METHOD FOR PRODUCING A COMBINATION SOLE-INSOLE COMPONENT FOR A SHOE
20220227087 · 2022-07-21
Inventors
Cpc classification
A43D2200/60
HUMAN NECESSITIES
B33Y80/00
PERFORMING OPERATIONS; TRANSPORTING
A43B13/181
HUMAN NECESSITIES
A43D999/00
HUMAN NECESSITIES
A43B13/12
HUMAN NECESSITIES
A43B7/28
HUMAN NECESSITIES
International classification
B29D35/12
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A method for manufacturing a combined sole/insole part for a shoe, which comprises a sole element and an insole element that is formed integrally therewith, said method comprising the following steps of: providing insole element data which describe the geometric/constructive design of an insole element of a sole/insole part to be manufactured, wherein the insole element data were generated on the basis of foot data which describe, at least in portions, optionally fully, the morphology of at least one foot of a wearer; and providing sole element data which describe the geometric/constructive design of a sole element of a sole/insole part to be manufactured, additively manufacturing a combined sole/insole part on the basis of the insole element data and the sole element data.
Claims
1. A method for manufacturing a combined sole/insole part (21) for a shoe (25), which comprises a sole element (23) and an insole element (22) that is formed integrally therewith, said method comprising the steps of: providing insole element data which describe the geometric/constructive design of an insole element of a sole/insole part to be manufactured, wherein the insole element data were generated on the basis of foot data which describe, at least in portions, the morphology of at least one foot of a wearer; providing sole element data which describe the geometric/constructive design of a sole element of the sole/insole part (21) to be manufactured; and additively manufacturing the combined sole/insole part on the basis of the insole element data and the sole element data.
2. The method according to claim 1, wherein the combined sole/insole part (21) is manufactured in a single additive manufacturing process.
3. The method according to claim 1, wherein the sole element data are provided which describe a geometric/constructive design of the sole element (23) which is formed, at least in portions, by a structural element arrangement (3) comprising a plurality of interconnected strut-like structural elements.
4. The method according to claim 1, wherein the insole elements are provided which describe a geometric/constructive design of the insole element which is formed at least in portions, in particular completely, by an ergonomic shaping selected in view of the morphology of the at least one foot described by the foot data.
5. The method according to claim 1, wherein the insole element is manufactured having an insole element region which is formed around an edge, at least in portions, in particular with respect to a reference plane, which insole element region surrounds the foot of a wearer, at least in portions, in the worn state of the combined sole/insole part.
6. The method according to claim 1, wherein the sole element and/or the insole element is manufactured at least in portions, having a plurality of zones (Z1-Zn) having different geometric/constructive and/or different mechanical properties.
7. The method according to claim 1, wherein the sole element is manufactured as a midsole or as an outsole.
8. The method according to claim 1, wherein the combined sole/insole part is manufactured at least in portions, from a plastics material.
9. The method according to claim 1, wherein the combined sole/insole part is manufactured by means of a stereolithographic process, binder jetting process, fused deposition modelling (FDM) process, or a continuous liquid interface production (CLIP) process.
10. A combined sole/insole part manufactured according to the method of claim 1.
11. A method for manufacturing a shoe comprising the steps of: manufacturing a combined sole/insole part for a shoe according to the method of claim 1, or providing a combined sole/insole part manufactured according to the method of claim 1; manufacturing at least one shoe construction element that forms a component of a shoe upper, or providing at least one a shoe construction element, in particular a shoe construction element that forms a component of a shoe upper; and connecting the manufactured or provided combined sole/insole part to the at least one manufactured or provided further shoe construction element, in particular the shoe construction element that forms a component of a shoe upper, forming the shoe to be manufactured.
12. The method according to claim 11, wherein a further shoe construction element which encloses the foot of a wearer, in particular the instep of the foot of a wearer, at least in portions, is manufactured or provided.
13. The method according to claim 11, wherein a further shoe construction element which is formed at least in portions, of a textile material structure, in particular a knitted fabric or woven fabric, is manufactured or provided.
14. A shoe manufactured according to the method according to claim 1.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0070] Embodiments of the present specification will be explained in greater detail with reference to embodiments that are shown in the figures, in which:
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DETAILED DESCRIPTION
[0080]
[0081] It can be seen that the sole/insole part 21 comprises an insole element 22 and a sole element 23 which is formed integrally therewith. The sole element 23 can also be referred to or considered as a sole portion of the sole/insole part 21, and the insole element 22 can also be referred to or considered as an insole portion of the sole/insole part 21. Thus, the sole/insole part 21 assumes two different functionalities, specifically both the functionality of a sole element and the functionality of an insole element. The sole/insole part 21 can thus be considered or referred to, generally, as an integrated part.
[0082] In particular with respect to a construction of a shoe 25 of which the sole/insole part 21 forms a component, the sole element 23 of the sole/insole part 21 may be a midsole element or an outer sole element (outsole element). In the embodiment as a midsole element, the sole element 23 does not comprise any outer surface or tread which is in contact with a substrate in the worn state of a shoe 25 equipped with the sole/insole part 21; in the embodiment as an outsole element, the sole element 23 comprises an optionally profiled outer surface or tread which is in contact with a substrate in the worn state of a shoe 25 equipped with the sole/insole part 21.
[0083] In particular with respect to a construction of a shoe 25 of which the sole/insole part 21 forms a component, the insole element 22 of the sole/insole part 21 may be an inner sole element. In the worn state of a shoe 25 equipped with the sole/insole part 21, the insole element accordingly forms the contact surface for a foot of a wearer. This also applies for the conceivable embodiment in which the insole element 22 is provided, at least in portions, optionally completely, with a functional layer consisting of a functional material, such as a leather material, a textile material, etc., in a contact surface region 4 that faces a foot of a wearer, with respect to the construction of a shoe 25 equipped with the sole/insole part 21. In connection with the insole element 22 it should therefore be mentioned that this typically comprises a closed contact surface region 4 for a foot of a wearer.
[0084]
[0085] Since the sole/insole part 21 is typically, but in no way essentially, manufactured, at least in portions, in particular completely, from a plastics material (the term “plastics material” also includes mixtures of chemically and/or physically different plastics materials)—the insole element 22 and the sole element 23 are typically made of the same material—in particular those additive manufacturing processes which allow for additive processing of plastics materials also come into consideration. Merely by way of example reference is made in this connection to stereolithography processes, binder jetting processes, fused deposition modelling (“FDM”) processes, or continuous liquid interface production (“CLIP”) processes. The sole/insole part can thus be manufactured for example by means of a stereolithography process, binder jetting process, fused deposition modelling (“FDM”) process, or a continuous liquid interface production (“CLIP”) process. Thus, in order to carry out the second step of the method, explained in greater detail in the following, for example additive manufacturing apparatuses, which are designed for performing stereolithography processes, binder jetting processes, FDM processes, or CLIP processes, can be used.
[0086] Should the sole/insole part 21 be manufactured at least in portions, in particular completely, from a material different from a plastics material, i.e. for example a metal, accordingly those additive manufacturing processes which allow for additive processing of at least one material different from a plastics material come into consideration. Merely by way of example reference is made to selective laser sintering methods, selective laser melting methods, metal binder jetting methods, etc.
[0087] The method specifically comprises the following steps:
[0088] In a first step of the method (cf. step S1), insole element data and sole element data are provided. The provision can take place for example via a data medium or a data connection, such as a local or global data network, i.e. for example an Intranet or the Internet. The provision of the insole element data and sole element data typically takes place on an additive manufacturing apparatus or a controller that is associated therewith and is hardware and/or software-implemented, which controller is designed for data processing of the insole element data and sole element data provided thereto, for preparing and/or carrying out an additive manufacturing process.
[0089] The provided insole element data describe the geometric/constructive design of an insole element 22 which, as mentioned, forms a component of the sole/insole part 21 to be manufactured. The insole element data typically contain all the geometric/constructive parameters of the insole element 22 of the sole/insole part 21 to be manufactured. The insole element data can also be referred to, considered or used as construction data of the insole element 22. The insole element data can be provided in any file format; merely by way of example reference is made to STL, COLLADA, OBJ, FBX and X3D formats.
[0090] The insole element data are or were generated basis of foot data which describe, at least in portions, optionally fully, the morphology of at least one foot of a wearer. The insole element data thus describe a geometric/constructive design of the insole element 22 which is adjusted, at least in portions, optionally fully, to the morphology of the at least one foot described by the foot data. According to the method, the insole element 22 can thus be designed, at least in portions, optionally completely, on the basis of corresponding insole element data, in a manner having a geometric/constructive design which is designed so as to be individually configured with respect to a foot of a user. Taking into account corresponding foot data (these can be established for example on the data of optical recordings (scans) of the foot, imprints of the foot, etc.) when generating the insole element data forms the basis for (highly) individualizable or (highly) individualised manufacture of the sole/insole part.
[0091] The provided sole element data describe the geometric/constructive design of a sole element 23 which, as mentioned, forms a component of the sole/insole part 21 to be manufactured. The sole element data typically contain all the geometric/constructive parameters of the sole element 23 of the sole/insole part 21 to be manufactured. The sole element data can also be referred to, considered or used as construction data of the sole element 23. The sole element data can also be provided in any file format; merely by way of example reference is made to STL, COLLADA, OBJ, FBX and X3D formats.
[0092] It is of course possible for the insole element data and the sole element data to be provided as a common dataset which contains both the insole element data and the sole element data. Accordingly, a corresponding common dataset typically contains all the geometric/constructive parameters of the sole/insole part 21.
[0093] In a second step of the method (cf. step S2), additive manufacture of a sole/insole part 21 takes place, on the basis of the insole element data and the sole element data or a corresponding common dataset. Thus, in the second step of the method the actual manufacture of the sole/insole part 21 takes place, by applying at least one additive manufacturing method for manufacturing the sole/insole part 21. In this case it is essential for the sole/insole part 21 to be manufactured in a productionally simple manner, in a single additive manufacturing process, which results in the one-piece or integral or monolithic configuration of the sole/insole part 21; the insole element 22 and the sole element 23 are thus manufactured together, in a single additive manufacturing process, forming the sole/insole part 21; this results in the integral design of the sole/insole part 21 which is characterised in that the insole element 22 is non-detachably connected to the sole element 23, and vice versa. The additive manufacturing process applied for manufacturing the sole/insole part 21 thus includes additive formation of the insole element 22 and of the sole element 23, which are manufactured within the context of the additive manufacturing process as a combined part and are thus manufactured so as to be integrally interconnected in a non-detachable manner (without damage or destruction). The insole element 22 and the sole element 23 thus directly adjoin one another or transition directly into one another. Thus, for an arrangement or orientation, by way of example, of the sole/insole part 21 in a construction space of an additive manufacturing apparatus, the insole element 22 can be constructed directly on the sole element 23, or vice versa. However, depending on the arrangement or orientation of the sole/insole part 21 in a construction space of an additive manufacturing apparatus, other construction strategies, in which portions of the insole element 22 and of the sole element 23 are constructed for example simultaneously (in a layer-based manner), are also conceivable.
[0094] Insole elements can be provided which describe a geometric/constructive design of the insole element 22 which is formed at least in portions, in particular completely, by an ergonomic shaping selected in view of the morphology of the at least one foot described by the foot data. The insole element 22 can thus for example be designed at least in portions, optionally completely, having a cushion that is configured individually in view of the foot morphology described by the foot data.
[0095] Sole element data can be provided which describe a geometric/constructive design of the sole element 23 which is formed, at least in portions, in particular completely, by a structural element arrangement 6 comprising a plurality of interconnected strut-like or strut-shaped structural elements 5. The sole element 23 can thus be manufactured in the form of a structural element arrangement 6 described by the sole element data, which comprises, at least in portions, in particular completely, by a plurality of interconnected strut-like or strut-shaped structural elements 5. As is explained in greater detail in the following, in connection with the embodiments according to
[0096] The insole element 22 can be manufactured having an insole element region which is formed around an edge, at least in portions, optionally completely, and which is raised in particular with respect to a reference plane (this can be defined for example by a contact surface region 4 of the insole element 22), which insole element region surrounds the foot of a wearer around the periphery (of the foot), at least in portions, in the worn state of the sole/insole part 21.
[0097] The sole element 23 and/or the insole element 22 can be manufactured at least in portions, optionally completely, having a plurality of zones Z1-Zn having different geometric/constructive and/or different structural properties, i.e. in particular mechanical properties. For example, as indicated merely by way of example in
[0098] Returning to
[0099] According to the method, in step S3 a further shoe construction element 27 which encloses the foot of a wearer, in particular the instep of the foot of a wearer, at least in portions, optionally completely, can be manufactured or provided. Therefore, completely closed shoes, partially closed shoes, or open shoes, can be manufactured using the method.
[0100] According to the method, in step S3 a further shoe construction element 27 which is formed at least in portions, optionally completely, of a textile material structure, in particular a knitted fabric or woven fabric, can be manufactured or provided. The sole/insole part can thus be connected to a further shoe construction element which is formed at least in portions, optionally completely, of a textile material structure, in particular a knitted fabric or woven fabric.
[0101]
[0102] It is clear on the basis of
[0103] The strut-like or strut-shaped geometric/constructive basic shape of the structural elements 4, 5 results from the elongate basic shape of the structural elements 4, 5. In the embodiments shown in the drawings, the cross-sectional geometry of the structural elements 4, 5 is polygonal, i.e. in particular square; however, other, i.e. for example circular or round, cross-sectional geometries are in principle also conceivable.
[0104] The structural properties of the sole element 23, i.e. in particular the mechanical properties of the sole element 23 that define the damping properties or the degree of hardness or deformation, substantially result from the geometric/constructive construction of the structural element arrangement 3, i.e. in particular the arrangement and/or orientation of the structural elements 4, 5. Accordingly, the structural properties of the sole element 23, i.e. in particular the mechanical properties of the sole element 23 that define the damping properties or the degree of hardness or deformation, can be purposely set by purposeful selection or variation in the arrangement and/or orientation of the structural elements 4, 5.
[0105] In particular, a purposeful selection by region or zone, or a purposeful variation, by region or zone, of the arrangement and/or orientation of respective structural elements 4, 5 makes it possible to achieve any number of regions or zones (cf.
[0106] It can be seen that the structural element arrangement 3 comprises first structural elements 4 which are arranged or formed in a first spatial direction or spatial orientation (vertical spatial direction or spatial orientation, z-direction), and second structural elements 5 which are arranged or formed in a second spatial direction or spatial orientation (horizontal spatial direction or spatial orientation, x-direction, y-direction) that is different from the first spatial direction or spatial orientation. The first spatial direction or spatial orientation is a vertical spatial direction or spatial orientation defined by a vertical spatial axis, the second spatial direction or spatial orientation is a horizontal spatial direction or spatial orientation defined by a horizontal spatial axis. The first structural elements 4 are accordingly arranged or oriented so as to be at right-angles to the second structural elements 5 (and vice versa).
[0107] In particular on account of the different arrangement and orientation thereof, the first and second structural elements 4, 5 are differently functionalised, i.e. they differ in terms of their function. The first structural elements 4 are arranged or designed to transmit forces (cf. arrow F in
[0108] On account of the arrangement and orientation of first and second structural elements 4, 5 shown in the drawings, combined force transmission/damping substructures 6 are formed. On account of the first structural elements 4 which function as force transmission elements, a respective substructure 6 has both force transmission properties and, on account of the second structural elements 5 which function as damping elements, also damping properties. A respective substructure 6 is thus characterised both by a force transmission function and by a damping function.
[0109] In the embodiments shown in
[0110] It is evident that the two damping elements (second structural elements 5) of a substructure 6 are arranged or formed so as to be in parallel with one another, forming a damping element arrangement 7. The damping properties of a respective damping element arrangement 7 result in particular from the thickness of the damping elements forming said arrangement, as well as the spacing between the damping elements forming said arrangement. Therefore for example the thickness of the damping elements, and the mutual spacing thereof, provide parameters for purposeful selection and setting of particular damping properties of a damping element arrangement 7. Selecting and setting the parameters accordingly makes it possible for, for example, a particular deformation, i.e. in particular a maximum deformation, for example a maximum deformation of 1 mm, of the damping element arrangement 7 to be defined for a particular force acting on the damping element arrangement 7.
[0111] Forces are introduced into a respective damping element arrangement 7 by means of respective force transmission elements (first structural elements 4) of a respective substructure 6. For this purpose, a first or upper force transmission element is arranged relative to a first or upper damping element, adjacent thereto, such that forces can be transmitted into the damping element arrangement 7 thereby. A second or lower force transmission element is arranged relative to a second or lower damping element, adjacent thereto, such that forces can be transmitted thereto from the damping element arrangement 7.
[0112] On account of the vertical orientation of the force transmission elements and the horizontal orientation of the damping elements, a double T-structure results for a substructure 6, in which the horizontally extending portions of the “T”, formed by the damping elements, are designed so as to be arranged in a manner lying on one another, and the vertically extending portions of the “T”, formed by the force transmission elements, are designed so as to be arranged in a manner aligned with one another in the vertical direction.
[0113] It is evident that the structural element arrangement 3 comprises a plurality of corresponding substructures 6, i.e. a plurality of substructures 6. The substructures 6 are arranged and oriented in a (common) plane (x-y plane) of the sole element 23. A plurality of substructures 6 can form a substructure arrangement 10.
[0114] In addition to the structural elements 4, 5, the sole element 23 comprises a plurality of planar, in particular plate-like or plate-shaped, force introduction elements 8 designed for introducing, into respective substructures 6, a force which acts on the sole element 23 during use as intended. In the embodiments shown in the drawings, the force introduction elements 8 have a polygonal, i.e. a square, basic shape. It can be seen that respective force introduction elements 8 are arranged or formed on a upper and/or a lower face of the structural element arrangement 3; in the embodiment shown in the drawings, first or upper force introduction elements 8 are provided which are arranged or formed on an upper face of the structural element arrangement 3, and second or lower force introduction elements 8 are provided which are arranged or formed on lower face of the structural element arrangement 3.
[0115] It can be seen that respective force introduction elements 8 arranged or formed on an upper or a lower face of a structural element arrangement 3 are not directly interconnected. A space is formed between force introduction elements 8 that are arranged or formed on an upper or a lower face of a structural element arrangement 3, so as to be directly adjacent. As a result, introducing a force into a first force introduction element 8 does not necessarily cause the introduction of a force into a second force introduction element 8 that is arranged or formed so as to be directly adjacent to the first force introduction element 8.
[0116] The force introduction elements 8 are designed for introducing a force, acting on the sole element 23, into the force transmission elements (first structural elements 4) of a respective substructure 6, and accordingly connected to at least one force transmission element; thus, at least one force transmission element is connected to respective force introduction elements 8. The respective force transmission element typically protrudes, in the vertical direction, from an upper or lower face of a respective force introduction element 8 facing the structural element arrangement 3, in the direction of the damping elements or a respective damping element arrangement 7.
[0117] A unit cell 9 of the sole element 23, shown in
[0118] The unit cell 9 shown in the embodiments shown in
[0119] The unit cell 9 has a cuboid-like or cuboid-shaped or cube-like or cube-shaped basic shape. The edge or side length of the unit cell 9 can for example be in a range between 5 and 15 mm, in particular between approximately 10 mm. The height of the unit cell 9 can also be for example in a range between 5 and 15 mm, in particular between approximately 10 mm.
[0120] The structural properties, i.e. in particular the mechanical properties, of a respective unit cell 9 can be or are defined by the structural properties, i.e. in particular the mechanical properties, the components of the unit cell 9, as well as the arrangement and orientation thereof relative to one another.
[0121] It can be seen from
[0122] Unit cells 9 arranged in identical zones of the sole element 23 typically exhibit the same structural properties, i.e. in particular the same mechanical properties. Unit cells 9 arranged in different zones of the sole element 23 can exhibit different structural properties, i.e. in particular different mechanical properties.
[0123] Accordingly, an arrangement of unit cells 9 with are identical or different with respect to the structural properties thereof, i.e. in particular mechanical properties, makes it possible for zones having the same or different structural properties, i.e. in particular different mechanical properties, damping, degrees of hardness, degrees of deformation, etc., to be formed. As has already been explained in conjunction with the embodiment shown in
[0124]
[0125] The embodiment shown in
[0126] It can be seen from the embodiment shown in
[0127] It is clear that structural element segments 5a-5d which are arranged or formed in parallel can be arranged or formed in pairs. The second structural elements 5 can thus comprise a plurality of structural element segments 5a-5d which are arranged or formed so as to be in parallel. In the embodiment shown in
[0128] It can furthermore be seen from the embodiment shown in
[0129]
[0130] For the respective structural element segment pairs of a second structural element 5, it is the case that a first structural element segment pair is arranged so as to extend at a first angle with respect to a horizontal or vertical reference axis or plane, and a second structural element segment pair of two structural element segments 5a-5d is arranged so as to extend at a second angle with respect to the horizontal or vertical reference axis or plane. The wedge-like or wedge-shaped geometry of the second structural elements 5, shown in
[0131] It is clear that there is a mirror-symmetrical arrangement of respective structural element segment pairs that form a respective second structural element 5. The angle between respective structural element segment pairs is obtuse, i.e. typically more than 90°, in particular more than 130°, optionally more than 150°.
[0132] Furthermore, optional third structural elements 13 are visible in the embodiment shown in
[0133] It can be seen that respective third structural elements 13 are arranged or formed between two second structural elements 5, in each case, and arranged in a horizontal spatial direction or spatial orientation defined by a horizontal spatial axis.
[0134] Individual, a plurality of, or all the features described in connection with a particular embodiment can be combined, as desired, with individual, a plurality of, or all the features of at least one other embodiment.