LIQUID THERMOPLASTIC POLYMER APPLICATION PATTERNS FOR HIGH TRACTION APPLICATIONS

Abstract

A sole structure, for a shoe (e.g., a sports shoe), comprising a base layer and a polymer layer arranged on a ground-facing side of the base layer in a pattern wherein the pattern comprises one or more first areas and one or more second areas having a lower thickness than the one or more first areas and wherein the pattern comprises an alternating arrangement of first areas and second areas such that a longitudinal extension of the first areas and of the second areas is essentially perpendicular to a longitudinal axis of the sole structure, and/or wherein the surface area of the first areas is at least two times the surface area of the second areas for providing grip when in contact to a surface, preferably a wet surface. Additionally, a shoe comprising the sole structure and a method of manufacturing the sole structure.

Claims

1. A sole structure for a shoe, comprising: a base layer; and a polymer layer arranged on a ground-facing side of the base layer in a pattern; wherein the pattern comprises one or more first areas and one or more second areas; wherein the one or more second areas have a lower thickness than the one or more first areas; and wherein the pattern comprises an alternating arrangement of first areas and second areas such that a longitudinal extension of the first areas and of the second areas is essentially perpendicular to a longitudinal axis of the sole structure; and wherein the surface area of the first areas is at least two times the surface area of the second areas.

2. The sole structure according to claim 1, wherein the polymer layer in the one or more first areas has a thickness ranging from 0.1 mm to 0.9 mm.

3. The sole structure according to claim 1, wherein the pattern is a grid, lattice, line, spiral, honeycomb, dots, wave, sine-wave pattern, or any combination thereof.

4. The sole structure according to claim 1, wherein each of the one or more first areas comprises a higher amount of polymer than each of the one or more second areas.

5. The sole structure according to claim 1, wherein the surface area of the one or more first areas is at least 2.5 times the surface area of the one or more second areas.

6. The sole structure according to claim 1, wherein the first areas have a length, depth and/or width in a direction essentially perpendicular to the longitudinal extension of at least 1.0 mm and of at most 9.0 mm, or wherein the second areas have a length, depth and/or width in a direction essentially perpendicular to the longitudinal extension of at least 0.2 mm and of at most 3.0 mm.

7. The sole structure according to claim 1, wherein the polymer in the polymer layer is selected from the group consisting of polyurethanes (PU), thermoplastic polyamides (TPE-A or TPA), thermoplastic polyesters (TPE-E or TPE), thermoplastic styrenic block copolymers (TPE-S or TPS), thermoplastic polyurethanes (TPE-U or TPU), thermoplastic vulcanizates (TPE-V or TPV), rubber, or ethylene-vinyl acetate copolymers (EVA), or combinations thereof.

8. The sole structure according to claim 1, wherein the one or more first areas and the one or more second areas have an undulating shape.

9. The sole structure according to claim 8, wherein the undulating shape has an amplitude of at least 1 mm and at most 9 mm.

10. The sole structure according to claim 8, wherein the undulating shape essentially corresponds to a sine wave.

11. The sole structure according to claim 8, wherein the undulating shape has a wavelength of at least 2 mm and at most 14 mm.

12. The sole structure according to claims 8, wherein the ratio between an amplitude and a wavelength of the undulating shape is at least 0.1:4 and at most 3:0.5.

13. The sole structure according to claim 1, wherein the pattern is a line-shaped pattern and a width of the first area of the one or more first areas is of at least 1 mm, or wherein the second area of the one or more second areas has a width of at least 0.3 mm.

14. The sole structure according to claim 1, wherein the base layer is a midsole of the shoe or a portion thereof.

15. The sole structure according to claim 1, wherein the polymer layer is arranged in one or more of a toe section, a forefoot section, a heel section, a midfoot section, a sidewall section, and an upper section of the shoe.

16. A shoe comprising the sole structure according to claim 1.

17. The shoe of claim 16, wherein the shoe is a running shoe.

18. The shoe of claim 16, wherein the sole structure forms an outsole of the shoe.

28. The sole structure according to claim 1, wherein the polymer layer is omitted in the one or more second areas.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0037] The accompanying figures, which are incorporated herein, form part of the specification and illustrate embodiments of the present disclosure. Together with the description, the figures further serve to explain the principles of and to enable a person skilled in the relevant art(s) to make and use the disclosed embodiments. These figures are intended to be illustrative, not limiting. Although the disclosure is generally described in the context of these embodiments, it should be understood that it is not intended to limit the scope of the disclosure to these particular embodiments. In the drawings, like reference numbers indicate identical or functionally similar elements.

[0038] FIG. 1 shows an embodiment of a sole structure comprising a line-shaped pattern.

[0039] FIG. 2 shows an embodiment of a sole structure comprising an undulating pattern.

[0040] FIG. 3 shows an embodiment of a sole structure comprising a grid-shaped pattern which has been post-processed.

[0041] FIG. 4 shows an embodiment of a sole structure comprising a wave-shaped pattern which has been post-processed.

[0042] FIG. 5 shows three embodiments of textured and post-treated sole structures.

[0043] FIG. 6 is a diagram showing friction properties of sole structures according to some embodiments in a comparative manner.

[0044] FIGS. 7a-7c show embodiments of sport shoes comprising sole structures according to some embodiments.

[0045] FIG. 8 shows a flow diagram of a method for manufacturing sole structure according to some embodiments.

DETAILED DESCRIPTION

[0046] Embodiments of the present disclosure are described below, predominately with respect to shoes, such as sport shoes. It is, however, once again emphasized that the different embodiments may also be practiced in different kinds of soles and shoes and are not limited to the specific embodiments set forth below.

[0047] Reference is further made to the fact that a skilled artisan will understand that the features and possible modifications described with reference to the specific embodiments discussed herein may also be further modified and/or combined with another embodiment in a different manner or in different sub-combinations, without departing from the scope of the present disclosure. Individual features or sub-features may also be omitted, where compatible.

[0048] Where a range of numerical values comprising upper and lower values is recited herein, unless otherwise stated in specific circumstances, the range is intended to include the endpoints thereof, and all integers and fractions within the range. It is not intended that the disclosure or claims be limited to the specific values recited when defining a range. Further, when an amount, concentration, or other value or parameter is given as a range, one or more ranges, or as list of upper values and lower values, this is to be understood as specifically disclosing all ranges formed from any pair of any upper range limit or value and any lower range limit or value, regardless of whether such pairs are separately disclosed.

[0049] Some embodiments of the present disclosure relate to a sole structure for a shoe, such as a sports shoe, comprising: [0050] a. a base layer; and [0051] b. a polymer layer arranged on a ground-facing side of the base layer in a pattern; wherein the pattern comprises one or more first areas and one or more second areas; wherein the one or more second areas have a lower thickness than the one or more first areas; and [0052] wherein the pattern comprises an alternating arrangement of first areas and second areas such that a longitudinal extension of the first areas and of the second areas is essentially perpendicular to a longitudinal axis of the sole structure, and/or [0053] wherein the surface area of the first areas is at least two times the surface area of the second areas.

[0054] In some embodiments, the sole structure of the present disclosure may enhance traction on smooth and wet surfaces while reducing the probability of slipping. When using the sole structure according to the present disclosure, the running performance of the wearer, e.g., an athlete, may be improved. Due to the reduced risk of slipping, e.g., on wet and smooth surfaces, the sole structure may provide an improved overall workout experience and result. For example, when comparing to conventional sole structures, the sole structure of the present disclosure may exhibit an improvement in friction. Moreover, the sole structure has the benefit that it may be individually designed based on the friction force, which acts on the sole structure. For example, individual gait patterns and leading force vectors may be used to tailor the specific application of the sole structure to, e.g., the individual running style of an athlete. Furthermore, the sole structure may be considerably lighter and thinner, due to its materials and manufacturing method, making the overall sole structure more desirable.

[0055] A sole structure according to present disclosure is, but not limited to, the bottom part of a shoe or footwear that provides cushioning, support, and traction for the wearer.

[0056] A polymer layer according to present disclosure is but not limited to, a layer comprising one or more polymers. The polymer layer may be made from durable and long-lasting materials. In particular, the polymer material may provide for the contacting zone, which is in contact with the ground during, e.g., the course of a gait. Furthermore, the polymer layer may provide flexibility, durability, cushioning, and support in the sole structure.

[0057] A base layer according to present disclosure is, but not limited to, a foundational part of the sole structure, and may help to maintain the structural integrity of the sole structure. The base layer may include materials that absorb shock and reduce the impact on the joints. The base layer may be made from durable materials to withstand the wear and tear of regular use. The base layer may work in conjunction with other layers of the sole structure and the shoe (e.g., a sports shoe), and in particular with the polymer layer.

[0058] In some embodiments, the polymer layer in the one or more first areas may have a thickness of 0.1 mm-0.9 mm, 0.2 mm-0.8 mm, 0.3 mm-0.7 mm, 0.4 mm-0.6 mm, and/or 0.5 mm.

[0059] In some embodiments, the thickness of the polymer layer provides for an overall thin sole structure. This may have the advantage that a more natural movement of the foot is enabled, which allows for a better flexion of the foot and, e.g., toe splay. In this manner, a more natural gait may be encouraged which reduces strain on certain parts of the foot and leg. Moreover, by using the polymer layer having a thickness according to some embodiments of the present disclosure, the proprioception of the feet on the ground for the wearer may be enhanced. This may be beneficial in sports like running, barefoot-style training, and agility drills, where precise foot placement and balance are important. Furthermore, by using the polymer layer of the present disclosure, less material between the foot and the ground may be provided than compared to conventional soles, which may lead to quicker response times for the wearer. This may be advantageous in sports requiring rapid changes in direction, acceleration, or deceleration. In addition, the polymer layer having a thickness according to some embodiments of the present disclosure may keep the foot closer to the ground which reduces the stack height of, e.g., the shoe (e.g., a sports shoe). This may improve stability and balance when using the polymer layer according to some embodiments of the present disclosure.

[0060] In some embodiments, the polymer layer in the one or more second areas may have a thickness of 0 mm. In this manner, the second areas are free from polymer and only comprise the base layer. This leads to an enlarged surface area of the sole structure, which may enhance the grip on the ground and the traction of the sole structure.

[0061] In some embodiments, the pattern may be a grid, lattice, line, spiral, honeycomb, dots, wave, sine wave pattern or any combination thereof. Alternatively, or in addition, the pattern may be an outlined and/or filled pattern in some embodiments. In some embodiments, the polymer layer in the one or more second areas may have the same thickness as in the one or more first areas.

[0062] In some embodiments, the pattern may improve the traction of the sole structure, which may help the wearer to maintain a secure footing on a variety of surfaces. Due to this improved traction, the wearer may experience greater stability, which may reduce the chances of slipping or losing balance. This may be helpful in sports requiring sudden stops, lateral movements, and quick turns, such as, e.g., running, football, basketball, and tennis. For example, using the patterns of the present disclosure may allow for faster turns, cuts, and lateral movements.

[0063] In some embodiments, each of the one or more first areas may comprises a higher amount of polymer than each of the one or more second areas.

[0064] In some embodiments, a difference in amount of the polymer on the first and second areas provides for a varying height which may offer better grip across multiple surface types, such as, for example, wet, dry, muddy, or uneven terrain. In such configurations, the first areas may dig into softer surfaces like grass or dirt, while the second areas may maintain contact on harder surfaces. In this manner, the grip of the sole structure may be improved.

[0065] In some embodiments, the surface area of the one or more first areas may be at least 2.5 times the surface area of the one or more second areas, preferably at least 3 times.

[0066] In some embodiments, the ratios of first and second areas may allow for the enhanced grip and traction of the sole structure.

[0067] In some embodiments, the pattern may comprise an alternating arrangement of first areas and second areas such that a longitudinal extension of the first areas and of the second areas may be essentially perpendicular to a longitudinal axis of the outsole, wherein the first areas may have a length, depth and/or width in a direction essentially perpendicular to the longitudinal extension of at least 1.0 mm, at least 2.0 mm, at least 2.5 mm, and/or at least 3.0 mm; and/or of at most 9.0 mm, at most 7.0 mm, at most 5.0 mm, and/or at most 3.5 mm, and/or [0068] wherein the second areas may have a length, depth and/or width in a direction essentially perpendicular to the longitudinal extension of at least 0.2 mm, at least 0.3 mm, at least 0.4 mm, and/or at least 0.5 mm; and/or of at most 3.0 mm, at most 2.5 mm, at most 2.0 mm, and/or at most 1.5 mm.

[0069] In some embodiments, the length, depth and/or width of the first and second areas may exhibit improved traction characteristics. For example, in some embodiments, the essentially perpendicular first and second areas may provide an improved grip of the sole structure on wet and/or smooth surfaces.

[0070] In some embodiments, the polymer in the polymer layer may be from the group of polyurethanes (PU), thermoplastic polyamides (TPE-A or TPA), thermoplastic polyesters (TPE-E or TPE), thermoplastic styrenic block copolymers (TPE-S or TPS), thermoplastic polyurethanes (TPE-U or TPU), thermoplastic vulcanizates (TPE-V or TPV), rubber or ethylene-vinyl acetate copolymer (EVA), and/or combinations thereof.

[0071] In some embodiments, the polymer may provide improved traction while reducing the probability of slipping. Moreover, the polymer may allow for a time efficient and sustainable process in the production of the sole structure while providing for a more durable and long-lasting sole structure. In some embodiments, the polymer may be elastic foam materials, such as thermoplastic elastomers and/or elastomers. In some embodiments, the polymer may be urethane-based thermoplastic elastomers (TPU), polyester-based thermoplastic elastomers (TPE), and/or polyamide-based thermoplastic elastomers (TPA), and/or combinations thereof.

[0072] In some embodiments, the polymer may be characterized by a Shore A value and/or Shore D value, wherein the Shore A value may be in the range of 20 to 120, 40 to 100, and/or 60 to 80; and the Shore D value may be in the range of 2 to 80, 5 to 75, and/or 8 to 70. Such configurations may improve the durability of the polymer layer and the overall sole structure.

[0073] In some embodiments, the one or more first areas and the one or more second areas may have an undulating shape.

[0074] In some embodiments, the undulating shape may provide an enlarged surface area of the sole structure while the longitudinal extension of the first and second areas are essentially perpendicular to the longitudinal axis of the sole structure. In this manner, the sole structure may provide enhanced traction and grip.

[0075] In some embodiments, the undulating shape may have an amplitude of at least 1 mm, at least 2 mm, at least 3 mm, and/or at least 3.5 mm; and/or at most 9 mm, at most 8 mm, at most 7 mm, at most 6 mm, at most 5 mm, and/or at most 4.5 mm.

[0076] In some embodiments, the amplitude value(s) of the undulating shape may improve the traction properties of the sole structure.

[0077] In some embodiments, the undulating shape may essentially correspond to a sine wave. In some embodiments, the undulating shape may have a wavelength of at least 2 mm, at least 4 mm, at least 6 mm, and/or at least 7 mm; and/or at most 14 mm, at most 12 mm, at most 10 mm, and/or at most 9 mm.

[0078] In some embodiments, the wavelength value(s) of the undulating shape may traction properties of the sole structure on wet surfaces.

[0079] In some embodiments, the ratio between the amplitude and wavelength of the undulating shape may be at least 0.1:4, at least 0.2:3, at least 0.3:2, and/or at least 0.8:3.5 and/or at most 3:0.5; at most 2:1, at most 1:1, and/or at most 1:2.

[0080] In some embodiments, the ratio between wavelength and amplitude may provide beneficial grip properties of the sole structure.

[0081] In some embodiments, the pattern may be a line-shaped pattern and the width of the first area of the one or more first areas may be of at least 1 mm, at least 1.5 mm, at least 2 mm, and/or at least 3 mm; and/or the second area of the one or more second areas may have a width of at least 0.3 mm, at least 0.7 mm, and/or at least 1 mm.

[0082] In some embodiments, the shoe may be a running shoe. By using the sole structure of the present disclosure, an improved shoe (e.g., a sports shoe) is provided which may exhibit improved traction on wet and smooth surfaces.

[0083] In some embodiments, the base layer may be a midsole of the shoe (e.g., a sports shoe) or a portion thereof.

[0084] In this manner, in some embodiments, the sole structure of the present disclosure may be directly integrated into the midsole. This configuration may reduce the overall weight of the sports shoe, making it more desirable and material efficient. In some embodiments, the base layer may comprise cushioning elements.

[0085] In some embodiments, the polymer layer may be arranged in one or more sections corresponding to sections of the shoe (e.g., a sports shoe), including a toe section, a forefoot section, a heel section, a midfoot section, a sidewall section and/or an upper section.

[0086] In some embodiments, the sole structure may be designed based on individual needs of the wearer. For example, the polymer layer may be arranged in sidewall sections for providing more grip when quickly turning and cutting when, e.g., playing basketball.

[0087] Some embodiments of the present disclosure are directed to a shoe (e.g., a sports shoes) comprising the sole structure according to embodiments of the present disclosure. The shoe (e.g., a sports shoe) of the present disclosure may exhibit improved traction and grip properties, for example on wet and/or smooth surfaces. Moreover, the grip and traction during workouts may be improved when using the shoe (e.g., a sports shoe) of the present disclosure. In some embodiments, the shoe may be a running shoe. The running shoe of the present disclosure may exhibit an improved traction when used during running. For example, when using the running shoe of the present disclosure, e.g., during wet weather conditions, the sole structure may provide a reduced risk of slipping of the wearer.

[0088] Some embodiments of the present disclosure are directed to a method for manufacturing a sole structure for a shoe, for example a sports shoe, comprising the steps of: [0089] A. providing a polymer, [0090] b. providing a solvent, [0091] c. mixing the polymer with the solvent, thereby forming a liquified polymer, [0092] d. arranging the liquified polymer of step c) onto a base layer, [0093] e. curing the arranged liquified polymer on the base layer, and [0094] f. thereby providing the sole structure with a pattern comprising one or more first areas and one or more second areas, [0095] wherein in step d) the liquified polymer is arranged on the base layer in the pattern and/or wherein after step e) the pattern is obtained by post-processing the cured polymer, and wherein arranging the liquified polymer provides for an alternating arrangement of first areas and second areas such that a longitudinal extension of the first areas and of the second areas is essentially perpendicular to a longitudinal axis of the sole structure, and/or wherein the surface area of the first areas is at least two times the surface area of the second areas.

[0096] A solvent according to present disclosure is, but not limited to, a compound capable of dissolving, dispersing, or extracting the polymer.

[0097] Curing according to present disclosure is to be understood, but not limited to, as a chemical and/or physical process of hardening, setting and/or solidification of the polymer. Curing may be carried out using radiation.

[0098] Mixing according to present disclosure is to be understood, but not limited to, as a process of combining two or more substances resulting in a mixture of the individual substances, preferably in a liquid form.

[0099] Arranging according to present disclosure is to be understood, but not limited to, as a process of applying and depositing for example the liquified polymer onto the base layer.

[0100] The liquified polymer is to be understood, but not limited to, as the polymer having semi-solid or liquid physical properties.

[0101] Post-processing, texturing or post-treating according to present disclosure is to be understood, but not limited to, as a process of manipulating physical properties of the sole structure that enhances the traction of the sole structure. For example, this may be done by external influence, e.g., mechanical force, laser and/or addition of additives. By doing so, a texture is provided by the sole structure which may improve the traction characteristic of the sole structure.

[0102] The advantages of some embodiments of the method for manufacturing a sole structure may include avoiding, e.g., glue-and injection molding-based deposition while providing a sole structure with enhanced traction and friction performance. While the sole structure may be used to create a lighter and thinner, e.g., outsole, the sole structure may be further used to enhance the grip of the shoe (e.g., a sports shoe) for particular workouts, e.g., when arranging the liquified polymer in particular zones of the sports shoe.

[0103] Some embodiments of the present disclosure are directed to the production of a liquified polymer by mixing the polymer and the solvent and which is applied and cured on the base layer, thereby forming, e.g., the outsole of the shoe (e.g., a sports shoe)-as opposed to forming the outsole via injection molding. In this manner, the sole structure may be manufactured more efficiently while the liquified polymer may be arranged more precisely and effectively. For example, in some embodiments, no material waste is produced, e.g., by cutting excess material. In this manner, the method according to present disclosure may provide an improved method for producing the sole structure for e.g., a sports shoe, by minimizing the material needed and avoiding waste production.

[0104] In some embodiments, using a liquified polymer may be advantageous for the overall manufacturing process, as the properties of the liquified polymer can be finetuned based on specific process requirements. For example, the liquified polymer may exhibit a different dynamic viscosity by increasing or decreasing the amount of solvent. In this manner, the deposition of the polymer may be affected such that, e.g., the polymer may be deposited onto the base layer in a more efficient manner.

[0105] In some embodiments, no manual assembly is required as well as a glue-less application is possible, providing for an efficient process with reduced material consumption and consequently reduced overall costs, that is applicable to automated processes. This is advantageous, as gluing may require complex pretreatment of the components and additionally adhesives used for the gluing of plastic components are often harmful or environmentally hazardous.

[0106] In some embodiments, the liquified polymer may be deposited on predetermined portions of the shoe (e.g., a sports shoe). For example, the liquified polymer may be arranged only in the heel section or the toe section. Moreover, in some embodiments, the liquified polymer may comprise different physical properties on each of the predetermined portions. In this manner, in some embodiments, the shoe (e.g., a sports shoe) may be adapted to individual needs while allowing for a lighter total weight of the shoe (e.g., a sports shoe) as well as enhancing its durability and traction.

[0107] In some embodiments, the method may further comprise the step of texturing, wherein the step of texturing may occur prior to the step of curing the liquified polymer. In some embodiments, the step of texturing may comprise adding additives. For example, in some embodiments, rubber particles may be added to the liquified polymer. In some embodiments, the rubber particles may have a grain size of 0.3-0.4 mm. In some embodiments, after curing the liquified polymer, the sole structure obtains a grainy design with an uneven surface structure. In some embodiments, the texturing comprises the addition of, e.g., silica, such as 2 wt.-% (e.g. Evonik Acematt TS100 or Evonik Acematt 790), to the polymer before mixing with the solvent. In this manner, in some embodiments, the produced sole structure has a matte appearance. In this manner, in some embodiments, post-treating the sole structure may provide a sole structure that exhibits 30% better traction as compared to conventional sole structures.

[0108] In some embodiments, texturing the polymer precedes the curing step. In some embodiments, the polymer is textured after curing the polymer. In this manner, the pattern may be obtained by post-treating, e.g., mechanically roughing the polymer.

[0109] In some embodiments, the method may further comprise post-treating mechanically the cured polymer.

[0110] For example, in some embodiments, the sole structure can be treated in an abrasive manner by using a rotary brush. In this manner a texture may added to the sole structureand additionally or alternatively the surface area of the sole structure may be enlarged, which may lead to better traction. In some embodiments, the surface of the sole structure may be manipulated in this manner and individual designs may be provided which may be desirable for, e.g., the wearer. In some embodiments, the post-treating device is selected based on the desired pattern and/or the physical characteristic of the cured polymer.

[0111] In some embodiments, post-processing the cured polymer may comprise laser treatment.

[0112] In some embodiments, the laser treatment may be performed by manipulating the thickness of the polymer layer, e.g., cutting out specific areas on the polymer layer which thereby provides for the second areas of the sole structure. For example, in some embodiments, the surface of the sole structure may be engraved via laser energy. In this manner, the top surface may be treated by the laser and, e.g., burnt away. In some embodiments, this will affect about 0.3 mm of the thickness of the cured polymer. Such configurations may provide an improved look of the sole structure while providing for second areas.

[0113] In some embodiments, the solvent may be a mixture selected from the group of solvent-borne and/or water-borne solvents. In some embodiments, the solvent-borne and/or water-borne solutions are selected from the group of solvent-borne solvents and/or from the group of (C1-C6) ethers, (C1-C10) esters, (C1-C8) ketones, (C1-C8) alkanes, and/or combinations thereof.

[0114] In some embodiments, the solvent may be a mixture of one or more of tetrahydrofuran (THF), methyl ethyl ketone (MEK), cyclohexane (CYC), ethyl acetate, butyl acetate. These solvents may be beneficial, as they provide for a homogenous mixture when mixed with the polymer. Moreover, the solvents may have the advantage that they can be removed in a time efficient manner during the curing process and allow for a production process that is capable of adapting to various physical properties of the liquid polymer.

[0115] In some embodiments, in step e) curing may take place at a temperature of between 20 C. to 150 C., 30 C. to 100 C., and/or 40 C. to 50 C., and the curing time may be between 2 min to 750 min, 5 min to 390 min, and/or 10 min to 30 min.

[0116] These curing temperatures may be beneficial to provide for a quick curing time.

[0117] In some embodiments, during step c) the ratio of the polymer to solvent in the mixture may be in the range of 10 to 90 wt. %., 20 to 80 wt. %, and/or 30 to 70 wt. %.

[0118] These ratios may provide a desirable viscosity of the liquified polymer.

[0119] In some embodiments, arranging the liquified polymer of step c) onto a base layer may be performed with a dynamic viscosity of 10000 to 50000 mPa.Math.s, and/or 20000 to 40000 mPa.Math.s.

[0120] These viscosities may provide a quick arranging process of the liquified polymer onto the base layer. In this manner, the overall process may be performed in a time-and energy-efficient manner.

[0121] The dynamic viscosity is measured via rotational viscometry. The viscosity is determined by applying rotational shear stress and observing the resistance to rotation. In particular, the viscosity is determined by measuring the fluid's resistance of the liquified polymer by rotating a probe in a sample of the liquified polymer and measuring the torque needed to turn the probe.

[0122] In some embodiments, the outsole may be the sole structure according to some embodiments of the present disclosure. Additionally or alternatively, in some embodiments, the sole structure may be a sole. Using the sole structure as an outsole and/or sole may improve the traction of the shoe (e.g., a sports shoe).

[0123] Some embodiments of the present disclosure are directed to an outsole which may be obtained by the method according to some embodiments of the present disclosure.

[0124] The many advantages discussed in the context of the other embodiments of the present disclosure may apply also to the outsole obtained by embodiments of the method according to the present disclosure.

[0125] FIG. 1 shows an embodiment of the sole structure 10. In some embodiments, the sole structure 10 may comprise a base layer 40 on which a polymer layer 30 is arranged in a line-shaped pattern 50.

[0126] In some embodiments, the pattern 50 comprises first areas 35 and second areas 45. The first and second areas 35, 45 may be arranged in an alternating manner in the pattern 50. As can be seen in FIG. 1, in some embodiments, the first and second areas 35, 45 may be essentially perpendicular to a longitudinal axis (shown as a dashed line) of the sole structure 10.

[0127] However, in some embodiments, the pattern 50 can be also a grid, lattice, line, spiral, honeycomb, dots, wave, sine wave pattern or any combination thereof.

[0128] In some embodiments, the first areas 35 may comprise a higher amount of polymer than the second areas 45. As can be seen, in some embodiments, the second areas 45 are free from the polymer layer 30. In other words, in some embodiments, the polymer layer 30 in these second areas 45 may have a thickness of 0 mm. In some embodiments, the polymer layer 30 in the first areas 35 has a thickness of 0.5 mm. However, in some embodiments, the thickness of the polymer layer in the first areas 35 may vary depending on the individual requirements of application. In some embodiments, the sole structure 10 may have a thickness which is in between 0.1-0.9 mm. In some embodiments, the surface area of the first areas 35 may be significantly higher than the surface area of the second areas 45. In some embodiments, the surface area of the first areas 35 is at least 3 times higher.

[0129] As shown in FIG. 1, in some embodiments, the first areas 35 have a depth in a direction essentially perpendicular to the longitudinal extension. In some embodiments, the depth of the first areas 35 may be at least 1.0 mm, at least 2.0 mm, at least 2.5 mm, and/or at least 3.0 mm. In some embodiments, the width of the second areas 45 may be at most 9.0 mm, at most 7.0 mm, at most 5.0 mm, and/or at most 3.5 mm. In some embodiments, the second areas 45 have may have a depth in a direction essentially perpendicular to the longitudinal extension of the sole structure. In some embodiments, the depth of the second areas 45 may be at least 0.2 mm, at least 0.3 mm, at least 0.4 mm, and/or at least 0.5 mm; and/or of at most 3.0 mm, at most 2.5 mm, at most 2.0 mm, and/or at most 1.5 mm.

[0130] In some embodiments, the first areas 35 may have a width which is of at least 1 mm. In some embodiments, the width of the first areas 35 may be at least 1.5 mm, at least 2 mm, and/or at least 3 mm. In some embodiments, the second areas 45 may have a width which is of at least 0.3 mm. In some embodiments, the width of the second areas 45 may be at least 0.7 mm, and/or at least 1 mm.

[0131] In some embodiments, the polymer layer 30 may comprise a TPU-based polymer. However, in some embodiments, the polymer in the polymer layer 30 may be from polyurethanes (PU), thermoplastic polyamides (TPE-A or TPA), thermoplastic polyesters (TPE-E or TPE), thermoplastic styrenic block copolymers (TPE-S or TPS), thermoplastic polyurethanes (TPE-U or TPU), thermoplastic vulcanizates (TPE-V or TPV), rubber or ethylene-vinyl acetate copolymer (EVA), and/or combinations thereof.

[0132] In some embodiments, the base layer 40 may be partly or completely integrated into a midsole of the shoe (e.g., a sports shoe). In some embodiments, the polymer layer 30 may be the outsole of the shoe (e.g., a sports shoe). In some embodiments, the shoe comprising the sole structure 10 may be a running shoe. In this manner, the running shoe may comprise beneficial traction properties due to the sole structure 10. This may be advantageous, for example, when running on wet and/or smooth ground, e.g., outside during wet weather conditions.

[0133] Additional features will be described in the following with respect to the embodiments shown in the FIGS. 2 to 7. Any compatible features discussed above with respect to FIG. 1 may be incorporated into any of the embodiments shown in FIGS. 2 to 7.

[0134] As can be seen in FIG. 2, in some embodiments, the first and second areas 35, 45 of the sole structure 10 may have an undulating shape which corresponds to a sine wave. For example, the second areas 45 may have a lower thickness and width than the first areas 35. In this manner, the surface area of the first areas 35 may be enlarged. In some embodiments, the surface area of the first areas 35 may be at least 2.5 times the surface area of the second areas 45. In some embodiments, the ratio of surface area between the first and second areas 35, 45 can be at least 3 times.

[0135] In some embodiments, the undulating shape of the first and second areas 35, 45 may have a wavelength of at least 2 mm. In some embodiments, the wavelength may be at least 4 mm, at least 6 mm, and/or at least 7 mm. Furthermore, in some embodiments, the wavelength of the undulating shape of the first and second areas 35, 45 may be at most 14 mm. In some embodiments, this wavelength may be at most 12 mm, at most 10 mm, and/or at most 9 mm.

[0136] In some embodiments, the undulating shape of the first and second areas 35, 45 may have an amplitude which is of at least 1 mm and at most 9 mm. In some embodiments, the amplitude may be of at least 2 mm, at least 3 mm, and/or at least 3.5 mm. Furthermore, in some embodiments, the amplitude of the undulating shape may be of at most 8 mm, at most 7 mm, at most 6 mm, at most 5 mm, and/or at most 4.5 mm.

[0137] In some embodiments, when putting the wavelength and the amplitude of the undulating shape in relation to each other, the ratio between amplitude and wavelength may be of at least 0.1:4. However, in some embodiments, the ratio may be of at least 0.2:3, at least 0.3:2, and/or at least 0.8:3.5.

[0138] In some embodiments, the ratio between the wavelength and the amplitude may be of at most 3:0.5. In some embodiments, the ratio may be of at most 2:1, at most 1:1, and/or at most 1:2.

[0139] As shown in FIG. 3, in some embodiments, the pattern 50 has a grid-shaped pattern. In some embodiments, the sole structure 10 may comprise an alternating arrangement of first areas and second areas 35, 45. In some embodiments, the arrangement comprises a longitudinal extension of the first and second areas 35, 45 that is essentially perpendicular to a longitudinal axis of the sole structure (shown in dashed line in FIG. 3). In some embodiments, the surface area of the first areas 35 may be two times the surface area of the second areas 45.

[0140] In some embodiments, the second areas 45 have lower thickness than the first areas 35. As can be seen in FIG. 3, in some embodiments, the second areas 45 may not be free from the polymer layer 30 but may comprise the polymer layer 30 with a specific thickness. In some embodiments, this thickness may be 0.2 mm. In some embodiments, the second areas 45 are crafted by using laser treatment. In this manner, in some embodiments, the polymer layer 30 in the second areas 45 may be cut out using laser with a depth of 0.3 mm.

[0141] Furthermore, as shown in FIG. 3, in some embodiments, the sole structure 10 comprises a texture. In some embodiments, this texture may be provided by using additives, such as silica-or rubber-based additives. In this manner, in some embodiments, the surface of the sole structure 10 is further enlarged, leading to improved traction and grip while maintaining a glossy and shiny appearance. In some embodiments, the textured sole structure may be post-treated using brushes or roller devices.

[0142] As shown in FIG. 4, in some embodiments, the first and second areas 35, 45 may have an undulating shape and both comprise polymer layer 30. In some embodiments, the polymer layer 30 in the first areas 35 may have a different thickness and width as compared to the polymer layer 30 in the second areas 45.

[0143] As can be seen in FIG. 4, in some embodiments, the width of the second areas 45 may be lower than the width of the first areas 35. For example, in some embodiments, the surface area of the first areas 35 may be three times the surface area of the second areas 45. Just as explained in the context of the embodiment shown in FIG. 3, the sole structure 10 shown in FIG. 4 may also have a texture. In some embodiments, the texture may be provided by adding silica-or rubber-based materials before curing the polymer. Moreover, in some embodiments, the surface of the polymer layer 30 may be roughened mechanically using devices such as pattern brushes. As can be seen in FIG. 4, in some embodiments, the sole structure 10 maintains a shiny appearance and a glossy design.

[0144] In FIG. 5, a detailed view of three different embodiments of sole structures 10 are shown that comprise different textures. The embodiments of sole structures 10 each comprise additives, which leads to an unlevelling of the surface of the sole structure 10. In addition, the embodiments of sole structures 10 have been mechanically roughened, as a result of which a matt and rough appearance of the embodiments of sole structures 10 is obtained.

[0145] The resulting appearance of the sole structure 10 depends at least in part on the mechanical treatment which has been applied. For example, in some embodiments, a mechanical treatment comprising the application of pattern brushes or rollers can be used during post-treatment.

[0146] In FIG. 6, various embodiments of the sole structure 10 according to the present disclosure have been tested compared to simple sole structures based on TPU and rubber material.

[0147] As can be taken from FIG. 6, the sole structures according to the present disclosure may exhibit higher friction values shown as CoF (coefficient of friction) than simple TPU soles.

[0148] The relationship between normal force and friction force is defined as coefficient of friction (CoF). For determining the CoF of the sole structures, a sample of a sole structure according to the present disclosure is placed on a test surface and a given load is applied, which corresponds to the normal force. Subsequently, the surface is moved relative to the sample through lateral force which is measured as the friction force. The measurement is performed using a Footwear/Shoe Slip Resistance Tester.

[0149] Embodiments of sole structures comprising the polymer layer 30 in the second areas 45 may reach the highest CoF value, and an improvement in friction of 30% as compared to conventional TPU soles. This demonstrates that the sole structures of the present disclosure may provide for a considerable enhancement of traction as compared to conventional TPU soles.

[0150] Coming now to FIGS. 7a to 7c which show embodiments of shoes 20 (e.g., sports shoes) or portions thereof comprising the sole structure 10 according to the present disclosure.

[0151] As shown in FIG. 7a, in some embodiments, the shoe 20 (e.g., a sports shoe) may have a sole structure 10 wherein the base layer 40 is a midsole 65. In some embodiments, the shoe 20 can be a running shoe 26. In some embodiments, the first and second areas 35, 45 which are arranged in an undulating manner provide for a sine-waved shape. The polymer layer 30 of the shoe 20 may be arranged in the toe section 21, the forefoot section 22, the heel section 23 and the midfoot section 24. In some embodiments, the polymer layer 30 is arranged in the sidewall section 27 and the upper section 28 of the shoe 20.

[0152] As can be seen in FIG. 7a, in some embodiments, the essentially perpendicular arrangement of the first and second areas 35, 45 may differ in the heel section 23 from the arrangement of the first and second areas 35, 45 in the toe, forefoot and midfoot sections 21, 22, 24 and are tilted of about 10 as compared to the longitudinal axis of the sole structure 10.

[0153] In some embodiments, the first and second areas 35, 45 may have a different arrangement and be tilted of at most 35, 25, 20, and/or 15 as compared to the longitudinal axis of the sole structure 10.

[0154] As can be seen in FIG. 7b, in some embodiments, the pattern 50 of the sole structure 10 may have a line shaped pattern. For example, in some embodiments, the first and second areas 35, 45 may be arranged as lines in a perpendicular arrangement as compared to the longitudinal axis of the sports shoe 20. In some embodiments, the arrangement of the first and second areas 35, 45 in the heel section may differ from their arrangement in the toe, forefoot and midfoot sections 21, 22, 24. For example, in some embodiments, the first and second areas 35, 45 may comprise an outlined design. In other words, the pattern 50 of the sole structure may be outlined. In some embodiments, the outline comprises the polymer layer 30 in the heel section and the midfoot to toe section 24-21.

[0155] As shown in FIG. 7c, in some embodiments, the sports shoe 20 may comprise an outsole based on the sole structure 10, which may comprise additives. In some embodiments, the sole structure 10 has been mechanically post-treated. In some embodiments, the addition of silica-and rubber-based materials together with the mechanical post-treatment may lead to an uneven surface of the sole structure 10 with a matt and rough design. In some embodiments, the second areas 45 which may be obtained by post-treating the sole structure 10, comprise essentially the same amount of polymer layer 30 as the first areas 35. In such configurations, the surface area of the first areas 35 may be at least two times the surface area of the second areas 45.

[0156] Coming to FIG. 8, which depicts a flowchart of a method 1000 according to the present disclosure.

[0157] In some embodiments, the method 1000 for manufacturing a sole structure 10, which may be for a shoe 20 (e.g., a sports shoe), comprises the first step 1010 of providing a polymer. In some embodiments, the polymer may be TPU. In some embodiments, the polymer may be from polyurethanes (PU), thermoplastic polyamides (TPE-A or TPA), thermoplastic polyesters (TPE-E or TPE), thermoplastic styrenic block copolymers (TPE-S or TPS), thermoplastic polyurethanes (TPE-U or TPU), thermoplastic vulcanizates (TPE-V or TPV), rubber or ethylene-vinyl acetate copolymer (EVA), and/or combinations thereof.

[0158] In some embodiments, in a second step 1020, a solvent is provided. The solvent may be a mixture selected from the group of solvent-borne solvents. In some embodiments, the solvent can be also a mixture based on water-borne solvents. In some embodiments, the solvent is from the group of solvent-borne solvents, such as from the group of (C1-C6) ethers, (C1-C10) esters, (C1-C8) ketones, (C1-C8) alkanes, and/or combinations thereof.

[0159] In some embodiments, in the next step 1030, the polymer is mixed with the solvent. In this manner, a liquified polymer may be formed. In some embodiments, the ratio of the polymer to solvent in step 1030 may be in the range of 10 to 90 wt. %. In some embodiments, the ratio may be from 20 to 80 wt. %, and/or 30 to 70 wt. %. Subsequently, in some embodiments, the liquified polymer may arranged onto a base layer in step 1040. When arranging the liquified polymer, in some embodiments, the liquified polymer may have a dynamic viscosity of 10000 to 50000 mPa.Math.s, and/or of 20000 to 40000 mPa.Math.s.

[0160] Afterwards, in some embodiments, in step 1050, the arranged liquified polymer may be cured on the base layer. In some embodiments, curing may take place at a temperature of between 20 C. to 150 C. In some embodiments, curing may take place at 30 C. to 100 C., and/or 40 C. to 50 C., and the curing time may be between 2 min to 750 min, 5 min to 390 min, and/or 10 min to 30 min.

[0161] In this manner, in some embodiments, the sole structure is provided in step 1060 with a pattern comprising first and second areas 35, 45. Arranging the liquified polymer in step 1050 may provide for an alternating arrangement of first and second areas 35, 45 such that a longitudinal extension of the first and second areas 35, 45 is essentially perpendicular to a longitudinal axis of the sole structure.

[0162] In addition, or alternatively, in some embodiments, the surface area of the first areas 35 may be at least two times the surface area of the second areas 45.

[0163] In some embodiments, the method 1000 further comprises the step 1070 of texturing, which may occur prior to the step of curing the liquified polymer 1050. In some embodiments, the step 1070 of texturing may comprise adding additives and in addition or alternatively post-treating mechanically the cured polymer.

[0164] In addition, or alternatively, in some embodiments, the pattern may be obtained by post-processing the cured polymer in step 1080. In some embodiments, post-processing 1080 may comprise laser treatment. In this manner, in some embodiments, the second areas 45 may be provided by post-processing the sole structure 10.

[0165] It is noted that the above embodiments and/or examples may be combined with further embodiments as described herein and details of the embodiments and/or examples may also be omitted, as will be understood by the skilled artisan. The scope of protection is determined by the claims and is not limited by the embodiments and/or examples disclosed in the above figures.