Method for producing a shoe and shoe that can be obtained by said method

Abstract

The subject matter of the present disclosure is a process for manufacturing a shoe comprising an outsole joined to the sole part of a first main liner comprising on its outer face at least two studs, and a first auxiliary liner, at least partially, in particular integrally, hot-melt, in a textile piece, covering at least part of the first main liner, the outsole, and the junction between the first main liner and the outsole, at least part or all of the first hot-melt auxiliary liner being melted and adhered to the first main liner and to the outsole.

Claims

1. A process for manufacturing a shoe comprising the following steps: (i) providing at least one main liner in a textile piece, having a sole part; (ii) placing at least the first main liner on a preform; (iii) joining an outsole to the sole part of the first main liner; (iv) providing at least one first auxiliary liner in a textile piece, at least part or all of which is thermofusible and has a melting temperature T1 (° C.); (v) arranging the first auxiliary liner on the first main liner and the outsole so as to cover, at least partially, the first main liner, the outsole, and the junction between the first main liner and the outsole; (vi) subjecting the assembly comprising the first auxiliary liner, the first main liner, and the outsole, placed on the preform, to a heating temperature Tc greater than or equal to the temperature T1 so as to achieve melting of the thermofusible part or the entire first auxiliary liner; (vii) removing the assembly from the preform and recovering the shoe.

2. The process for manufacturing a shoe as claimed in claim 1, wherein the first auxiliary liner is in a unitary textile piece.

3. The process for manufacturing a shoe as claimed in claim 1, wherein the thermofusible part of the first auxiliary liner represents at least 50% by mass of the total mass of said first auxiliary liner.

4. The process for manufacturing a shoe as claimed in claim 1, wherein the outsole comprises on its outer face at least one projection projecting from the outer face, and wherein the sole part of the first auxiliary liner comprises at least one area adapted to receive, at least in part, said at least one projection projecting from the outer face of the outsole.

5. The process for manufacturing a shoe as claimed in claim 4, wherein the at least one projection comprises a lower face configured to come into contact with the ground.

6. The process for manufacturing a shoe as claimed in claim 4, wherein the process comprises a step of providing a second main liner having a sole part comprising at least one area adapted to receive, at least in part, said projection, the second main liner being arranged: on the first auxiliary liner in step (v) such that the first auxiliary liner is disposed, at least in part, between the second main liner and the first main liner; or on the first main liner in step (v) such that the second main liner is disposed, at least in part, between the first main liner and the first auxiliary liner.

7. The process for manufacturing a shoe as claimed in claim 6, wherein it comprises: providing a second auxiliary liner in a textile piece, at least part or all of which is thermofusible and has a melting temperature T2 (° C.); and arranging in step (v) the second auxiliary liner on the second main liner and the outsole so as to cover, at least partially, the first main liner, the first auxiliary liner, the second main liner, the outsole, and the junction between the first main liner and the outsole; the heating temperature Tc is greater than or equal to the temperature T2 in order to obtain the fusion of the thermofusible part or of the whole of the second auxiliary liner.

8. The process for manufacturing a shoe as claimed in claim 1, wherein at least one of the sole part of the first main liner and the sole part of the first auxiliary liner comprises a thermofusible region whose melting temperature is less than or equal to the heating temperature Tc, said thermofusible region(s) being oriented opposite the outsole.

9. The process for manufacturing a shoe as claimed in claim 8, wherein the sole part of the first main liner comprises opposite inner and outer layers, the outer layer being oriented opposite the outsole, in that the outer layer comprises said thermofusible region, and the inner layer comprises at least one non-thermofusible region.

10. The process for manufacturing a shoe as claimed in claim 4, wherein the area(s) of the sole part of the first auxiliary liner that is/are adapted to receive at least in part one or more projection(s) of the outsole is/are a through-opening or a pocket.

11. The process for manufacturing a shoe as claimed in claim 10, wherein at least one of the through-opening(s) and pocket(s) is formed by at least one of: during the textile construction of at least one of the first auxiliary liner, by stamping, and by fusion.

12. The process for manufacturing a shoe as claimed in claim 1, wherein at least one of the liners selected from a list comprising: the first main liner and the first auxiliary liner comprises an instep region having left and right edges, and further comprises a temporary detachable textile piece of unitary textile construction with said at least one selected liner, said removable temporary textile piece comprising left and right edges in connection with the left and right edges of said instep region, respectively.

13. The process for manufacturing a shoe as claimed in claim 1, wherein the first main liner and the first auxiliary liner are in a unitary textile piece.

14. The process for manufacturing a shoe as claimed in claim 1, wherein the first main liner is in a unitary textile piece, the unitary textile piece also comprises an additional liner, and the first main liner and the additional liner are joined at foot insertion openings.

15. The process for manufacturing a shoe as claimed in claim 14, wherein the additional liner is folded into the first main liner after step (vi) so as to form a comfort sock.

16. The process for manufacturing a shoe as claimed in claim 14, wherein the additional liner is folded over the first main liner and forms the first auxiliary liner.

17. The process for manufacturing a shoe as claimed in claim 1, wherein the outsole comprises a plurality of projections projecting from its outer face.

18. The process for manufacturing a shoe as claimed in claim 1, wherein the first main liner comprises at least 80% by mass of its total mass one or more materials whose melting or degradation temperature(s) are higher than Tc.

19. The process for manufacturing a shoe as claimed in claim 1, wherein the assembly comprises a first region in the vicinity of a foot insertion opening extending towards a forefoot area in which the first main liner and the second main liner are superimposed and substantially not joined.

20. A shoe for the practice of sport, obtainable by the implementation of the process as claimed in claim 1, comprising a first main liner in a textile piece having a sole part, an outsole joined to the sole part of the first main liner and comprising on its outer face at least one projection, and a first auxiliary liner, at least partially thermofusible, in a textile piece, at least partially covering the first main liner, the outsole, and the junction between the first main liner and the outsole, at least part or all of the first thermofusible auxiliary liner being melted and adhering to the first main liner and to the outsole.

21. The shoe as claimed in claim 20, wherein the outsole comprises one or more projections projecting from its outer face, and wherein the sole part of the first auxiliary liner comprises one or more areas adapted to each receive, at least in part, a projection.

22. The shoe as claimed in claim 20, comprising a rear reinforcement element of unitary textile construction with the first main liner or the first auxiliary liner, said rear reinforcement element comprising melted thermofusible yarns.

23. The shoe as claimed in claim 22, wherein the rear reinforcement element opens into an inner volume for receiving a foot of a wearer, and the rear reinforcement element forms a housing delimiting an inner volume receiving an elastically deformable element.

24. The shoe as claimed in claim 20, wherein the projections are at least two studs.

25. The process for manufacturing a shoe as claimed in claim 1, wherein at least one liner chosen among the first main liner and the first auxiliary liner is a shell comprising a sole part, a lateral part, a medial part, a front part as an extension of the medial, lateral and sole parts, and a rear part as an extension of the medial, lateral, and sole parts, the shell delimits an inner volume configured to receive a foot of a wearer, and said shell is a unitary textile piece.

26. The process for manufacturing a shoe as claimed in claim 1, wherein said process comprises providing a rear reinforcement element that is of unitary textile construction with the first main liner or the first auxiliary liner, said rear reinforcement element comprising melted thermofusible yarns.

27. The process for manufacturing a shoe as claimed in claim 26, wherein said rear reinforcement element opens into an inner volume configured to receive a foot of a wearer, and the rear reinforcement element forms a housing delimiting an inner volume receiving an elastically deformable element.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The disclosure and its advantages will be better understood by reading the detailed description of the particular embodiments, taken by way of non-limiting examples and illustrated by the appended drawings wherein:

(2) FIG. 1 is a schematic side-view representation of the first main liner of a first example shoe according to the disclosure;

(3) FIG. 2 is a schematic bottom-view representation of the first main liner shown in FIG. 1;

(4) FIG. 3 is a schematic cross-sectional representation of the first example shoe according to the disclosure comprising the first main liner shown in FIGS. 1 and 2;

(5) FIG. 4 is a side-view representation of a part of the first example shoe according to the disclosure;

(6) FIG. 5 is a schematic cross-sectional representation of a second example shoe according to the disclosure;

(7) FIG. 6 is a schematic side-view representation of the second example shoe shown in FIG. 5;

(8) FIGS. 7 and 8 schematically represent steps (ii), (iii) and step (v) of the process according to the disclosure for the manufacture of the first example shoe shown in FIG. 3;

(9) FIG. 9 is a schematic cross-sectional representation of a third example shoe according to the disclosure;

(10) FIG. 10 is a schematic side-view representation of a variant of the first main liner joined to the outsole shown in FIG. 4;

(11) FIG. 11 is a schematic top-view representation of a fourth example shoe according to the disclosure comprising a temporary detachable textile piece;

(12) FIG. 12 is a schematic top-view representation of an example of the first main liner according to the disclosure.

DETAILED DESCRIPTION

(13) The first main liner 5 shown in FIGS. 1 and 2 comprises a sole part 10, a forefoot part 15, a lateral part 20, a medial part 25 and a rear part 30. The first main liner 5 is in particular in a unitary knitted textile shell 35, in particular with picked stitches, having an inner volume 40 configured to receive the user's foot. The rear 30, lateral 20, medial 25 and forefoot 15 parts project vertically from the plane P comprising the sole part 10. The lateral 20 and medial 25 parts are arranged between and in connection with the rear part 30 and forefoot part 15.

(14) The forefoot part 15 comprises in the instep area 18 first and second sets of lacing through-openings 45, 50. Each first and second set of lacing through-openings 45, 50 comprises five sets of two openings 55, 60, the two openings 57, 58; 67, 68 of each set 55, 60 being separated by a knitted portion forming first and second bridges 70, 75. The first bridges 70 and the second bridges 75 are substantially aligned by sets of openings 55, 60 in a transverse direction T substantially perpendicular to the longitudinal axis L of the first main liner 15.

(15) The forefoot part 15 also comprises in the instep area 18, a set of ventilation through-openings 80, in particular arranged between the two sets of lacing through-openings 45,50. The set of ventilation openings 80 is placed in an area of the first main liner 15 substantially centered between the medial 25 and lateral 20 parts. The set of ventilation openings 80 comprises for example ten through-openings.

(16) The first main liner 5 shown in FIG. 1 comprises at the foot insertion region 16, a area in the form of a closed collar 90, in a mesh pattern of the type rib n×p, where n and p are integers different from 0 and less than or equal to 5, for example ribs 1×1, or 1×2. This area 90 thus forms a soft and elastic border facilitating the insertion of the foot.

(17) The first main liner 5 is joined to an outsole 100 comprising a set of studs 105, particularly arranged for playing soccer, projecting from its outer face 101.

(18) As shown in FIGS. 7 and 8, the first main liner 5 is placed on a rigid preform 110 in the shape of a foot. It is possible to place a lace in the first and second set of lacing through-openings 45, 50 to facilitate the positioning and plating of the first main liner 5 on the preform 110. Then, the sole part 10 of the first main liner 5 is placed in a counter-mold 130 (in one or two parts) so that the outer face of the sole part 10 projects into the inner volume of the counter-mold into which a polymer composition is injected to make the outsole 100. The preform 110 is removed from the mold, the main liner 5 and the outsole 100 comprising studs 105 are thus joined together (see FIG. 4). Then, a first auxiliary liner 200 in a textile piece at least part or all of which is thermofusible and has a melting temperature T1 (° C.) is placed on the first main liner 5 and the outsole 100 so as to cover, at least in part, the first main liner 5, the outsole 100, and the junction 150 between the first main liner 5 and the outsole 100. The first auxiliary liner 200 comprises sole 210, forefoot 220, medial 230, lateral 240 and rear 250 parts, of which the forefoot 220, medial 230, lateral 240 and rear 250 parts are in whole or in part respectively against the forefoot, medial, lateral and rear parts of the first main liner 5. The sole part 210 of the first auxiliary liner 200 comprises a set of areas 260 adapted to receive the studs 105, said areas 260 are in particular through-openings from which the studs 105 project. In this specific example, the first auxiliary liner 200 is in a fully fusible textile piece with a melting temperature T1. Then, the assembly forming the upper 280 comprising the first main liner 5 and the first auxiliary liner 200, is subjected to a heating temperature Tc greater than or equal to the temperature T1 in order to obtain the complete fusion of the first auxiliary liner 200. Preferably, a heating system is placed inside the preform 110. The shoe 300 obtained, shown in part in cross-section in FIG. 3, has an improved resistance to delamination between the outsole 100 and the first main liner 5 since the junction 150 is covered with a polymer film 400 showing in relief the textile aspect of the first main liner 5. It is also possible, complementarily, to place the upper assembly 280 in a mold whose inner face is engraved so as to impart one or more specific pattern(s) to the polymer film 400 according to the regions of the upper assembly 280 of the shoe 300.

(19) The first main liner 5 is in a textile shell knitted with stitches picked up in three dimensions at the exit of a circular or rectilinear knitting machine, in particular rectilinear. In this specific example, the first main liner 5 is knitted with 500 dtex polyethylene terephthalate multifilament yarns for about 204 filaments. The mass of the first main liner 5 is comprised between 100 g/m.sup.2 and 250 g/m.sup.2, in particular of the order of 170 g/m.sup.2.

(20) The first auxiliary liner 200 is in a textile piece knitted with picked stitches (in three dimensions) on a circular knitting machine from monofilament single-component yarns, in particular polyurethane, the diameter of which is comprised between 0.10 mm and 2 mm, in particular of the order of 1 mm. The first auxiliary liner 200 can comprise areas with varying yarn densities in order to create areas with a greater thickness than other areas and thus ultimately a film 400 having areas of greater thickness.

(21) The mass of the first auxiliary liner 200 is comprised between 30 g/m.sup.2 and 200 g/m.sup.2, in particular of the order of 50 g/m.sup.2.

(22) The outsole 100, including the studs 105, has a mass comprised between 100 g/m.sup.2 and 400 g/m.sup.2. The final mass of the shoe 300 depends finally on the size of the shoe, it is in particular comprised between 200 and 250 g/m.sup.2 (including the laces), in particular for a European size 43.

(23) The outsole 100 is in this example made of elastomer material, in particular TPU.

(24) FIG. 5 shows a sectional view of another example shoe 500 according to the disclosure. The shoe 500 comprises a first main liner 600 preferably with a melting or decomposition temperature greater than the temperature Tc, a first auxiliary liner 700 preferably fully thermofusible (T1 less than Tc), a second main liner 800 preferably with a melting or decomposition temperature greater than the temperature Tc, a second auxiliary liner 900 preferably fully thermofusible (T2 less than Tc) and an outsole 550 with studs 560. The first and second main liners 600, 800 and the first and second auxiliary liners 700, 900 each comprise rear, sole, forefoot, medial and lateral parts.

(25) The outsole 550 is preferably over-molded, in particular by injection as described in reference to FIGS. 7 and 8, on the outer face 615 of the sole part 610 of the first main liner 600.

(26) The first main liner 600 joined to the outsole 550 and placed on a rigid preform (as described above in reference to the shoe 300), and optionally heated, is covered with a first auxiliary liner 700, a second main liner 800 and then a second auxiliary liner 900 determining an upper assembly 950. The sole parts of the first and second auxiliary liners 700, 900 and of the second main liner each comprise a set of areas adapted to receive the studs 560, in particular through-openings through which the studs project. The junction 580 between the outsole 550 and the first main liner 600 is thus completely covered by two layers of polymer films from the first and second auxiliary liners 700, 900 and the textile shell of the second main liner 800, thus further improving the resistance to delamination.

(27) The first main liner 600 comprises in this specific example first and second sets of through-openings to form lacing loops similar to those 45,50 supported by the first main liner 5 (by their structures and their placements) but does not comprise ventilation openings 80. The second main liner 800 comprises ventilation openings similar to those 80 of the first main liner 5 (by their structures and their placements).

(28) It is also possible (not shown) that the second main liner 800 also comprises said first and second sets of through-openings to form lacing loops, which first and second sets are then not present on the first main liner 600.

(29) Furthermore, in this embodiment, the second main liner 800, the second auxiliary liner 900, and the first auxiliary liner each comprise in their forefoot region at least one lacing opening, in particular two sets of lacing openings placed on either side of the instep area and arranged so as to cooperate with the lacing loops of the first main liner so as to project through the lacing openings. A lace 990 is passed through the lacing openings, as shown in FIG. 6. The junction 580 between the outsole 550 and the first main liner 600 is invisible. Preferably, with the exception of the studs 560, the outsole 550 is not visible.

(30) The first and second main liners 600, 800 can be identical or different.

(31) The first and second auxiliary liners 700, 900 can be identical or different, in particular similar to the first auxiliary liner 200.

(32) FIG. 9 shows a shoe 301, which is a variant of the shoe 300, in which the first main liner 51 comprises a first region 52, in particular forming a housing, integrally knitted with the latter 51 and projecting from the inner face 12 of the sole part 11 into the inner volume 53 of the first main liner 51. During the manufacture of the outsole 102 by injection molding for example, the injected polymer composition intended to form the outsole 102 flows into the knitted housing 52 and fills said housing 52 thus forming a cushioning element and/or a fastening member.

(33) The first main liner 51 may comprise a first knitted region 52 disposed in the heel region of sole part 11 and/or a first knitted region 52 disposed in the forefoot region of the sole part 11. Said fastening member may cooperate with a complementary fastening member supported by an sole for example for their removable attachment.

(34) FIG. 10 shows a first main liner 1000 in conjunction with an additional liner 1100 at their respective insertion openings 1010, 1110 of the respective foot.

(35) The first main liner 1000 is shown joined to the outsole 1050 provided with studs 1055. The additional liner 1100 can thus be folded into the inner volume 1020 of the first main liner 1000 and thus forms a receiving liner. The additional liner 1100 can also be used as a first or second auxiliary liner or as a second main liner within the meaning of the present disclosure. In the latter case, it is necessary to arrange a first auxiliary liner between the first main liner 1000 and the second main liner formed by the additional liner 1100.

(36) The shoe 1200 shown in FIG. 11 comprises a temporary detachable textile piece 1210 of unitary textile construction with the first auxiliary liner 1230, which is completely melted and thus forms a heat-melted outer coating at least partially covering a second main liner 1220. The temporary piece 1210 is not thermofusible, and therefore as shown in FIG. 11 after step vi). The second main liner 1220 comprises an instep region 1240 having left 1250 and right 1260 edges. The temporary detachable textile piece 1210, in particular knitted, comprises left 1270 and right 1280 edges connected, in particular joined, respectively with left 1250 and right 1260 edges of said instep region 1240, in particular through at least a plurality of breakable connecting areas 1290, in particular textile connecting loops, in particular knitted.

(37) The temporary detachable textile piece 1210, which is in particular breakable, helps to position the liners in relation to each other, in particular to keep the left and right edges of the instep region 1240 sufficiently close together in step vi).

(38) After step vi), the temporary textile piece 1210 is separated from the shoe 1200, in particular by cutting the breakable connecting areas 1290.

(39) FIG. 12 represents a variant of the first main liner according to the disclosure allowing a rear reinforcement element to be formed. The first main liner 1300, shown alone in FIG. 12 and before its assembly with other liners, thus comprises a rear reinforcement element 1400 of unitary textile construction with the first main liner 1300, and consisting partly or entirely, preferably entirely, of thermofusible yarns whose melting temperature(s) is/are lower than Tc. Thus, after step vi), the rear textile reinforcement element 1400 is totally or partially melted.

(40) The rear reinforcement element 1400 is shown in FIG. 12 before folding it into the inner volume 1350 for receiving the foot of the first main liner 1300. During superimposition of the first main liner 1300 with one or more other liners according to the disclosure to form an assembly undergoing a step of thermocompression in step vi), the rear reinforcement element 1400 is folded in the direction of the arrow shown in FIG. 12 so as to be found on the finished shoe as opening directly into the inner volume for receiving the foot of the shoe. Advantageously, the rear reinforcement element 1400 is made during the knitting or weaving of the first main liner 1300.

(41) The rear reinforcement element 1400 extends at least partially into the rear 1360, lateral 1370 and medial 1380 parts of the first main liner 1300.

(42) In this specific example, the main reinforcement element 1300 has an open C-shape on the front part 1340 of the first main liner 1300.

(43) The main reinforcement element 1400 is preferably a textile housing, in particular a textile pocket, in particular projecting from the area for inserting the foot 1330 of the first main liner 1300.

(44) Preferably, the shoe comprises an elastically deformable element 1500, in particular a foam, disposed in the inner volume of the textile housing of the rear reinforcement element 1400.

(45) The elastically deformable element can be deformed and/or compressed and recover its initial shape substantially without residual deformation, or with a residual deformation of less than 5% in relation to its original dimensions.

(46) Preferably, the elastically deformable element comprises rear, side and medial portions.

(47) Before step vi), the rear reinforcement element 1400 preferably comprises at least one opening 1410, in particular at least two openings 1410,1420, allowing access to its inner volume to place the elastically deformable element 1500 therein.

(48) The rear reinforcement element 1400 undergoes step vi) in a folded state against, at least partially, the rear, lateral and medial parts of the first main liner 1300, so that it is joined to these parts of the first main liner 1300. The openings 1410 and 1420 are then closed by the melted thermofusible yarns. The elastically deformable element is thus perfectly maintained in the housing of the rear reinforcement element 1400.