclable article of footwear 100 is simplified, and provides a reliable connection between the upper 106 and the midsole layer 104, contributing to an overall durability of the recyclable article of footwear 100.

[0027] The use of thermoplastic polyurethane TPU as both the first type of recyclable material and the second type of recyclable material provides severaladvantages. TPU is known for versatility, durability, and flexibility - an ideal choice for different components of the recyclable article of footwear 100. The first type of recyclable material, used in the outsole layer 102, offers robust protection against wear and tear, ensuring the recyclable article of footwear 100 can withstand various surfaces and conditions. For example, a person wearing the footwear 100 can walk on rough terrains or urban pavements without worrying about significant damage to the outsole layer 102.

[0028] The second type of recyclable material, which is softer than the first type of recyclable material, is used in the midsole layer 104 to provide enhanced comfort and cushioning. The softness of the second type of recyclable material helps in absorbing shocks and reducing the impact on the feet, which is particularly beneficial for daily wear. For instance, someone using the recyclable article of footwear 100 for long walks or standing for extended periods will experience less foot fatigue due to cushioning effect of the midsole layer 104.

[0029] The recyclable material used in the outsole layer 102, midsole layer 104, and plurality of straps 112 is designed to be recycled. Thus, the recyclable article of footwear 100 does not contribute to long-term waste.

[0030] The integration of TPU in both the first type of recyclable material and the second type of recyclable material, along with the use of recyclable material for all components, exemplifies a commitment to creating a fully sustainable product. The advantages include reduced environmental impact, enhanced user comfort, and the ability to recycle the footwear 100 efficiently.

[0031] The plurality of straps 112 are mechanically attached to the interior face 104A of the midsole layer 104 via a recyclable adhesive 114. The use of the recyclable adhesive 114 to attach the plurality of straps 112 to the midsole layer 104 offers several advantages. The recyclable adhesive 114 ensures that the entire article of footwear 100 remains environmentally friendly, aligning with overallsustainable design. Additionally, use of moulded straps with integrally formed buttons provides a secure and durable mechanical attachment, enhancing structural integrity of the footwear 100.

[0032] The recyclable article of footwear 100 is recyclable as a whole through direct conversion into granules for recycling without a need for prior disassembly. Thus, the direct conversion approach significantly reduces a complexity and labor involved in a recycling process of the recyclable article of footwear 100. Instead of having to separate different components, the entire footwear 100 can be processed together, making recycling more efficient and cost-effective. For instance, after the recyclable article of footwear 100 reaches an end of lifecycle, the recyclable article of footwear 100 can be collected and directly fed into a recycling machine, which converts the entire footwear 100 into granules. The granules can then be used to manufacture the first layer 102 and the plurality of straps 112 of new footwear or other products, promoting a circular economy.

[0033] The recyclable article of footwear 100 further comprises a customizable layer 108 which is directly bonded onto the interior face 104A of the midsole layer 104. The customizable layer 108 is customizable based on a plurality of designs, allowing for personalization and aesthetic variety. For example, consumers can choose from different colors, patterns, or textures for the customizable layer 108, making the recyclable article of footwear 100 more appealing and unique. This feature enhances the user experience by providing options for individual expression while maintaining the environmental benefits of the recyclable design.

[0034] The midsole layer 104 comprises a layer of Expanded TPU (ETPU), which offers additional advantages. ETPU is known for its lightweight and highly resilient properties, providing superior cushioning and comfort. The inclusion of ETPU in the midsole layer 104 ensures that the footwear 100 offers excellent shock absorption and energy return, making it comfortable for extended wear. For example, someone wearing the footwear 100 for long walks or standing forprolonged periods will benefit from the enhanced cushioning provided by the ETPU layer.

[0035] The recyclable article of footwear 100 is configured to be processed as a whole in an extruder, and thereby converted into TPU granules. The use of an extruder streamlines the recycling process, allowing the entire footwear 100 to be transformed into reusable material efficiently. The extruder breaks down the footwear 100 into small granules, which can then be used to create new products. For instance, the TPU granules produced from the recycled footwear 100 can be used to manufacture new soles, uppers, or other components, ensuring that the material is continuously reused and reducing waste.

[0036] The invention of the recyclable article of footwear 100 offers numerous advantages due to its innovative design and sustainable materials. One advantage is the environmental sustainability provided by the recyclable materials used in the outsole layer 102, midsole layer 104, and upper 106. Another advantage is the enhanced durability of the footwear 100, as the outsole layer 102 is made of a robust recyclable material that withstands various surfaces and conditions, ensuring a longer lifespan.

[0037] A further advantage is the comfort and cushioning provided by the midsole layer 104, which incorporates a softer recyclable material and Expanded TPU (ETPU). This design improves shock absorption and reduces foot strain during prolonged use. The mechanical attachment of the plurality of straps 112 to the midsole layer 104 via recyclable adhesive 114 or with buttons / plugs ensures a secure fit and structural integrity, contributing to the overall durability of the footwear 100.

[0038] The ability to recycle the footwear 100 as a whole without prior disassembly significantly reduces the complexity and labor involved in recycling, making the process more efficient and cost-effective. The use of thermoplastic polyurethane(TPU) as the first and second types of recyclable materials provides versatility, durability, and flexibility, making the footwear 100 suitable for different applications and conditions.

[0039] The innovative design also supports a circular economy by allowing the entire footwear 100 to be processed in an extruder and converted into TPU granules, which can be reused to manufacture the outsole layer 102 of new products, reducing waste. Lastly, the combination of structural integrity, comfort, and user-friendly features in the recyclable article of footwear 100 demonstrates a thoughtful approach to creating a sustainable product that does not compromise on performance or user experience.

[0040] The article of footwear 100 incorporates several innovative features to enhance its functionality and sustainability. The straps, essential for securing the footwear 100, can be configured as single or multiple units and are fixed to the midsole layer 104 through either buttons or adhesive bonding. In one example, the midsole layer 104, crafted from ETPU or TPU, is independently molded to include arch support, emphasizing ergonomic design. The ETPU layer, however, cannot be integrally molded with the outsole layer 102 and must be adhered separately using the recyclable adhesive 114. The recyclable adhesive 114 belongs to the TPU family, allowing for streamlined recycling without the need for component separation.

[0041] Furthermore, the outsole layer 102 can be directly converted into granules, which can be recycled and used to create new outsole layers. For instance, a worn-out outsole from an old pair of Footwear can be processed into granules and then re-molded into the outsole for a new pair of Footwear, significantly reducing waste and the need for virgin materials . This process not only conserves resources but also minimizes the environmental impact associated with the production of new materials.

[0042] Moreover, the recycled TPU granules can be further utilized to manufacture an outsole layer 102 of new footwear. This ensures the use of recycled materials in the production cycle, promoting a circular economy. For example, the granulated TPU from old Footwear can be mixed with new TPU to create a durable and sustainable bottom layer for new footwear. This approach not only helps in managing waste but also in reducing the carbon footprint associated with the production of new TPU.

[0043] The customizable layer 108 can only be applied to the midsole 104, offering aesthetic flexibility without compromising recyclability. This design ensures the footwear meets sustainability goals while providing superior comfort and performance. The integration of recycled TPU in both the outsole, the bottom layer and upper straps 106 of new footwear exemplifies a commitment to eco-friendly practices, delivering products that are not only high-performing but also environmentally responsible.

[0044] In one example, the recyclable article of footwear 100 also made with the outsole layer 102 and a combination of the midsole layer 104 and the upper 106 is made of same ETPU material. Here the combination of the midsole layer 104 & the upper 106 is joined with the outsole layer 102 by the recyclable adhesive to 114.

Claims

CLAIMWe claim,1) A recyclable article of footwear comprising:an outsole layer configured for ground contact, made of a first type of recyclable material;a midsole layer directly bonded to an interior face of the outsole layer, forming a dual-layer sole construction, wherein the midsole layer is made of a second type of recyclable material, and the second type of recyclable material is softer than the first type of recyclable material;an upper comprising a plurality of straps, made of the recyclable material, mechanically attached to an interior face of the midsole layer,wherein:the outsole layer, the midsole layer, and the plurality of straps are made of a recyclable material,the plurality of straps are mechanically attached to the interior face of the midsole layer, andwherein the article of footwear is recyclable as a whole through direct conversion into granules for recycling without a need for prior disassembly.2) The recyclable article of footwear of claim 1, wherein the first type of recyclable material and the second type of recyclable material comprises thermoplastic polyurethane (TPU).3) The recyclable article of footwear of claim 1, wherein the plurality of straps are moulded straps that are integrally formed with buttons for mechanical attachment to the midsole layer.4) The recyclable article of footwear of claim 1, wherein the plurality of straps are mechanically attached to the interior face of the midsole layer via a recyclable adhesive.5) The recyclable article of footwear of claim 1, further comprising a customizable layer which is directly bonded to an interior face of the midsole layer, wherein the customizable layer is customizable based on a plurality of designs.6) The recyclable article of footwear of claim 1, wherein the midsole layer comprises a layer of Expanded TPU (ETPU).7) The recyclable article of footwear of claim 1, wherein the recyclable article of footwear is configured to be processed as a whole in an extruder, and thereby converted into TPU granules.8) The recyclable article of footwear of claim 1, wherein the outsole layer, the midsole layer, and the plurality of straps, are made from the recyclable material.

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