DEEP-DRAWN SEGMENT

Abstract

A method for producing a water-tight, water-vapour-permeable segment, having a three-dimensional contour, for a shoe shaft, an item of clothing or a rucksack or for producing a shoe shaft, an item of clothing or a rucksack, the segment being free of connection points in its surface, and the method for producing the segment being a thermoforming process in which the two-dimensional flat structure obtained is completely laminated in its entirety, the segment being free of connection points in its surface. Also, a water-tight, water-vapour-permeable segment of a three-dimensional functional laminate for introduction into a shoe or shoe shaft, an item of clothing or a rucksack, the segment being dimensionally stable under its own weight, of a single piece and free of connection points in its surface.

Claims

1. Method for producing a water-tight, water-vapour-permeable segment, having a three-dimensional contour, for a shoe shaft, an item of clothing or a rucksack or for forming the same, the segment being free of connection points in its surface, and the method comprising the following steps: a. presentation of a stack of at least one first and one second twat dimensional sheet structures arranged one on top of the other, whereby at least two sheet structures contained in the stack adjacent to one another and lying directly on top of one another are not connected to one another and whereby the first sheet structure forms a water-tight, water vapour-permeable functional layer, b. presentation of a mould body comprising the three-dimensional contour, c. thermoforming of the stack of at least a first and a second sheet structure by means of the mould body and simultaneous lamination of the sheet structures contained in the stack, resulting in an adhesion of at least 1.0 N, measured according to DIN 53530:1981-02 with a test piece width of 25 mm, between at least one first and one second two-dimensional sheet structures arranged one on top of the other and not originally connected to one another, with heating of the stack to a process temperature, whereby the process temperature is to be set in such a way that plastic deformation of the stack and lamination for planar connection of the two-dimensional sheet structure contained in the stack is obtained, whereby the segment is formed.

2. Method according to claim 1, whereby at least on two-dimensional sheet structure contains at least one thermoplastic ply or at least thermoplastic components.

3. Method according to claim 1, whereby thermoforming is assisted by applying a vacuum between the mould body and the stack or the deformed stack.

4. Method according to claim 1, whereby the thermoforming comprises deep drawing with forming tools, deep drawing with active media deep drawing with active energy, or combinations thereof.

5. Method according to claim 1, whereby the functional layer comprises a non-porous membrane, a microporous membrane, or a combination thereof.

6. Method according to claim 5, whereby the functional layer comprises at least one material selected from a group consisting of polyurethane (PU), polyolefin (PO), polyester (PES), polyether ester (PEEST), polyacrylonitrile (PAN), polyamide (PA), polyether imide (PEI), polytetrafluoroethylene (PTFE), polysulfone (PSU), cellulose acetate (CA) and their block or random copolymers and/or mixtures thereof.

7. Method according to claim 1, whereby the stack comprises at least one textile ply.

8. Method according to claim 7, whereby the textile ply comprises areas with different properties and/or anisotropic areas.

9. Method according to claim 7, whereby the material of the textile ply is selected from a group of polymers comprising polyolefins, polyesters, polyamides, polyurethanes and polyacrylonitriles or a combination thereof.

10. Method according to claim 1, whereby the first sheet structure comprises a functional layer.

11. Method according to claim 1, whereby the first sheet structure is a pre-laminate comprising a functional layer and at least one further ply, which are connected by means of a hot-melt adhesive or a reactive adhesive, the adhesive being applied continuously or discontinuously to the functional layer and/or the at least one further ply.

12. Method according to claim 1, whereby the at least one further ply is a textile ply comprising a hot-melt adhesive or a reactive adhesive, by means of which the functional layer and the textile ply are connected to one another in a planar manner.

13. Method according to claim 1, whereby the two-dimensional sheet structures have an elongation at break of at least 50% in their directions of extension at room temperature, measured according to DIN EN ISO 13934-1:1999.

14. Water-tight and water-vapour-permeable three-dimensional segment for or for the forming of a shoe shaft, an item of clothing or a rucksack, whereby the segment comprises a water-tight and water-vapour-permeable functional layer and at least one further ply, and the functional layer and/or the at least one further ply comprises a thermoplastic material and whereby the segment is dimensionally stable under its own weight, is of a single piece and is free of connection points in its surface, wherein the segment consists of a stack of at least two two-dimensional sheet structures which were simultaneously laminated with an adhesion of at least 1.0 N, measured according to DIN 53530:1981-02 with a test piece width of 25 mm, and transferred to the three-dimensional segment.

15. The segment according to claim 14, whereby it comprises the entire shaft of a shoe.

Description

[0150] The invention is explained in more detail with reference to the following figures and examples, although the figures and examples are not to be understood as restrictive:

[0151] FIG. 1A schematically shows a cross-section of a mould body with a three-dimensional segment according to the invention.

[0152] FIG. 1B shows an exemplary photographic image of a side view of a mould body/shoe last with a three-dimensional segment according to the invention enclosing the mould body on its shoe shaft side.

[0153] FIG. 2 schematically shows a cross-section of a 2-ply functional shoe shaft laminate according to the invention.

[0154] FIG. 3 schematically shows a cross-section of a 3-ply shoe shaft functional laminate according to the invention.

[0155] FIG. 4A shows a schematic sketch of a side view of a shoe last commonly used in the footwear industry.

[0156] FIG. 4B shows a schematic sketch of a top view of a shoe last commonly used in the footwear industry.

[0157] FIG. 5 schematically shows a cross-section of a three-dimensional segment of a functional shoe shaft laminate connected to a sole construction according to the invention.

[0158] FIG. 6 schematically shows a cross-section of a shoe containing a three-dimensional segment of a functional shoe shaft laminate according to the invention.

[0159] FIGS. 1A and 1B schematically illustrate in cross-section (FIG. 1A) or by means of an exemplary photographic illustration (FIG. 1B) the result of the deformation, carried out according to the method of the invention, of a two-dimensional sheet structure to form a suitable three-dimensional segment of a functional shoe shaft laminate 5 or 5a using a mould body 10 or 10a, which provides the three-dimensional contour of the segment 5 or 5a.

[0160] FIG. 2 schematically shows a cross-section of a section of a three-dimensional segment 20 formed and laminated according to the method of the invention, which is composed of a textile ply 30, an adhesive layer 40 and a water-tight and water-vapour-permeable functional layer 50. In an advantageous embodiment, the functional layer 50 is made of polyether ester (PEEST), such as a Sympatex® membrane. In a preferred embodiment, the adhesive layer 40 may also be a non-woven fabric comprising fibres or filaments containing the adhesive. The segment in this embodiment can thus also be considered a 3-ply functional shoe shaft laminate.

[0161] By way of an example, FIG. 3 schematically shows a cross-section of a part of a three-dimensional segment 60 deformed and laminated according to the method of the invention, consisting of a first textile ply 30, a first adhesive layer 40, a water-tight and water-vapour-permeable functional layer 50, a second adhesive layer 70 and a second textile ply 80. The textile plies 30 and 80 can be identical or different. The same applies to the adhesive layers 40 and 70, irrespective of the textile plies. As described for FIG. 2, the adhesive layers 40 and 70 can also each be a non-woven fabric consisting of fibres or filaments containing the adhesive. The segment in this embodiment can thus also be considered a 5-ply functional shoe shaft laminate.

[0162] FIGS. 4A and 4B schematically show, in a side view and in a top view respectively, an example known to the person skilled in the art of a shoe last 85 reproducing the foot contour as it can be used as a mould body in the method according to the invention.

[0163] FIG. 5 schematically shows the three-dimensional segment of a functional shoe shaft laminate 90 according to the invention, which in an advantageous embodiment is connected to a sole structure 100 by adhesion 95a or sewing 95b.

[0164] FIG. 6 schematically shows a cross-section of a three-dimensional segment of a functional shoe shaft laminate 105 according to the invention in a water-tight and water-vapour-permeable shoe with an outer material 110 (e.g. made of leather), an attached sole construction 115 and an outer sole 120. The segment produced according to the method according to the invention or the segment 105 according to the invention reproduces the shoe contour in optimum fashion so that no gaps or only small ones occur between the outer material 110 and the segment 105 comprising at least parts of the inner shaft. This ensures an optimum fit of the shoe.

EXAMPLE 1

[0165] A stack consisting of a pre-laminate, a thermoplastic adhesive layer and a lining material, whereby the pre-laminate consists of:

[0166] 1. a knitted fabric of 81% by weight polyethylene terephthalate and 19% by weight elastane, weighing 50 g/m.sup.2,

[0167] 2. a reactive, moisture-curing polyurethane adhesive applied in a grid pattern and weighing approx. 12 g/m.sup.2,

[0168] 3. a polyether ester-based Sympatex® membrane with a membrane thickness of 10 μm,

[0169] the adhesive layer (adhesive non-woven) is composed of a non-woven of a thermoplastic adhesive made of polyurethane with a melting range of approx. 115° C. and a weight of 20 g/m.sup.2 and the lining material is a knitted fabric made of polyester with a weight of 265 g/m.sup.2.

[0170] The pre-laminate, adhesive non-woven and lining material are unrolled from rolls and positioned on a thermoforming machine (Illig) in such a way that the knitted fabric side of the pre-laminate and the lining material face the two infrared heaters of the machine, each set to 175° C., and the stack is heated there for 16-18 seconds. The upright last is then moved through the plane of the stack from below by positive mould formation. The lining material side of the stack faces the last, the knitted side faces away from the last. After reaching the end position, a vacuum is created between the last and the laminate. Here, the stack is formed into a 3D functional shoe shaft laminate and the pre-laminate and lining material are connected to each other by the adhesive non-woven. After a cooling time of approx. 15 s, the vacuum is released, the last is moved down again and the finished 3D functional shoe shaft laminate is removed from the machine.

[0171] The finished 3D functional shoe shaft laminate has an adhesion of 2.3 N, measured according to DIN 53530:1981-02 with a test piece width of 25 mm.

EXAMPLE 2

[0172] Example 1 was repeated with the modification that the adhesive non-woven is now part of the pre-laminate. Therefore:

[0173] A stack consisting of a pre-laminate and a lining material, the pre-laminate consisting of:

[0174] 1. a knitted fabric of 81% by weight polyethylene terephthalate and 19% by weight elastane, weighing 50 g/m.sup.2,

[0175] 2. a reactive, moisture-curing polyurethane adhesive applied in a grid pattern and weighing approx. 12 g/m.sup.2,

[0176] 3. a polyether ester-based Sympatex® membrane with a membrane thickness of 10 μm,

[0177] 4. a non-woven of a thermoplastic adhesive (adhesive non-woven) made of polyurethane with a melting range of approx. 115° C. and a weight of 20 g/m.sup.2,

[0178] and the lining material is a knitted polyester fabric weighing 265 g/m.sup.2.

[0179] The pre-laminate and lining material are unrolled from rolls and positioned on a thermoforming machine (Illig) in such a way that the knitted fabric side of the pre-laminate faces the two infrared heaters of the machine, each set to 175° C., and is heated there for 16-18 seconds. The upright last is then moved through the plane of the stack from below by positive mould formation. The lining material side of the stack faces the last, the knitted side faces away from the last. After reaching the end position, a vacuum is created between the last and the laminate. Here, the stack is formed into a 3D functional shoe shaft laminate and the pre-laminate and lining material are connected to each other by the adhesive non-woven. After a cooling time of approx. 15 s, the vacuum is released, the last is moved down again and the finished 3D functional shoe shaft laminate is removed from the machine.

[0180] The 3D functional shoe shaft laminate has an adhesion of 4.0 N, measured according to DIN 53530:1981-02 with a test piece width of 25 mm.

EXAMPLE 3

[0181] Example 1 was repeated with the modification that the lining material is made from recycled material. Therefore:

[0182] A stack comprising the pre-laminate from Example 1, a thermoplastic adhesive layer from Example 1 and a lining material which is a knitted pile of recycled polyester weighing 350 g/m.sup.2.

[0183] The pre-laminate, adhesive non-woven and lining material are unrolled from rolls and positioned on a thermoforming machine (Illig) in such a way that the knitted fabric side of the pre-laminate and the lining material face the two infrared heaters of the machine, each set to 165° C., and are heated there for 16-18 seconds. The upright last is then moved through the plane of the stack from below by positive mould formation. The lining material side of the stack faces the last, the knitted side faces away from the last. After reaching the end position, a vacuum is created between the last and the laminate. Here, the stack is formed into a 3D functional shoe shaft laminate and the pre-laminate and lining material are connected to each other by the adhesive non-woven. After a cooling time of approx. 15 s, the vacuum is released, the last is moved down again and the finished 3D functional shoe shaft laminate is removed from the machine.

[0184] The finished 3D functional shoe shaft laminate has an adhesion of 2.1 N, measured according to DIN 53530:1981-02 with a test piece width of 25 mm.

COMPARISON EXAMPLE 4

[0185] Example 1 was repeated with the modification that the adhesive layer is now an adhesive net. Therefore:

[0186] A stack consisting of the pre-laminate from Example 1, a thermoplastic adhesive layer consisting of a net of a thermoplastic adhesive made of polyurethane with a melting range of about 110° C. and a weight of 35 g/m.sup.2 and the lining material from Example 1.

[0187] The pre-laminate, adhesive net and lining material are unrolled from rolls and positioned on a thermoforming machine (Illig) in such a way that the knitted fabric side of the pre-laminate and the lining material face the two infrared heaters of the machine, each set to 175° C., and are heated there for 16-18 seconds. The upright last is then moved through the plane of the stack from below by positive mould formation. The lining material side of the stack faces the last, the knitted side faces away from the last. After reaching the end position, a vacuum is created between the last and the laminate. Here, the stack is formed into a 3D functional shoe shaft laminate and the pre-laminate and lining material are connected to each other by the adhesive non-woven. After a cooling time of approx. 15 s, the vacuum is released, the last is moved down again and the finished 3D functional shoe shaft laminate is removed from the machine.

[0188] In the finished 3D functional shoe shaft laminate, detachment sometimes occurs within the laminate composite due to uneven distribution of the thermoplastic adhesive. In the area of these points, the adhesion is <1.0 N, measured according to DIN 53530:1981-02 with a test piece width of 25 mm.

COMPARISON EXAMPLE 5

[0189] Example 1 was repeated with the modification that the adhesive non-woven now has a lower melting point. Therefore:

[0190] A stack consisting of the pre-laminate from Example 1, a thermoplastic adhesive layer of a non-woven of a thermoplastic adhesive (adhesive non-woven) made of polyurethane with a melting range of about 50° C. and a weight of 20 g/m.sup.2 and the lining material from Example 1.

[0191] The pre-laminate, adhesive non-woven and lining material are unrolled from rolls and positioned on a thermoforming machine (Illig) in such a way that the knitted fabric side of the pre-laminate and the lining material face the two infrared heaters of the machine, each set to 140° C., and are heated there for 16-18 seconds. The upright last is then moved through the plane of the stack from below by positive mould formation. The lining material side of the stack faces the last, the knitted side faces away from the last. After reaching the end position, a vacuum is created between the last and the laminate. Here, the stack is formed into a 3D functional shoe shaft laminate and the pre-laminate and lining material are connected to each other by the adhesive non-woven. After a cooling time of approx. 15 s, the vacuum is released, the last is moved down again and the finished 3D functional shoe shaft laminate is removed from the machine.

[0192] In the finished 3D functional shoe shaft laminate, detachment sometimes occurs within the laminate composite due to uneven distribution of the thermoplastic adhesive. In the area of these points, the adhesion is <1.0 N, measured according to DIN 53530:1981-02 with a test piece width of 25 mm.

[0193] The comparative examples described above show that simultaneous deformation and lamination in the thermoforming process is crucial in order to achieve the adhesion between the unconnected sheet structures in the functional laminate required according to the invention.