SOLE ELEMENT, FOOTWEAR ARTICLE COMPRISING SUCH A SOLE ELEMENT AND METHODS FOR MANUFACTURING SUCH A SOLE ELEMENT AND SUCH A FOOTWEAR ARTICLE

Abstract

The object of the present disclosure is a sole assembly element comprising at least one textile, in particular thermocompressed, sole element comprising one or several at least partly hot-melted yarn(s) as well as at least one housing and particles disposed in said at least one housing. The present disclosure also relates to a footwear article comprising such a sole assembly element, the methods for manufacturing such a sole assembly element and such a footwear article.

Claims

1. A sole assembly element wherein said sole assembly element comprises at least one textile sole element comprising one or several at least partly hot-melted yarn(s) and particles, wherein at least one textile sole element comprises at least one housing, and wherein said particles are disposed in said at least one housing.

2. The sole assembly element according to claim 1, wherein the textile sole element comprises a knitted tubular part.

3. The sole assembly element according to claim 1, wherein the particles comprise at least partly hot-melted particles.

4. The sole assembly element according to claim 1, wherein the particles comprise particles having a melting or softening temperature, or a degradation temperature, higher than or equal to 200? C.

5. The sole assembly element according to claim 1, wherein the particles comprise particles having at least one dimension greater than or equal to 1 mm.

6. The sole assembly element according to claim 1, wherein the particles comprise cushioning particles.

7. The sole assembly element according to claim 1, wherein the particles comprise at least partly biosourced particles.

8. The sole assembly element according to claim 1, wherein the particles comprise particles derived from at least one recycled and crushed element.

9. The sole assembly element according to claim 1, wherein the particles comprise mobile particles.

10. The sole assembly element according to claim 1, wherein the textile sole element extends at least partly in a heel region of the sole assembly element, at least partly in a midfoot region of the sole assembly element, and at least partly in a forefoot region of the sole assembly element, and wherein the textile sole element extends between a medial edge and a lateral edge of the sole assembly element.

11. The sole assembly element according to claim 1, wherein said at least one housing is a longitudinal housing, extending at least partly in a heel region of the sole assembly element or at least partly in a forefoot region of the sole assembly element.

12. The sole assembly element according to claim 1, wherein the textile sole element comprises several housings which are textile housings, and comprises particles disposed in each of said textile housings, the textile housings each comprise one or several at least partly hot-melted yarn(s).

13. The sole assembly element according to claim 1, wherein the textile sole element is thermocompressed.

14. A footwear article wherein said footwear article comprises at least one sole assembly element according to claim 1.

15. The footwear article according to claim 14, wherein said footwear article comprises an upper comprising at least a first textile element comprising a knitted tubular part, and wherein said knitted tubular part comprises one or several at least partly hot-melted yarn(s).

16. The footwear article according to claim 15, wherein said at least one textile sole element of the sole assembly element is in textile connection with the first textile element of the upper.

17. The footwear article according to claim 15, wherein the first textile element is a knitted sock, and wherein the sole assembly element is at least a part chosen from: a part of a midsole, a part of an outsole, or a combination thereof.

18. The footwear article according to claim 14, wherein the footwear article comprises a foot-receiving void configured to receive a foot, and wherein the sole assembly element is removable and configured to be disposed in the foot-receiving void.

19. A method for manufacturing a sole assembly element wherein said method comprises: (i) providing at least one textile sole element comprising one or several at least partly thermofusible yarn(s) and comprising at least one pocket, and particles; (ii) disposing the particles in said at least one pocket; (iii) molding said textile sole element comprising one or several at least partly thermofusible yarn(s); (iv) obtaining a sole assembly element comprising at least said textile sole element comprising one or several at least partly hot-melted yarn(s) and at least one housing receiving said particles.

20. The method according to claim 19, wherein step (iii) comprises disposing said at least one textile sole element in a mold structure comprising a sole cavity; and heating said at least one textile sole element so as to melt the at least partly thermofusible yarn(s) and substantially mold the sole cavity on an outer face of said textile sole element.

21. The method according to claim 19, wherein said at least one pocket comprises one or several at least partly thermofusible yarn(s), and wherein said at least one pocket is molded during step (iii) so as to form at least two housings receiving said particles.

22. A method for manufacturing a footwear article wherein said method comprises: (i) providing at least one textile sole element comprising one or several at least partly thermofusible yarn(s) and comprising at least one pocket, particles, and at least one first textile element comprising a tubular part comprising one or several at least partly thermofusible yarn(s); (ii) disposing the particles in said at least one pocket; (iii) molding said at least one textile sole element comprising one or several at least partly thermofusible yarn(s); (iv) molding said at least one first textile element comprising at least partly thermofusible yarn(s); step (iii) and step (iv) are carried out separately or carried out in a single molding step; a footwear article comprising a sole assembly element comprising at least said textile sole element comprising one or several at least partly hot-melted yarn(s), and at least one housing receiving said particles, and comprising a upper comprising said at least one first textile element comprising one or several at least partly hot-melted yarn(s).

Description

DESCRIPTION OF THE DRAWINGS

[0295] The present disclosure will be better understood upon reading the description of the embodiments of the present disclosure given by way of non-limiting examples, with reference to the appended drawings, in which:

[0296] FIG. 1 schematically illustrates, in a side view, a first example of a textile sole element not comprising particles, before thermocompression, according to the present disclosure;

[0297] FIG. 2 schematically illustrates, according to section plane II-II, the first example of a textile sole element of FIG. 1, before thermocompression, according to the present disclosure;

[0298] FIG. 3 schematically represents, in side view, the first example of a textile sole element represented in FIG. 1 comprising particles, before thermocompression;

[0299] FIG. 4 schematically represents, in perspective, the first example of a textile sole element represented in FIG. 1 after thermocompression;

[0300] FIG. 5 schematically represents, according to the section plane V-V of FIG. 4, the first example of a textile sole element after thermocompression;

[0301] FIG. 6 schematically represents, in top view, a second example of a textile sole element according to the present disclosure without particles, and before thermocompression;

[0302] FIG. 7 schematically represents the second example of a textile sole according to the section plane VII-VII represented in FIG. 6;

[0303] FIG. 8 schematically represents, in top view, a third example of a textile sole element according to the present disclosure, before thermocompression;

[0304] FIG. 9 schematically represents the third example of a textile sole element according to the section plane IX-IX, before thermocompression;

[0305] FIG. 10 schematically represents the third example of a textile sole element, after thermocompression;

[0306] FIG. 11 schematically represents the third example of a textile sole element according to the section plane XI-XI, after thermocompression;

[0307] FIG. 12 schematically illustrates, in side view, a first example of an assembly comprising a sole assembly element according to the present disclosure for the manufacture of a footwear article, before thermocompression;

[0308] FIG. 13 schematically illustrates, in side view, a second example of an assembly comprising a sole assembly element according to the present disclosure for the manufacture of a footwear article, before thermocompression;

[0309] FIG. 14 schematically illustrates, in side view, a first example of a footwear article after thermocompression;

[0310] FIG. 15 schematically illustrates, in bottom view, the first example of a footwear article after thermocompression.

DETAILED DESCRIPTION

[0311] FIG. 1 represents a first example of a textile sole element 10, not thermocompressed and empty, comprising a knitted tubular part 12. In this specific example, the knitted tubular part 12 has a cross section of a substantially constant diameter d11 over its entire length l11. The tubular part 12 comprises an open front end 14 and an open rear end 16 and forms in this specific example a single pocket. The tubular part 12 comprises one or several at least partly thermofusible yarn(s), particularly consists of thermofusible yarn(s), for example monofilament or multifilament yarn(s) made of thermofusible polyurethane (for example whose melting temperature is of the order of 130? C.). The diameter d11 and the length l11 of the tubular part are determined according to the regions of the foot to be covered and to the desired properties. In this specific example, the length l11 substantially corresponds to the length of a foot of a given size and the diameter d11 substantially corresponds to the width of a foot of a given size. The textile sole element 10 comprises a heel region, a midfoot region and a forefoot region. The textile sole element 10 comprises a longitudinal axis ls1 and a transverse axis ts1, substantially perpendicular to each other.

[0312] The tubular part 12 comprises an upper textile layer 18 and a lower textile layer 20, represented in FIGS. 2 and 3, and delimiting a knitted pocket 22. The upper 18 and lower 20 layers are substantially opposite to each other and fixed together along their lateral 18a, 20a and medial 18b, 20b borders by knitting (or by stitching or by welding). The front end 14 is closed according to a fixing area 14a, which can be made during the knitting of the tubular part 12 or by stitching or by welding (ultrasonic, high-frequency, thermal welding for example). Then, the tubular part 12, forming the knitted pocket 22, is filled with a determined amount of particles 30. The open rear end 16 is then closed according to a fixing area 16a, which can be made similarly to the fixing area 14a. As a specific example, the textile sole element 10 comprising particles 30 which are wood sawdust, weighs approximately 100 g.

[0313] The textile sole element 10 can then undergo a thermocompression molding step during which, the textile sole element 10 being disposed in a mold structure, heat is applied so as to melt the at least partly thermofusible yarn(s) and a pressure is applied so as to mold the textile sole element 10 to the shape of a sole cavity of the mold structure. The heating temperature Tc is for example of the order of 200-220? C. and the pressure applied is of the order of 4 to 6 bars. The pressure can be applied by an inflatable bladder or using a conventional press.

[0314] A sole assembly element 40 is thus obtained comprising a textile sole element 11 comprising one or several at least partly hot-melted, in this specific example completely hot-melted, yarn(s) as well as several housings 50, 51, 52, 53 in which the particles 30 have been distributed under the effect of the pressure exerted. The textile sole element 11 comprises an upper textile layer 19 comprising one or several at least partly hot-melted yarn(s) forming its outer face 41, and a lower textile layer 21 comprising one or several at least partly hot-melted yarn(s) forming its inner face 42.

[0315] The textile sole element 11 has a thickness e1. The housings 52 and 53 are represented in more detail in FIG. 5. The housing 52 comprises an upper partition 52a, a lower partition 52b and lateral partitions 52c, 52d, 52e, 52f, 52g, each of these partitions consists of one or several hot-melted yarn(s). Likewise, the housing 53 comprises an upper partition 53a, a lower partition 53b and lateral partitions 53c, 53d, 53e, each of these partitions consists of one or several hot-melted yarn(s). It would also be possible that these partitions comprise non-hot-melted, and/or partially hot-melted yarns, depending on the desired properties. The partitions can be different from each other due to the yarns they comprise. The housings 50-53 communicate with each other. The housing 52 communicates with the housing 53. The air, and possibly particles if they are mobile, can thus flow from the housing 52 towards the housing 53, and the two other housings 50 and 51. In this specific example, the sole cavity of the mold structure and the pressure applied during pressing are determined so as to form grooves (negative cavities) according to the outer face 41 and to the inner face 42 of the sole assembly element 40. A groove 46 thus separates the upper partitions 52a and 53a, and a groove 56 separates the lower partitions 52b and 53b.

[0316] The textile sole element 11 comprises a rear edge 11a, a lateral edge 11b, a medial edge 11c and a front edge 11d. In this specific example, the rear border 11a extends from the heel region 12a towards the front border 11d of the forefoot region 12c by passing through the midfoot region 12c. The lateral edge 11b corresponds to the lateral edge of a footwear article and the medial edge 11c corresponds to the medial edge of a footwear article.

[0317] The sole assembly element 40 comprises a longitudinal axis Ls1 substantially parallel to the longitudinal axis ls1 of the textile sole element 11 (identical to that of the non-thermocompressed textile sole element 10), and a transverse axis Ts1 substantially parallel to the transverse axis ts1 of the textile sole element 11 (identical to that of the non-thermocompressed textile sole element 10).

[0318] The number, size and configuration of the housings 50-53 vary depending on the properties and aesthetics sought.

[0319] It is also possible to thermocompress the textile sole element 10 at the same time as a first textile element of an upper as will be described below.

[0320] In this specific example, the outer 41 and inner 42 faces of the sole assembly element 11 comprise a sole cavity. It is possible that only one of the two faces 41 and 42 comprises a sole cavity while the other is substantially smooth.

[0321] The particles 30 can be wood sawdust, for example with a size on average from 1 mm to 3 mm.

[0322] The particles 30 can alternatively be beads in an expanded polymer, particularly made of expanded polyurethane or expanded polyamide. The beads are distinct/separated from each other during the filling of the pocket, and are molded following thermocompression so as to be at least partly hot-melted. The beads form a functional insert providing cushioning and ensuring the midsole function. The outsole function is ensured at least partly by the at least partly hot-melted textile layer 21. One or several additional outsole element(s) can be attached according to one of the faces of the sole assembly element 40.

[0323] The second example of textile sole element 70 differs from the first example of textile sole 10 due to its general shape. The textile sole element 70 is a knitted tubular part but whose cross section varies so as to substantially follow the general shape of a foot. The tubular part forms a single knitted pocket 75 whose front 72 and rear 74 ends can be open at the outlet of the knitting machine. One of the two ends is however closed during knitting, or after knitting by stitching or by welding (thermal or ultrasonic or high-frequency welding) but before the filling with particles 80. The end left open is then closed (by stitching or by welding) after the filling with particles 80. The ends 72 and 74 are closed according to fixing areas 72a and 74a. The textile sole element 70 comprises an upper textile layer 85 and a lower textile layer 90 each comprising one of the at least partly thermofusible yarns, particularly consist of thermofusible yarns.

[0324] The textile sole element 70 has a longitudinal axis ls2, and a transverse axis ts2.

[0325] The textile sole element 70 can be thermocompressed in an equivalent manner to the textile sole element 10 so as to form a textile sole element comprising one or several at least partly hot-melted yarn(s) and several housings communicating together.

[0326] The particles 80 can be similar to the particles 30.

[0327] The third example of textile sole element 100 is a knitted tubular part whose cross section varies in order to have a general foot shape and having two front 100a and rear 100b ends. The textile sole element 100 comprises pockets 105, 107 and 109 delimited by the lateral 101 and medial 102 edges as well as the fixing areas, particularly knitted areas 110 and 115. The pockets 105, 107 and 109 are longitudinal pockets extending parallel to the longitudinal axis ls3 of the textile sole element 100. The longitudinal axis ls3 is substantially perpendicular to the transverse axis ts3 of the textile sole element 100.

[0328] The textile sole element 100 comprises an upper textile layer 120 and a lower textile layer 122 in connection along their medial 102 and lateral 101 borders by knitting. The upper and lower layers 120 and 122 are in connection, knitted connection or connection via stitching or welding (thermal, ultrasonic, or high-frequency welding), with each other also according to fixing areas 110 and 115. The pockets 105, 107 and 109 are filled respectively with particles 90, 92 and 94, for example from a front or rear open end 100a or 100b of the textile sole element 100 or one or several other filling opening(s) provided for this purpose. The open end(s) for the filling, once the textile sole element 100 comprising the particles 90, 92 and 94, is/are closed.

[0329] Each pocket 105, 107 and 109 comprises a determined amount of particles, which can be identical or different from one pocket to another. The textile sole element 100 has a thickness e2. The textile sole element 100, and therefore the upper and lower layers 120 and 122, consist of preferably thermofusible yarns, for example monofilament or multifilament yarns made of polyurethane. The textile sole element 100 undergoes a thermocompression step as described above with a mold structure having a specific sole cavity. The obtained sole assembly element 130 comprises a textile sole element 133 comprising one or several at least partly hot-melted, preferably entirely hot-melted, yarn(s). The textile sole element 133 comprises housings 132, 134 and 136 which are longitudinal because they are disposed parallel to the longitudinal axis ls3 of the textile sole element 133 and to the axis Ls3 of the sole assembly element 130. These housings 132, 134 and 136 comprise particles 30 which are distributed as a function of the pressure exerted. In this specific example, each pocket is thermocompressed into a housing. It is possible, depending on the cavity of the mold structure, that a pocket is thermocompressed so as to form several housings which are communicating.

[0330] The housings 132, 134 and 136 are in this embodiment non-communicating.

[0331] In FIG. 11, it is observed that the housing 136 comprises an upper partition 136a, a lower partition 136b and lateral partitions 136c and 136d. The upper partition 136a comprises a portion of the upper textile layer 120 which is wholly or partly hot-melted. The lower partition 136b comprises a portion of the lower textile layer 122, which is wholly or partly hot-melted. The lateral partitions comprise portions of the wholly or partly hot-melted upper and/or lower layers 122 and 120.

[0332] The particles 90, 92 and 94 can be similar or different in colors or natures. The upper and/or lower partitions of the housings 132, 134 and 136 can be transparent in order to visualize the particles.

[0333] The particles 90, 92 and 94 can thus be waste recycled from sports shoes and/or textiles for clothing. After thermocompression of the textile sole element 130, the particles can comprise partly hot-melted particles and non-hot-melted particles and therefore mobile relative to each other.

[0334] The textile sole element 133 extends into a heel region 142 of the sole assembly element 130, into a midfoot region 152 of the sole assembly element 130, and a forefoot region 162 of the sole assembly element 130. The textile sole element 133 extends between the medial edge 138 and the lateral edge 139 of the sole assembly element 130. The textile sole element 133 therefore comprises a heel region 140, a midfoot region 150 and a forefoot region 160.

[0335] The textile sole element 133 could be arranged differently and comprise only a heel region, or a heel region and a midfoot region. In this case, the configuration of the textile sole element 100 is arranged accordingly.

[0336] The at least partly hot-melted textile sole element 40 or 133 or sole element 70 can be fixed to an upper by stitching and/or by bonding, for example by implementing a Strobel type construction, and/or by welding (thermal or ultrasonic or high-frequency welding) reactivating the fusible material. This textile sole element can also be fixed to an upper comprising one or several at least partly thermofusible yarn(s) during the thermoforming of the upper for the shaping of the upper, or can also be thermocompressed into a single step during the thermalcompression of the upper.

[0337] The first example of assembly 300 for the manufacture of a footwear article having a longitudinal axis L1 is represented in FIG. 12 before thermocompression. This assembly 300 comprises a first textile element which is a knitted sock 310 comprising one or several at least partly thermofusible yarn(s), a textile sole element 320, such as the textile sole element 10, 70 or 100. The textile sole element 320 comprises in this specific example, a heel region, a midfoot region and a forefoot region, and extends between medial and lateral edges. The textile sole element 320 could however comprise only a heel region or a forefoot region.

[0338] The assembly 300 is disposed in a mold structure comprising at least one sole cavity. The mold structure is configured to receive the textile sole element 320 and the knitted sock 310. Heat is applied to melt the fusible material of the yarns and a pressure is applied to an inflatable bladder (for example of the order of 4-6 bars) disposed in the internal foot-receiving volume of the sock 310. The obtained footwear article (not represented) advantageously comprises an upper comprising one or several at least partly hot-melted yarn(s), and a sole assembly element comprising one or several at least partly hot-melted yarn(s), and one or several housing(s) each receiving particles. The sole assembly element can be the sole assembly element 40 of FIGS. 4 and 5 or the sole assembly element 130 of FIGS. 10 and 11. It is possible to attach an outsole along certain parts of the outer face of the sole assembly element to improve the abrasion resistance of the sole assembly element.

[0339] The second example of assembly 400 for the manufacture of a footwear article is represented in FIG. 13 before thermocompression. This assembly 400 comprises a first textile element which is a first internal knitted sock 410 disposed in the foot-receiving volume of a second external knitted sock 420. The first sock 410 and the second sock 420 can be two separate socks or in knitted connection at their openings for introducing the foot. The assembly 400 also comprises a textile sole element 430 disposed between the sole part 415 of the first sock 410 and the sole part 425 of the second sock 420. In this specific example, the first sock comprises more than 50% by mass, particularly approximately 80% by mass, relative to its total mass of thermofusible textile material. The second sock comprises less than 50% by mass relative to its total mass of thermofusible textile material, for example of the order of 30%. The assembly 400 is disposed in a mold structure (not represented) comprising a first receiving region for receiving the textile sole element, and sole parts 415 and 425, and a second receiving region for receiving at least partly the first and second socks 410 and 420. Heat is applied to melt the fusible material of the yarns and a pressure is applied to an inflatable bladder (for example of the order of 4-6 bars) disposed in the interior of the foot-receiving volume of the second sock 420. The assembly 400 is thus sandwiched between the mold structure and the inflatable bladder, particularly in the shape of a foot. The assembly 400, still disposed in the mold structure, is left to cool to be set and stiffened. Then, the assembly 400 is demolded. The obtained sole assembly element (not represented) thus comprises the at least partly hot-melted sole part 425 and textile sole element 430. It is possible to attach an outsole along some parts of the outer face of the sole part 425 comprising at least partly hot-melted yarns to improve the abrasion resistance of the sole assembly element. The sole part 425 can comprise one or several at least partly thermofusible yarn(s) having a significant count (dtex) or comprise two superimposed knitted textile layers each comprising one or several at least partly thermofusible yarn(s) in order to provide a significant amount of hot-melted material. This arrangement makes it possible to reinforce the outer face of the sole assembly element. The assembly 400 can also comprise a sole member, for example an injected plate, particularly disposed in the heel region of the assembly, disposed between the sole part 425 of the second sock 420 and the textile sole element 430. The assembly 400 can also comprise a sole member, for example a shock-absorbing gel plate, particularly disposed in the heel or forefoot region, and disposed between the textile sole element 430 and the sole part 415 of the first sock 410.

[0340] The first example of footwear article 500 represented in FIGS. 14 and 15 comprises an upper 510 and a sole assembly element 520. The upper 510 is obtained by thermoforming an assembly comprising a first knitted inner sock and a second knitted outer sock receiving in its interior volume the first knitted inner sock. The sole assembly element 520 can be a thermocompressed sole assembly element independently of the assembly intended to form the upper, such as the sole assembly element 40 or 130. The sole assembly element 520 is represented in FIG. 15 viewed along its outer face 521. In this specific example, the sole assembly element 520 comprises five housings 522 to 526 each comprising particles 540-544 visible through the substantially transparent or translucent upper partitions of the housings 522-526. The sole assembly element 520 is then fixed by bonding or by stitching to the upper 510. The sole assembly element 520 can also be fixed to the upper during thermoforming or thermocompression of the partly textile assembly intended to form the upper 510. The hot transformation of the partly textile assembly intended to form the upper, reactivates the fusible material derived from the at least partly thermofusible yarn(s) of the sole element 520, possibly with the possible application of pressure, which makes it possible to fix the sole assembly element 520 to the sole part of the upper 510.

[0341] The particles 540-544 can be similar or different (colors, compositions, etc.), preferably the particles are wood sawdust particles whose size is comprised between 1 mm and 8 mm. The housings 522-526 are preferably communicating and thus form a closed assembly receiving the particles. The housings are however partially separated by grooves forming lateral partitions as described with reference to FIG. 5.