U.S. patent application number 12/997108 was filed with the patent office on 2011-07-14 for sole unit for footwear.
Invention is credited to Marc Peikert.
Application Number | 20110167678 12/997108 |
Document ID | / |
Family ID | 40936684 |
Filed Date | 2011-07-14 |
United States Patent
Application |
20110167678 |
Kind Code |
A1 |
Peikert; Marc |
July 14, 2011 |
Sole Unit For Footwear
Abstract
A water-vapour-permeable and water-permeable sole unit (15) for
footwear (11), having at least one sole layer (25) with at least
one large aperture (27) extending through the thickness thereof and
at least two sheet-like formations arranged one on top of the
other, which seal the at least one aperture and of which a first
sheet-like formation has a textile water-vapour-permeable barrier
layer (39) and a second sheet-like formation has a
water-vapour-permeable decorative layer (45), which is arranged
under the first sheet-like formation, at least in the region of the
at least one aperture, and is visible from the underside of the
sole layer (25) in the at least one aperture. A decorative layer
(45) according to the invention allows the achievement of aesthetic
and visual design possibilities for the appearance of the underside
or the sole unit (15) that would either be prevented by the
material of the fibrous layer (39) or could only be accomplished
with the fibrous layer (39) with some difficulty.
Inventors: |
Peikert; Marc; (Bad Tolz,
DE) |
Family ID: |
40936684 |
Appl. No.: |
12/997108 |
Filed: |
June 19, 2009 |
PCT Filed: |
June 19, 2009 |
PCT NO: |
PCT/EP2009/004442 |
371 Date: |
February 10, 2011 |
Current U.S.
Class: |
36/3R ;
36/30R |
Current CPC
Class: |
A43B 7/08 20130101; A43B
13/12 20130101; A43B 1/0027 20130101; A43B 7/125 20130101 |
Class at
Publication: |
36/3.R ;
36/30.R |
International
Class: |
A43B 7/06 20060101
A43B007/06; A43B 13/14 20060101 A43B013/14 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 20, 2008 |
DE |
10 2008 029 296.6 |
Claims
1. Water vapor permeable and water permeable sole unit for footwear
having: at least one sole layer with at least one large through
hole extending through the sole layer thickness; at least two one-
or multi-piece sheet structures arranged one above the other which
close the at least one through hole, wherein a first sheet
structure has a textile water vapor permeable barrier layer and a
second sheet structure has a water vapor permeable decor layer,
which is arranged beneath the first sheet structure at least in the
area of at least one through hole and is visible from the bottom of
the sole layer in the at least one through hole.
2. Sole unit according to claim 1, wherein the decor layer
comprises a material that is dyed or has at least one dye.
3. Sole unit according to claim 1, wherein the decor layer
comprises a substrate and a coating covering the surface of the
substrate, wherein the coating is made of a material which is dyed
or has at least one dye.
4. Sole unit according to claim 1, wherein the decor layer is
bonded to the barrier layer only in the edge areas in such a way
that especially during walking movement a movement of the decor
layer relative to barrier layer is made possible.
5. Sole unit according to claim 1, wherein the decor layer is
constructed with dirt-repellant material.
6. Sole unit according to claim 1, wherein the material of the
decor layer is chosen from the material group of grid-like,
net-like, porous or perforated sheet material.
7. Sole unit according to at least one of the preceding claims,
wherein the material of the decor layer is chosen from the material
group metal, plastic, textile, leather or a combination
thereof.
8. Sole unit according to claim 7, wherein the decor layer is
constructed with monofilament fibers.
9. Sole unit according to claim 7, wherein the decor layer is
constructed with yarn, which is encased with silicone or with
essentially colorless silicone-like material in such a way that
net- or grid-like openings in this decor layer remain open and
water vapor permeability is therefore retained.
10. Sole unit according to claim 7, wherein the decor layer is
constructed with yarn, which is impregnated with silicone or
essentially colorless silicon-like material in such a way that
capillary areas occurring in the yarn in which soiling substances
might otherwise penetrate are closed.
11. Sole unit according to claim 7, wherein the decor layer is made
entirely of metal.
12. Sole unit according to claim 1, wherein the decor layer is
constructed with a metalized plastic grid.
13. Sole unit according to claim 1, wherein the large area through
hole is at least partially spanned by a stabilization
connector.
14. Sole unit according to claim 13, wherein the decor layer is
bonded to the barrier layer only in peripheral edge areas and/or in
edge areas formed with the at least one stabilization
connector.
15. Sole unit according to claim 1, wherein the barrier layer is
formed as protection against penetration of foreign objects
penetrating through the large area through hole to above the first
sheet structure of the components of the sole unit.
16. Sole unit according to claim 16, wherein the barrier layer is
embodied as puncture-proof for protection from puncturing foreign
objects, like nails.
17. Sole unit according to claim 1, wherein the barrier layer is
constructed with the material that stabilizes the shoe sole
composite.
18. Sole unit according to claim 1, wherein: the barrier layer
comprises at least two fibrous components which differ with regard
to their melting temperatures; at least one portion of a first
fibrous component has a first melting temperature and a lower first
softening temperature range and at least one portion of a second
fibrous component has a second melting temperature and a lower
second softening temperature range and the first melting
temperature and the first softening temperature range are higher
than the second melting temperature and the second softening
temperature range; and the barrier layer is thermally mechanically
consolidated, as a consequence of thermal activation of the second
fibrous component with a tackifying temperature in the second
softening temperature range while maintaining water vapor
permeability in the thermally consolidated range.
19. Sole unit according to claim 18, wherein the second softening
temperature range of the second fibrous component lies below the
temperature necessary for the dyeing of the second fibrous
component.
20. Sole unit according to claim 1, wherein the barrier layer has a
water vapor permeability in the range from 3,000 g/m.sup.224 h to
20,000 g/m.sup.224 h, especially in the range from 8,000
g/m.sup.224 h to 15,000 g/m.sup.224 h, and especially 12,588
g/m.sup.224 h.
21. Sole unit according to claim 1, wherein the decor layer has a
water vapor permeability in the range from 10,000 g/m.sup.224 h to
50,000 g/m.sup.224 h, especially in the range from 20,000
g/m.sup.224 h to 30,000 g/m.sup.224 h, and especially 26,000
g/m.sup.224 h.
22. Sole unit according to claim 1, which has a water vapor
permeability in the range from 1,000 g/m.sup.224 h to 20,000
g/m.sup.224 h, especially in the range from 6,000 g/m.sup.224 h to
12,000 g/m.sup.224 h, and especially 9,337 g/m.sup.224 h.
23. Sole unit according to claim 1, wherein the sole layer is made
up of an injectable material.
24. Sole unit according to claim 23, wherein the sole layer is
injected onto the barrier layer and the decor layer in such a way
that the barrier layer and the decor layer are connected via the
sole layer material with the sole layer.
25. Sole unit according to claim 23, wherein the barrier layer and
the decor layer are connected to each other by means of sole layer
material.
26. Sole unit according to claim 23, wherein the barrier layer and
the decor layer are penetrated by sole layer material.
27. Sole unit according to claim 1, wherein the sole layer is an
outsole of the sole unit.
28. Sole unit according to claim 1, wherein the sole layer is a
midsole of the sole unit.
29. Sole unit according to claim 1, wherein the barrier layer and
the decor layer are connected to a unit that is usable as an
insert.
30. Footwear with a sole unit according to at claim 1 and
comprising a shaft provided on a sole sided shaft end region with a
waterproof and water vapor permeable shaft bottom functional layer,
wherein the sole unit is bonded to the shaft end region such that
the shaft bottom functional layer is unbonded to the barrier layer
at least in the region of the at least one through hole.
Description
[0001] For quite some time, footwear has been available with a
waterproof and water vapor permeable shaft, which allows such
footwear to release sweat moisture in the shaft area despite its
waterproofness. In order for sweat moisture to also escape into the
sole area, a switch was made to a sole structure having an outsole
with through holes extending through its thickness and also a
waterproof and water vapor permeable sole functional layer, for
example, in the form of a membrane. One example is shown in EP 0
382 904 A2, whose outsole has through holes in the form of
microperforations with a corresponding limitation of water vapor
permeability.
[0002] In order to provide greater water vapor permeability with
respect to the strong sweating tendency of the human foot, a switch
has been made to providing the outsole with large through holes in
comparison with microperforations. One example is shown in EP 0 275
644 A2 from whose teaching it is known to make the through holes as
large as possible in order to achieve particularly high water vapor
permeability.
[0003] The larger the through holes of the outsole, the greater the
hazard that a waterproof membrane situated above the through holes
of the outsole will be damaged by foreign objects, such as pebbles,
that penetrate the through holes, and therefore that its
waterproofness will be compromised. EP 0 275 644 A2 therefore
proposes that a protective layer, for example, made of a latticed
or felt material, be arranged between the outsole with its through
holes and the membrane situated above it, which protective layer
keeps foreign objects that penetrate the through holes of the
outsole from reaching the membrane.
[0004] Additional examples having large through holes of the
outsole, in which the through holes are closed by means of a
membrane against the penetration of water to the shoe interior and
in which a protective layer is situated beneath the membrane and is
intended to prevent the penetration of foreign objects to the
membrane are known from WO 2004/028284 A1, WO 2006/010578 A1, WO
2007/147421 A1 and WO 2008/003375 A1. In all these cases, a textile
backing in the form of a fine mesh is laminated onto one side of
the membrane, usually a film. A mesh-like protective layer arranged
between the membrane and through holes of the outsole offers a
certain degree of protection against the penetration of foreign
objects to the membrane. To improve protection for the membrane an
additional protective layer, which is a felt layer, for example, is
arranged between the membrane and the mesh-like protective layer.
Double protection for the membrane is therefore created in which
two superimposed layers participate, each of which has its own
technical protective function.
[0005] The material choice for these layers and their thickness and
perforation strength values must be adapted to the requirements of
the corresponding practical variant. This applies to the known
solutions and to the solutions presented with the present
invention.
[0006] Another example of very large sole openings is shown in WO
2007/101624 A1, according to which the large through holes of the
outsole are stabilized by stabilization connectors and/or
stabilization lattices. These carry water vapor permeable textile
material, for example, a felt-like material, fit into the through
holes. The shoe sole composite constructed in this way is connected
to a shaft whose shaft bottom is closed with a waterproof and water
vapor permeable shaft bottom functional layer so that the entire
shoe is waterproof and water vapor permeable.
[0007] A fibrous layer having at least two fibrous components that
differ in terms of their melting temperatures is particularly well
suited for the textile material, wherein at least a portion of a
first fibrous component has a first melting temperature and a lower
first softening temperature range, and at least a portion of a
second fibrous component has a second melting temperature and a
lower second softening temperature range, and the first melting
temperature and first softening temperature range are higher than
the second melting temperature and the second softening temperature
range, and wherein the fibrous layer is mechanically consolidated
as a result of thermal activation of the second fibrous component
with a tackifying temperature in the second softening temperature
range, while maintaining water vapor permeability in the thermally
consolidated area. In this case either the through hole or
optionally several through holes of the outsole can be closed with
individual pieces of the textile material or all through holes of
the outsole are closed with a single piece of textile material.
[0008] The textile material in this known footwear has two
functions. In the first place it serves for stabilization of the
sole structure, especially with respect to the fact that an outsole
with large openings cannot adequately contribute itself to
stabilization of the sole structure. The textile material is formed
with a relatively high intrinsic stability, which favors the
overall stability of the sole structure. In the second place, in
the finished footwear according to WO 2007/101624 A1, for example,
a waterproof, water vapor permeable membrane is situated above the
sole structure, and is protected by the textile material from
damage by foreign objects, such as pebbles, that could damage the
membrane.
[0009] Polymers chosen, for example, from PES (polyester),
polypropylene, PA (polyamide) and mixtures of polymers are
especially well suited for the textile material.
[0010] In one variant according to the already mentioned WO
2007/101624 A1 the textile material consists of a fibrous composite
in the form of a nonwoven fabric mechanically consolidated
thermally and additionally surface-consolidated by thermal surface
treatment, with two fibrous components, each of which is
constructed with polyester fibers. The first fibrous component
with
the higher melting temperature then forms a support component of
the fibrous composite, and the second fibrous component with the
lower melting temperature forms a consolidating component. In order
to guarantee temperature stability of the entire fibrous composite
of at least 180.degree. C., especially in view of the fact that
footwear can be exposed to relatively high temperatures during
production, for example, during molding-on of an outsole, in the
considered variant, polyester fibers having a melting temperature
above 180.degree. C. are used for both fibrous components. There
are different variations of polyester polymers that have different
melting temperatures and softening temperatures lying
correspondingly below them. In the considered variant of the
felt-like material, a polyester polymer having a melting
temperature of about 230.degree. C. is chosen for the first
component, whereas for the second fibrous component a polyester
polymer having a melting temperature of about 200.degree. C. is
chosen. The second fibrous component can be a core-shell fiber, the
core of this fiber consisting of a polyester with a softening
temperature of about 230.degree. C. and the shell of this fiber
consisting of a polyester with a tackifying temperature of about
200.degree. C. Such a fibrous component with two fibrous fractions
of different melting temperatures is also referred to as "Bico".
Additional information concerning such textile materials in which a
felt-like material can be involved can be found in the already
mentioned WO 2007/101624 A1.
[0011] The thermally mechanically consolidated textile material
which is particularly well suited for the two aforementioned
purposes, namely stabilization and membrane protection, has the
disadvantage that its fibrous component with the lower melting
temperature, which serves as the consolidating component, cannot be
satisfactorily dyed, or can be only insufficiently dyed, and
therefore remains white in the fibrous composite, which gives the
textile material overall an unsatisfactory appearance. This becomes
noticeable as a drawback because the textile material is visible
through the large through holes of the outsole. The increasing
demand to configure the entire footwear and therefore also its sole
bottom fashionably by also giving the bottom of
the sole structure a fashionable appearance, especially by
appropriate and varied dyeing, can therefore not be satisfied with
this textile material.
[0012] It is also known to close large openings in a sole with
other materials, for example, with felt-like material consisting at
least partially of aramid fibers like KEVLAR. However, aramid
fibers also are not able to be dyed, or can be dyed only very
poorly, so that the already mentioned problems occur in this case
too.
[0013] For example, it is known from the already mentioned WO
2006/010578 A1 to close large sole openings with a mesh made of
nylon, for example. A membrane, which can be connected on the mesh
side with a protective layer of felt material, is situated above
this mesh. A mesh consists of a mesh structure, in which from
external contact, especially during walking with the
correspondingly designed shoe, meshes can be released from the
structure which then hang down within the sole opening. Loose
meshes and/or hanging fibers are not visually desirable and under
some circumstances can reduce the safety of the shoe.
[0014] It is also conceivable for a textile fabric or knit to be
used instead of a felt-like material, which also has the problem of
non-dyeability because of the fibers that are used, and here again
individual fibers can become separated from the fabric
composite.
[0015] In the cited cases, either the non-dyeability of the fibers
that are used, or smaller damage to the fibrous structure can lead
to an unsatisfactory appearance of the material that is used and
therefore the shoe that is equipped with it.
[0016] A sole unit for footwear is created with the present
invention, which permits a satisfactory and largely arbitrary
fashionable configuration of the bottom of the sole structure with
respect to
dyeing and patterning, as well as material choice, without
seriously compromising the water vapor permeability of the sole
unit or its barrier or protective function.
[0017] This is achieved with a sole unit according to the invention
as specified in Claim 1, with which footwear according to invention
can be produced according to Claim 25. Variants of the invention
are specified in the dependent claims.
[0018] A sole unit for footwear according to the invention is water
vapor permeable and water-permeable, and has at least one sole
layer with at least one large-surface through hole extending
through its thickness. It also has at least two superimposed sheet
structures that close the at least one through hole, a first sheet
structure of which has a textile water vapor permeable barrier
layer and a second sheet structure of which has a water vapor
permeable decor layer, which is arranged beneath the first sheet
structure at least in the area of the at least one through hole and
is visible from the bottom of the sole layer in the at least one
through hole.
[0019] In one variant of the invention the barrier layer is
constructed with a fibrous layer, which has at least two fibrous
components which differ with regard to their melting temperatures,
wherein at least one portion of a first fibrous component has a
first melting temperature and a lower first softening temperature
range and at least one portion of a second fibrous component has a
second melting temperature and a lower second softening temperature
range and the first melting temperature and the first softening
temperature range are higher than the second melting temperature
and the second softening temperature range. The fibrous layer is
mechanically consolidated thermally as a consequence of thermal
activation of the second fibrous component with a tackifying
temperature in the second softening temperature range while
maintaining water
vapor permeability in the area mechanically thermally consolidated
range.
[0020] There can be different reasons in footwear with a sole unit,
especially of the type just mentioned, for covering the material of
the sole unit visible from the bottom of the outsole through its
large area through holes, also called openings, at least partially
by means a decor layer according to the invention.
[0021] The use according to the invention of such a decor layer in
a sole unit having an aforementioned fibrous layer is based on the
finding that dyeing of the fibrous component with the lower melting
temperature, which serves as the consolidating component, requires
that this fibrous component be heated to a temperature above the
softening temperature of this fibrous component so that this
fibrous component cannot be dyed. This is different with the other
fibrous component that has the higher melting temperature. Its
melting temperature is higher than the temperature required for
dyeing. Dyeing is therefore possible only with respect to the
fibrous component having the higher melting temperature, but not
with respect to the fibrous component having the lower melting
temperature, so that white spots within the fibrous composite of
the textile material cannot be avoided, which leads to an
aesthetically unappealing appearance.
[0022] This problem is countered in a sole structure with such a
fibrous layer according to the invention in that the unsatisfactory
coloring of the textile material is tolerated and a decor layer is
positioned in front of this textile material, which is made of
material with appropriate color or dyeing, this material, for
example, being grid-like or net-like or consisting of a perforated
sheet or a textile material with high water vapor permeability,
which therefore scarcely compromises the water vapor permeability
of the sole unit by the decor layer. Therefore, with the solution
according to the invention, with essentially no adverse effect on
water vapor permeability, the less attractive appearance of the
textile fibrous layer can be concealed behind the decor layer,
which is not subject to the limitation with respect to color or
dyeing described above in conjunction with the textile material.
The decor layer can therefore be dyed and configured independently
and according to almost any fashion ideas, which is not possible
for the textile material of the aforementioned fibrous layer. One
can deliberately use materials for the decor layer that are readily
dyed and/or can be patterned or naturally have attractive colors
and/or patterns.
[0023] With the solution according to the invention a technical
requirement, namely a protective function, and an aesthetic
requirement, namely a visually attractive appearance, can be more
easily implemented and also made commercially more attractive in
that meeting these two requirements is no longer attempted with a
single layer, and the requirements are instead divided between two
different layers, each of which can be deliberately configured with
respect to its special requirement and function. On the one hand,
in the layer with the technical function, compromises no longer
need be made in order to achieve at least a half-way attractive
aesthetic impression. On the other hand, the layer with the
aesthetic function can be configured almost exclusively according
to this function, because it does not need to provide the technical
function of the other layer.
[0024] There are various commercial advantages of decoupling
according to the invention of the technical function, for example,
stabilization function, and the aesthetic function. The layer with
the technical function, for example, the stabilization layer, can
be produced in a standard color so that it can be used for all
shoes that are to be equipped with such a technically effective
layer, which is very cost effective. The layer with the aesthetic
function, namely the decor layer, can be chosen from a standard
assortment, which is also very cost effective.
[0025] Using a decor layer according to the invention can also be
advantageous for a case in which materials for both components of
the thermally consolidated fibrous layer are or should be available
that are not subject to the aforementioned limitation with respect
to color or dyeing. For
example, the thermally mechanically consolidated textile material
of the fibrous layer is higher in price than materials suitable for
the decor layer. There is a strong trend especially in the high
fashion market sector of leisure shoes to provide the same or
different shoe models with different colors and different patterns,
for example, in order to respond to different age groups with
different fashion configurations. If this requirement had to be met
with differently colored and patterned fibrous layers, each shoe
manufacturer would have to acquire and stock correspondingly
colored and/or patterned different fibrous layers. This would be a
drawback not only from a logistical standpoint both for the
manufacturer of the fibrous layers and for the shoe manufacturer,
but also with respect to higher purchasing costs for the shoe
manufacturer as a result of the relatively limited number of pieces
per color and/or pattern. Owing to the fact that, when the decor
layer is used, the appearance of the bottom of the sole unit is no
longer determined by the fibrous layer material but by the
appearance of the decor layer, the shoe manufacturer can order
uniform fibrous layer material and can concentrate on the decor
layer with respect to the visual and fashion appearance of the
bottom of the sole unit. The shoe manufacturer or, if the shoe
manufacturer itself does not produce the soles for his shoes, the
sole manufacturer can order material for this purpose in targeted
amounts and colors, as well as structures and material types, or
can himself configure the material with respect to dyeing and color
pattern, in which case he can order materials for the decor layers
desired by him from a larger number of suppliers, so that he can
turn to different material manufacturers both with respect to
pricing and also with respect to availability of different
materials. Regardless of whether or not the material of the fibrous
layer can be dyed according to the desired ideas, it can be worth
considering to visually configure the bottom of the sole unit with
respect to color and pattern with an additional decor layer,
especially for the aforementioned reasons of logistics,
versatility, and pricing.
[0026] If the material for the decor layer is to be dyed after its
production, for example, by spraying, screen printing or the like,
it need only be kept in mind that dyeing or patterning must be
performed in such a way that the meshes or other openings or pores
of the material of the decor layer remain open far enough that the
desired water vapor permeability is retained. Such color
configuration with such means and methods would not be possible in
a textile layer, especially a felt layer, which in known cases is
visible through the through holes of the outsole. On the one hand,
color patterns, especially of a finely structured type, cannot be
produced with sufficient resolution on the surfaces of textile
materials like felt. On the other hand, it can be avoided only with
difficulty that during the application of color by spraying or
screen printing the surfaces of such materials are significantly
clogged so that the desired water vapor permeability can no longer
be achieved. In addition, such techniques are relatively expensive.
Embossing of textile materials results in a non-uniform surface
height, which is again a drawback during molding on of the sole
material, since the flow of sole material into the textile layer
cannot be calculated.
[0027] A decor layer according to the invention is particularly
advantageous in a variant in which the fibrous layer has two
fibrous components and a material is used for the second fibrous
component in which the softening temperature range of the second
fibrous component is lower than the temperature required for dyeing
the second fibrous component. In this case the aesthetically less
attractive appearance of the fibrous layer with its white spots can
only be laminated with a decor layer according to the invention so
that the bottom of the sole unit can be configured as visually
attractive.
[0028] Especially for the case in which shoes with a sole unit
provided with a decor layer according to the invention are directed
toward younger consumers, a "metal look" achieved with the decor
layer can be attractive. Consequently, in one variant of the
invention the decor layer consists of material that offers the
appearance of metal. In a first variant of the invention prescribed
for this purpose the material of the decor layer consists
exclusively of metal, for example, a metal grid or
metal net. In a second variant of the invention proposed for this
purpose the material of the decor layer consists of a metalized
plastic grid or is constructed with metalized fibers that are
brought to a yarn structure or in the form of a yarn net.
[0029] Material examples for a purely metallic decor layer are
iron, aluminum and steel. Material examples for a decor layer of
metalized plastic are woven, knit and warp knit fabrics with a
sheathing of tin, silver, copper, nickel or other alloys, for
example, POLYMET.RTM. from Platingtech Beschichtung GmbH & Co.
KG, Niklasdorf, Austria, The material becomes tear resistant, wear
resistant and corrosion resistant. Material examples for a decor
layer of non-metalized plastic include polyester, polypropylene,
polyurethane, polymers, polyamide, for example, polyamide mesh
silver from Panatex, 25030 Zocco d'Erbusco, Italy.
[0030] However, materials made water vapor permeable by machining,
for example, perforation, or also perforated sheet material, for
example, made of polyamide, polyurethane, etc. or naturally water
vapor permeable sheet material, for example, plastic, textile,
leather, metal, glass fibers or a combination thereof, are also
suitable as material for the decor layer.
[0031] One can also combine the aforementioned material examples
for the decor layer with each other or with additional materials in
order to achieve desired color and pattern effects.
[0032] In one variant of the invention the decor layer has a
substrate and a coating covering the surface of the substrate, the
coating being constructed with a material that is dyed or has at
least one dye. In this way different material requirements for a
decor layer can be combined, for example, a substrate with desired
mechanical properties and desired water vapor permeability can be
combined with a coating that can be dyed and patterned exclusively
according to aesthetic
viewpoints, because it need not contribute to the desired or
required mechanical properties and the desired water vapor
permeability of the decor layer.
[0033] In one variant of the invention the decor layer is
constructed with dirt repellant material.
[0034] For the case in which the decor layer is constructed with
net-like, grid-like or mesh-like material, for example, textile
material, the decor layer can be constructed either with
monofilament fibers or with multifilament yarns.
[0035] Multifilament yarns are composed of several fibers, between
which capillary areas exist. Soiling substances, such as dirt,
contaminated liquids, such as dirty water, or contaminating
liquids, such as oils, can penetrate into said yarns, and can
scarcely be removed again from the yarn so that the yarn and the
decor layer constructed with it appear permanently and irreversibly
soiled or can at least be visually compromised.
[0036] In one variant of the invention this is prevented by the
fact that the decor layer is constructed with monofilament fibers
that naturally have no capillary channels. In a particularly
preferred variant of this type a fibrous material that is
nonabsorbent, for example, a plastic material, is used for the
monofilament fibers.
[0037] In one variant of the invention in which the decor layer is
constructed with yarn, i.e., with a multifilament structure, the
incorporation of soiling substances is prevented by encasing the
yarn in plastic, such as silicone or essentially colorless
silicone-like material, so that net or grid-like openings in this
decor layer remain open and water vapor permeability is therefore
retained. By this sheathing of the yarn such soiling substances
cannot penetrate between the fibers forming the yarn. A soiling of
the decor layer that can hardly be eliminated and therefore is
permanent is
thereby prevented. On the other hand, the color of the yarn and
therefore of the decor layer remains visible by sheathing with such
essentially colorless materials.
[0038] In another variant the capillary areas of the multifilament
yarn are at least partially filled or impregnated with a plastic.
The penetration of dirt into the capillary areas is thereby
suppressed and a permanent soiling of the decor layer is
prevented.
[0039] In one variant of the invention the decor layer is connected
to the barrier layer only in edge areas such that, especially
during walking movements, a relative movement of the decor layer is
made possible relative to the barrier layer. This means that
everywhere the decor layer is situated above a large area through
hole in the underlying sole layer, especially the outsole (and is
visible through this large-surface through hole), the decor layer
is not joined to the barrier layer, which makes relative movement
of the decor layer possible relative to the barrier layer at least
in the areas of this large area through hole. Soiling substances,
like especially dry sludge or the like, which has become fixed in
the grid or net openings, can be loosened or released by this
relative movement of the decor layer so that it can fall off and a
clean decor layer remains. This dirt-loosening relative movement
can also be produced by the sole structure of the footwear, which
has been removed from the foot, being bent by hand, for example,
when the dirt is so firmly attached that it is not adequately
loosened from the decor layer by walking movements.
[0040] In one variant of the invention the decor layer is connected
to the barrier layer only in peripheral edge areas. For a case in
which the barrier layer is assigned one or more stabilization
connectors, the decor layer can also or additionally be connected
to the barrier layer in the area of the stabilization connector or
connectors. It is important only that the decor layer remain
unconnected from the barrier layer where the at least one through
hole of the sole layer, for example, the outsole, is situated, so
that the dirt loosening relative movement of the decor layer
relative to the barrier layer is possible there.
[0041] In one variant of the invention the two expedients just
disclosed for keeping the decor layer clean are combined. In this
variant, on the one hand, the decor layer is connected to the
barrier layer only in the edge areas so that the mentioned relative
movement is made possible, which promotes the loosening and falling
off of dirt that has adhered in the openings of the decor layer. On
the other hand, in this variant the decor layer is constructed
either with monofilament material or with yarn encased by or
impregnated with silicone or silicone-like material, so that
soiling substances cannot penetrate the yarn and the yarn remains
clean and in its original color appearance. In this variant dirt
can penetrate into the openings of the net-like or grid-like decor
layer, where it is loosened again and can fall out as a result of
the outlined relative movement between the decor layer and barrier
layer, so that the decor layer becomes clean again and has its
original visual appearance.
[0042] The loosening of dirt from the openings of the decor layer
is particularly effective and thorough in a variant in which, in
addition to the expedients just explained, a barrier layer is used
that is relatively smooth at least on its side facing the decor
layer and has a closed surface, for example, because it consists of
a fibrous material that can be smoothed and superficially closed by
means of a thermal surface treatment. When such a barrier layer is
used, dirt settles only in the openings of the decor layer because
it does not adhere to the smooth, closed surface of the barrier
layer. In this variant, which is constructed by a combination of a
barrier layer with a smooth surface and a decor layer, which is
connected, on the one hand, only in edge to the barrier layer and,
on the other hand, is constructed with monofilament material or
yarn impregnated with or encased by silicone or similar material, a
particularly effective and thorough keeping clean of the decor
layer are achieved, and therefore a maintenance of an unimpaired
visual appearance of the decor layer and therefore the bottom of
the shoe structure of the footwear, are achieved.
[0043] In one variant of the invention the decor layer is
constructed with leather, which is finished so as to be water-,
oil- and dirt-repellant in order to counteract a penetration of
soiling substances into the leather structure and therefore an
impairment of the visual appearance of this decor layer.
Fluorocarbons, especially in the form of fluorocarbon resins,
silicone-containing agents, and the
like, for example, are suitable as finishing material for this
purpose. In this variant the leather serving as the decor layer is
also preferably joined to the barrier layer only in its edge areas
in order to permit the relative movement between the decor layer
and barrier layer just explained and therefore to promote the
falling out of dried dirt from the decor layer.
[0044] In variants of the invention, the decor layer can have a
water vapor permeability in the range of 10,000 g/m.sup.224 h to
50,000 g/m.sup.224 h, especially in the range of 20,000 g/m.sup.224
h to 30,000 g/m.sup.224 h. In one variant of the invention, the
decor layer has a water vapor permeability of 26,000 g/m.sup.224 h.
In variants of the invention, the stabilization layer, here also
called the barrier layer or fibrous layer (textile material), has a
water vapor permeability in the range of 3,000 g/m.sup.224 h to
20,000 g/m.sup.224 h, especially in the range of 8,000 g/m.sup.224
h to 15,000 g/m.sup.224 h. In one variant of the invention, the
stabilization layer has a water vapor permeability of 12,588
g/m.sup.224 h. With such values for water vapor permeability for
the decor layer and the stabilization layer, a water vapor
permeability desired for the entire sole unit can be achieved.
[0045] In variants of the invention, the entire sole unit can have
a water vapor permeability in the range of 1,000 g/m.sup.224 h to
20,000 g/m.sup.224 h, especially in the range from 6,000
g/m.sup.224 h to 12,000 g/m.sup.224 h. In one variant of the
invention the water vapor permeability in the entire sole unit is
9,337 g/m.sup.224 h.
[0046] In one variant of the invention the sole layer of the sole
unit to which the decor layer is assigned consists of an injectable
material, especially a plastic material. This permits another
variant of the invention, in which the sole layer is molded onto
the fibrous layer and the decor layer in such a way that the
fibrous layer and decor layer are joined to the sole layer via sole
layer material. In one variant the fibrous layer and decor layer
can be joined to each other by means of sole layer material.
[0047] In one variant the fibrous layer and decor layer can be
penetrated by sole layer material. These variants permit a
particularly advantageous connection of the sole layer, fibrous
layer and decor layer because it is inexpensive and technically
less demanding.
[0048] In one variant of the invention the sole layer forms an
outsole. In another variant of the invention the sole layer forms a
midsole of the sole unit.
[0049] In one variant of the invention the fibrous layer and decor
layer form an insert. This leads to the possibility that sole
structures of the same type, which have the same outsole or midsole
and/or other identical components, for example, can make available
a relatively large number of sole units according to the invention
in a rational and therefore cost-effective fashion from a
logistically advantageous standpoint by their combination with
differently configured inserts, which differ from each other
especially with respect to their decor layer.
[0050] The invention also creates footwear with a sole unit
provided with a decor layer according to the invention and having a
shaft which is provided on a sole sided shaft end region with a
waterproof and water vapor permeable shaft bottom functional layer,
wherein the sole unit provided with the shaft bottom functional
layer is bonded to the shaft end region such that the shaft bottom
functional layer is unbonded to the fibrous layer at least in the
region of the at least one through hole. The latter provides
particularly high water vapor permeability, because no glue is
present between the fibrous layer and shaft bottom functional layer
in the area of the through hole(s), which would lead to a reduction
in water vapor permeability.
[0051] In one variant of the invention the footwear, in addition to
the shaft bottom functional layer, has a shaft functional layer
extending over a significant area of the shaft outer material,
which is
bonded waterproof to the shaft bottom functional layer or is bonded
to it to form a sock-like insert (also called a bootie).
[0052] Such footwear (except for the foot insertion opening), on
the one hand, is waterproof all the way around but is still water
vapor permeable, and on the other hand can be configured in largely
any way with respect to the appearance of the sole bottom of the
footwear, which is particularly important in fashion shoes for
aesthetic reasons or because the shoe manufacturer desires a
special visual configuration of the sole bottom pointing toward
him.
Definitions and Test Methods
Footwear:
[0053] Foot covering with a closed upper part (shaft arrangement)
which has a foot insertion opening and at least one sole or one
sole unit.
Shaft outer material:
[0054] A material which forms the outside of the shaft and
therefore the shaft arrangement and consists, for example, of
leather, textile, plastic, or other known materials and
combinations thereof, or is constructed with them and generally
consists of a water vapor permeable material. The lower end of the
shaft outer material on the sole side forms an area adjacent to the
upper edge of the sole or sole unit and above a boundary plane
between the shaft and sole or sole unit.
Inlay sole (insole):
[0055] An inlay sole is part of the shaft bottom. A lower shaft end
area on the sole side is fastened to the inlay sole.
Sole:
[0056] A shoe has at least one outsole, but can also have several
types of sole layers arranged one above the other and forming a
sole unit.
Outsole:
[0057] Outsole is understood to mean that part of the sole area
that touches the floor/ground or produces the main contact with the
floor/ground. The outsole has at least one tread surface that
touches the floor.
Midsole:
[0058] In a case in which the outsole is not directly applied to
the shaft arrangement, a midsole can be inserted between the
outsole and the shaft arrangement. The midsole can serve, for
example, for cushioning, damping or as filler material,
Bootie:
[0059] A sock-like inner lining of a shaft arrangement is referred
to as a bootie. A bootie forms a sack-like lining of the shaft
arrangement which essentially completely covers the interior of the
footwear.
Functional layer:
[0060] Waterproof and/or water vapor permeable layer, for example,
in the form of a membrane or a correspondingly treated or finished
material, for example, a textile with plasma treatment. The
functional layer can form at least one layer of a shaft bottom of
the shaft arrangement in the form of a shaft bottom functional
layer, but can also be provided as a shaft functional layer that at
least partially lines the shaft. Both the shaft functional layer
and the shaft bottom functional layer can be part of a multilayer,
generally two-, three- or four-layer membrane laminate. The shaft
functional layer and the shaft bottom functional layer can each be
part of a functional layer bootie. If, instead of a functional
layer bootie, a shaft functional layer and a separate shaft
bottom
functional layer are used, these are sealed, for example, in the
sole sided lower region of the shaft arrangement relative to each
other in a waterproof seal. Shaft bottom functional layer and shaft
functional layer can be formed from different materials or the same
material.
[0061] Appropriate materials for the waterproof, water vapor
permeable functional layer include especially polyurethane,
polypropylene and polyester, including polyether esters and their
laminates, as described in documents U.S. Pat. No. 4,725,418 and
U.S. Pat. No. 4,493,870. In one variant the functional layer is
constructed with microporous expanded polytetrafluoroethylene
(ePTFE), as described, for example, in documents U.S. Pat. No.
3,953,566 and U.S. Pat. No. 4,187,390. In one variant the
functional layer is constructed with expanded
polytetrafluoroethylene provided with hydrophilic impregnation
agents and/or hydrophilic layers; see, for example, document U.S.
Pat. No. 4,194,041. A microporous functional layer is understood to
mean a functional layer whose average pore size is between about
0.2 .mu.m and about 0.3 .mu.m.
Laminate:
[0062] Laminate is a composite consisting of several layers that
are permanently bonded to each other, generally by mutual gluing.
In a functional layer laminate, a waterproof, water vapor permeable
functional layer is provided with at least one textile layer. The
at least one textile layer, also called backing, primarily serves
for protection of the functional layer during its processing. One
speaks here of a two-layer laminate. A three-layer laminate
consists of a waterproof, water vapor permeable functional layer
embedded in two textile layers. The functional layer and the at
least one textile layer are bonded to one another by means of a
continuous water vapor permeable glue layer or by means of a
discontinuous glue layer of non-water vapor permeable glue. In one
variant, glue in the form of a spot-like pattern can be applied
between the functional layer and the one or two textile layers. The
spot-like or discontinuous application of glue occurs because a
full surface layer of a glue that is not water vapor permeable
itself would block the water vapor permeability of the functional
layer. Barrier layer:
[0063] A barrier layer serves as a barrier against penetration of
substances, especially in the form of particles or foreign objects,
for example, pebbles, to a material layer to be protected,
especially to a mechanically sensitive functional layer or
functional layer membrane.
Decor layer:
[0064] A decor layer is a material layer provided for aesthetic
reasons whose function includes covering the appearance of a
material layer that is visible without the decor layer but is
covered by the decor layer and is provided especially for its
technical function, especially if the material layer has an
unsatisfactory or undesired aesthetic appearance.
Porous:
[0065] Within the context of a decor layer according to the
invention, porous means that the material of the decor layer is
naturally water permeable and water vapor permeable or permeable as
a result of processing.
Puncture resistant:
[0066] The puncture resistance of a textile fabric can be measured
with a measurement method used by the EMPA (Federal Material
Testing and Research Institute) using a test instrument of the
Instron tensile testing machine (model 4465). By means of a punch,
a round textile piece 13 cm in diameter is punched out and fastened
to a support plate in which 17 holes are situated. A punch to which
17 pin-like needles (sewing needle type 110/18) are fastened is
brought down with a speed of 1,000 mm/min far enough that the
needles pass through the textile piece into the holes of the
support plate. The force for puncturing the textile piece is
measured by means of a
measurement probe (a force sensor). The result is determined from a
sample number of three samples.
[0067] The puncture resistance of a material layer like the barrier
layer or stabilization layer is tested by means of the test method
TM 37 SATRA of SATRA Technology Centre, Wyndham Way, Kettering,
Northamptonshire, NN16 8SD, United Kingdom.
REFERENCE DOCUMENT
[0068] European Standard EN 344-1, especially section 4.3.3
(penetration resistance).
Test Description:
[0069] The force required to drive a hardened steel nail with a
sharp tip through a boot or shoe bottom is determined.
Test Device-Parameters:
[0070] Tear testing device from Instron Deutschland GmbH,
Werner-von-Siemens-Strasse 2, 64319 Pfungstadt;
[0071] A steel nail provided with a sharp tip with a diameter of
4.5 mm and a tip angle of 30.degree. serves as anvil;
the advance speed is 10.+-.3 mm/min; Test locations: The test TM 37
SATRA prescribes for the puncture resistance test of a sole four
test sites distributed over the sole having a spacing at least 20
mm from each other (ball of the foot inside, ball of the foot
outside, instep area, heel). Since the puncture resistance of the
barrier layer is at issue in conjunction with the present
invention, which, however, is directly threatened with penetration
by pointed objects only in the area of the large-surface through
hole provided for high water vapor permeability of the sole layer
equipped with it, for those variants of the invention in which no
such through holes are prescribed in the heel area, the test
location in the heel area is left out during use of the test TM 37
SATRA.
Definition of Puncture Resistance:
[0072] Within the context of the present invention, puncture
resistant means that the tested material, especially the shoe
stabilization material or barrier material according to the
invention, withstands a force of at least 40 Newton in the puncture
test TM 37 SATRA.
Thickness:
[0073] The thickness of the shoe stabilization material according
to the invention is tested according to DIN ISO 5084 (10/1996).
Waterproof:
[0074] A functional layer/functional layer laminate/membrane is
considered waterproof, optionally including seams provided on the
functional layer/functional layer laminate/membrane, if it
guarantees a water entry pressure of at least 1.times.10.sup.4 Pa.
The functional layer material preferably guarantees a water entry
pressure of more than 1.times.10.sup.5 Pa. The water entry pressure
is to be measured according to a test method in which distilled
water at 20.+-.2.degree. C. is applied to a sample of 100 cm.sup.2
of the functional layer with increasing pressure. The pressure
increase of the water is 60.+-.3 cm H.sub.2O per minute. The water
entry pressure then corresponds to the pressure at which water
first appears on the other side of the sample. Details of the
procedure are stipulated in ISO Standard 0811 from 1981.
[0075] Whether a shoe is waterproof can be tested, for example,
with a centrifuge arrangement of the type described in US-A-5 329
807.
Water Vapor Permeable:
[0076] A functional layer/functional layer laminate is considered
water vapor permeable if it has a water vapor permeability number
Ret of less than 150 m.sup.2.times.Pa.times.W.sup.-1. Water vapor
permeability is tested according to the Hohenstein skin model. This
test method is described in DIN EN 31092 (02/94) or ISO 11092
(1993).
[0077] The water vapor permeability values of the barrier
layer/fibrous layer/stabilization layer/decor layer according to
the invention are tested by means of the so-called cup method
according to DIN EN ISO 15496 (09/2004) [A3].
[0078] The gauge of water vapor permeability of the sole unit [A4]
can be determined with the measurement method specified in document
EP 0 396 716 B1, which was conceived for measurement of the water
vapor permeability of an entire shoe. For measuring the water vapor
permeability of only the sole unit of a shoe, the measurement
method according to EP 0 396 716 B1 can also be used by measuring
with the measurement layout depicted in FIG. 1 of EP 0 396 716 B1
in two consecutive measurement scenarios, namely once of the shoe
with a water vapor permeable sole unit and another time of the
otherwise identical shoe with a water vapor impermeable sole unit.
The percentage of water vapor permeability that is attributed to
the water vapor permeability of the water vapor permeable sole unit
can then be determined from the difference between the two measured
values.
[0079] In each measurement scenario, using the measurement method
according to EP 0 396 716 B1, the following sequence is used:
[0080] 1. Conditioning the shoe by leaving it in a climatized room
(23.degree. C., 50% relative humidity) for at least 12 hours.
[0081] 2. Removal of the insert sole (foot bed). [0082] 3. Lining
the shoe with a waterproof, water vapor permeable lining material
adapted to the shoe interior, which material is waterproof and can
be closed, water vapor tight, in the area of the foot insertion
opening of the shoe with a waterproof, water vapor permeable
sealing plug (for example, made of Plexiglas and with an inflatable
sleeve). [0083] 4. Filling water into the lining material and
closure of the foot insertion opening of the shoe with the sealing
plug. [0084] 5. Preconditioning of the shoe filled with water by
leaving it at rest for a predetermined period of time (3 hours) in
which the temperature of the water is [0085] kept constant at
35.degree. C. The climate of the surrounding room is also kept
constant at 23.degree. C. and 50% relative humidity. The shoe is
blown against frontally during the test by a fan with an average of
at least 2 m/s to 3 m/s wind velocity (to destroy a resting air
layer forming around the standing shoe, which would cause
significant resistance to water vapor passage). [0086] 6.
Reweighing the shoe filled with water and sealed with a sealing
plug after preconditioning (gives the weight m2 (g)). [0087] 7.
Allowing it to stand again and an actual test phase of 3 hours
under the same conditions as in step e). [0088] 8. Reweighing the
sealed shoe filled with water (gives the weight m3 (g)) after the
test phase of 3 hours. [0089] 9. Determination of the water vapor
permeability of the shoe from the water vapor amount that has
escaped during the test time of 3 hours through the shoe (m2-m3)
(g) according to the relation M=(m2-m3) (g)/3 (h).
[0090] After both measurement scenarios have been conducted in
which the water vapor permeability values have been measured on the
one hand for the entire shoe with water vapor permeable sole unit
(value A) and on the other hand for the entire shoe with water
vapor impermeable shaft bottom structure (value B), the water vapor
permeability value for the water vapor permeable sole unit alone
can be determined from the difference A-B.
[0091] It is important during measurement of the water vapor
permeability of the shoe with the water vapor permeable sole unit
to avoid a situation in which the shoe or its sole stands directly
on a closed substrate. This can be achieved by raising the shoe or
by placing the shoe on a grate structure so that it is ensured that
the ventilation air flow can flow additionally or completely
beneath the outsole.
[0092] It is useful in each test layout for a certain shoe to
conduct repeat measurements and to consider average values from
them so as to better be able to estimate the measurement scatter.
At least two measurements should be conducted for each shoe with
the measurement layout. In all measurements a natural fluctuation
of the measurement results of .+-.0.2 g/h around the actual
value (for example, 1 g/h) should be assumed. For this example,
measured values between 0.8 g/h and 1.2 g/h could therefore be
obtained for the identical shoe. Influencing factors for these
fluctuations could be the person performing the test, for example,
or the quality of sealing on the upper shaft edge. By averaging
several individual measured values for the same shoe a more exact
picture of the actual value can be obtained.
[0093] All values for water vapor permeability of the sole unit are
based on a normally tied man's shoe of size 43 (French size) in
which this size statement is not standardized and shoes of
different manufacturers can come out differently.
[0094] The invention will now be further explained by means of
variants that represent merely nonrestrictive examples for
implementation of the invention. In the accompanying drawings:
[0095] FIG. 1 shows a perspective view of the variant of a shoe
with a shaft and a shoe sole composite with a sole unit designed
according to the invention;
[0096] FIG. 2 shows a perspective view of the shoe according to
FIG. 1 in which the shoe sole composite is still not bonded to the
shoe shaft;
[0097] FIG. 3 shows the shoe sole composite according to FIGS. 1
and 2 in a perspective plan view;
[0098] FIG. 4 shows a schematic cross-sectional view of the shoe
depicted in FIG. 1 in a variant with a glued on shoe sole composite
in the assembly stage according to FIG. 2, in which the shaft is
not completely shown; and
[0099] FIG. 5 shows a schematic cross-sectional view according to
FIG. 4, but for a variant of a shoe with a shoe sole composite
injected onto the shaft, in which the shaft is also not fully
shown.
[0100] When terms like top, bottom, right, left, etc. are used
here, this invariably refers only to the specific depiction in the
corresponding figure and does not apply absolutely.
[0101] FIGS. 1 and 2 show a perspective oblique view from the
bottom of an embodiment example of a shoe 11 according to the
invention with a shaft 13 and a sole unit 15 according to the
invention. The shoe 11 in FIG. 1 is shown in a state in which the
shaft 13 and the sole unit 15 are bonded to each other. FIG. 2
shows the shoe according to FIG. 1 in an assembly stage, before the
sole unit 15 is bonded to shaft 13.
[0102] The shoe 11 has a forefoot area 17, a midfoot area 19, a
heel area 21 and a foot insertion opening 23. The sole unit 15 has
a sole layer in the form of a support layer 25, which contributes
critically to the stabilization of the finished sole unit 15 and
which has large area through holes 27 in the forefoot area 17 and
midfoot area 19 (FIG. 2). As a result of its stabilization effect,
the support layer 25 here is also called the stabilization layer.
Large area in this context means that the individual through holes
27 have an area in the range of a few to several cm.sup.2, for
example, in the range from about 2 cm.sup.2 to about 30 cm.sup.2,
within this range, for example, from 10 cm.sup.2 to 20 cm.sup.2.
The through holes 27 are chosen as large as possible in order to
provide a sole unit 15 having the largest possible water vapor
permeability.
[0103] An outsole 29 assembled from several individual outsole
parts is situated beneath the support layer 25, namely an outsole
part 29a in the heel area, an outsole part 29b in the ball of the
foot area and an outsole part 29c in the toe area. These outsoles
parts are fastened to the bottom of the support layer 25. In the
ball of the foot area and in the toe area the outsole parts 29b and
29c have large area through holes 27 which are dimensioned such
that the through holes 27 of the support layer 25 remain completely
or essentially free of outsole material, so that the water vapor
permeability of the sole unit achieved by the through holes 27 of
the support layer 25 is not adversely affected.
[0104] In the depicted variant, a damping sole layer 31 is situated
above the support layer 25 and causes tread damping, thereby
improving the walking comfort of the shoe. The damping sole layer
31 has a damping sole part 4131a in the heel area and a damping
sole part 4131b in the forefoot area. The damping sole parts 4131a
and 4131b also have large area through holes which fully or at
least essentially leave open the through holes 27 of support layer
25 in order to avoid compromising or significantly compromising the
water vapor permeability achieved with the through holes 27 of the
support layer 25.
[0105] In one variant of the invention, the sole can also be made
in one part. This means that the damping layer and the outsole
layer are then combined to form a single sole layer, in which, with
respect to tread damping properties and walking properties, a
material selection that best allows for the two properties is
made.
[0106] Not only the damping sole layer 31 but also the parts of the
outsole 29 consist of an elastic material having a certain
softness, in order to achieve good walking comfort and to produce
an outsole with good tread properties. Because of this relatively
soft elastic material and because of its composition from
individual parts with large through holes, the outsole 29 cannot
sufficiently contribute to the stability of the entire sole unit
15. Even in variants with a one-part outsole,
because of the soft elastic material and the large through holes a
sufficiently satisfactory stability of the entire sole unit is not
achieved.
[0107] Because of its relatively soft material and its large area
through holes, on the one hand, and its composition of individual
parts, on the other, neither the parts of the outsole 29 nor the
parts of the damping sole layer 31 offer the stability desired for
a sole unit. For this reason the support layer 25 acting as a
stabilization layer is provided, which can be made from a
relatively stiff material because it need not allow for either
tread damping properties or outsole properties. In order to improve
the stabilization properties of the stabilization layer 25, which
can be adversely affected to a certain extent despite its
relatively stiff material because of the large area through holes
27, the individual through holes 27 of the support layer 25 are
spanned by stabilization connectors 33. The support layer 25
therefore acquires a degree of bending and warping rigidity, which
imparts the desired stabilization to the entire sole unit 15.
[0108] As shown in FIG. 2, the lower end of shaft 13 is closed with
a shaft bottom 35 before the sole unit 15 is bonded to shaft 13.
The shaft bottom 35 is provided with a shaft bottom functional
layer 37, as explained below in conjunction with FIGS. 4 and 5.
Said shaft bottom functional layer 37 has a membrane, for example,
which is at least waterproof and preferably also water vapor
permeable.
[0109] Whereas FIG. 2 shows the sole unit 15 in a perspective
oblique view from the bottom, the sole unit 15 is shown in FIG. 3
in a perspective oblique view from the top. As shown in FIG. 3,
several pieces 39a, 39b, 39c and 39d of a barrier layer formed as a
fibrous layer 39 are situated on the top of the support layer 25
that faces away from outsole 29 in its middle area 25b and its
forefoot area 25c. Through holes 27 and support layer 25 not
visible in FIG. 3 are covered with these fibrous layer pieces 39a,
39b and 39e, The tread damping layer parts 4131a and 4131b
arranged in the heel area and in the forefoot area of the sole unit
15 on the top of support layer 25 are also visible in FIG. 3. The
tread damping layer part 4131a in the heel area is essentially
full-surface in the depicted variant, whereas the tread damping
layer part 4131b in the forefoot area is provided with recesses in
places where the fibrous layer pieces 39b, 39c and 39d are
situated. The fibrous layer pieces 39a to 39d lie above the
stabilization connectors 33 that are not visible in FIG. 3. In the
variant depicted in FIG. 3 the support layer 25 has limitation
edges 43a, 43b and 43c, which enclose the corresponding through
holes 27 of support layer 25 and serve as receptacles for the
corresponding fibrous layer peaks.
[0110] Since the outsole parts of outsole 29, the support layer 25
and the tread damping layer parts 4131a and 4131b have different
functions within the shoe sole composite that forms the sole unit
15, they are expediently also constructed with different materials.
The outsole parts that have good abrasion resistance and are
supposed to offer tread safety, consist of thermoplastic
polyurethane (TPU) or rubber suitable as outsole material. The
tread damping layer parts 4131a and 4131b, which are supposed to
cause impact damping during walking movements for the user of the
shoe, consist of correspondingly elastically compliant material,
for example, ethylene-vinyl-acetate (EVA) or polyurethane (PU). The
stabilization layer 25, which serves as support for the unconnected
outsole parts 29a, 29b, 29c and for the also unconnected tread
damping layer parts 4131a and 4131b and as a stabilization element
for the entire sole unit 15 and which is supposed to have a
corresponding elastic rigidity, consists of at least one
thermoplastic, for example.
[0111] The fibrous layer pieces 39a, 39b and 39c and 39d, on the
one hand, serve as mechanical protection for the shaft bottom
functional layer 37 with which the shaft bottom 35 is provided.
Small particles like pebbles, for example, which penetrate the
through holes 27 of support layer 25 and reach the shaft bottom
functional layer 37 and could damage it are kept away from the
fibrous layer pieces to protect the shaft bottom functional layer
37. In one variant of the footwear
according to the invention the fibrous layer pieces 39a, 39b and
39c, 39c and 39d additionally have a stabilizing function. For this
purpose, the fibrous layer pieces 39a, 39b and 39c, 39c and 39d
consist of a mechanically thermally consolidated fibrous material
of the already mentioned type with at least two fibrous components
of different melting temperatures and correspondingly different
softening temperatures. By choosing the ratio of fractions of the
fibrous components having two different melting temperatures and by
the degree of heating and therefore softening of the second fibrous
component, the thermal consolidation, on the one hand, and water
vapor permeability of the fibrous layer, on the other hand, can be
influenced as desired. Owing to its thermal consolidation, the
fibrous layer 39 or the fibrous layer pieces 39a, 39b, 39c and 39d
can act as stabilization elements for the sole unit 15.
[0112] The fibrous layer 39 as such is already known from WO
2007/101624 A1. Additional details with respect to fibrous layer
39, of which the fibrous layer pieces 39a, 39b and 39c, 39c and 39d
consist, specifically with respect to the material choice and
material composition and with respect to production and thermal
activation, are therefore not specified in greater detail here, but
can be taken from WO 2007/101624 A1. The same applies to details
with respect to the outsole 29, the tread damping layer 31 and the
support layer 25, for example, with respect to structure, shape and
employed materials, which can also be taken from WO 2007/101624
A1.
[0113] As was already mentioned previously, the fibrous layer
material used in practical variants has the drawback that the
material used for the second fibrous component with the lower
melting temperature cannot be dyed, because temperatures are
required for dyeing that lie above the melting temperature of this
fibrous component. The fibrous component with the higher melting
temperature in this fibrous layer material can therefore be dyed
while the second fibrous component with the lower melting
temperature remains white. As already mentioned, the visual
and aesthetic configuration possibilities of the fibrous layer
therefore have very narrow limits.
[0114] This problem is remedied with a decor layer 45 according to
the invention, which is shown in FIGS. 1 and 2 as the grid visible
in the through holes 27 and in the following explained FIGS. 4 and
5 by a series of square points. In the variant of a sole unit 15
depicted in FIGS. 1 and 2 several decor layer pieces 45 are
provided, each of which is assigned to one of the through holes 27
of the stabilization layer 25, and each of which has the dimensions
of the corresponding through hole 27 according to the fibrous layer
pieces 39a, 39b, 39c and 39d depicted in FIG. 3. In this way the
bottom of each of these fibrous layer pieces 39a, 39b, 39c and 39d
that are visible through the corresponding through holes 27 is
covered by a corresponding decor layer piece and therefore made
invisible. Since almost any materials can be used for the decor
layer 45, as long as they are dyed or are able to be dyed, on the
one hand, and are water vapor permeable, on the other, the desired
coloring and patterning of the decor layer 45 has virtually no
limits.
[0115] Two variants of footwear according to the invention in the
production stage according to FIG. 2 are shown in a cross-sectional
view in FIGS. 4 and 5, in the case of FIG. 4 with respect to
footwear with the sole unit 15 glued onto the shaft 13 and in the
case of FIG. 5 with respect to footwear with the sole unit 15
molded onto the shaft 13. Each of the figures shows a cross section
through a forefoot area of a shaft 13 and a shoe 11, very
schematically and not absolutely realistic in terms of dimension
and scale. Only the shaft bottom 35 and a left shaft part of shaft
13 are shown, in which the right shaft part not shown is mirror
symmetrical to the depicted shaft part.
[0116] In the two variants depicted in FIGS. 4 and 5 the shaft 13
has an outer material layer 47, a shaft functional layer 49 and a
liner layer 51. In both variants the lower shaft end 55 on the sole
side is closed by means of a multilayer shaft bottom 35, which has
a shaft bottom functional layer 37. In
both variants the shaft functional layer 49 and the shaft bottom
functional layer 37 are bonded to each other essentially
waterproof, which leads to a waterproof shoe all the way around
and, when a not only waterproof but also water vapor permeable
functional layer is used, a water vapor permeable shoe all the way
around. And in both variants the sole unit 15 has the components
already mentioned in conjunction with FIGS. 1 to 3, namely an
outsole 29 and a support layer 25. In both cases the large area
through hole 27, which extends through the mentioned sole layers,
is covered by a fibrous layer 39, beneath which a decor layer 45 is
situated.
[0117] The two variants in FIGS. 4 and 5 differ with respect to the
layers of their sole unit 15, the structure of their shaft bottom
35 and the type of fastening of the sole unit 15 to the shaft 13,
and the type of sealing between the shaft functional layer 49 and
the shaft bottom functional layer 37.
[0118] In the variant depicted in FIG. 4, the sole unit 15 has, in
addition to outsole 29 and support layer 25, a tread damping layer
31, and the shaft bottom 35 has an inlay sole 53, often also called
an insole, which is connected to the lower shaft end 55 on the sole
side by means of a Strobel seam 57. A shaft bottom functional layer
laminate 59 is situated beneath the inlay sole 53, a three-layer
laminate in the depicted variant, which has the shaft bottom
functional layer 37 embedded between a lower functional layer
support layer 61 and an upper functional layer support layer 63.
The two functional layer support layers 61 and 63 each consist of a
textile layer, for example. The upper textile layer 63 is designed
such that it can be penetrated by liquid sealing material 65, which
is located between the bottom of the sole sided lower end of the
shaft functional layer 49 and the top of the peripheral edge of the
shaft bottom functional layer 37, in order to produce a waterproof
seal between the shaft functional layer 49 and the shaft bottom
functional layer 37. As shown in FIG. 4, the sole sided lower end
of the shaft outer material 47 is raised from the sole sided lower
end of the shaft functional layer 49 and glued to the bottom of the
shaft bottom functional layer laminate 59 by means of sole adhesive
67. The sole unit 15 is
prefabricated and is fastened by means of the one sole adhesive 67,
which was applied at least to the top of the peripheral edge zone
of the sole unit 15, to the sole sided lower shaft end 55.
[0119] In the variant depicted in FIG. 5 with the sole unit 15
molded onto shaft 13, the sole unit 15 has no tread damping layer
31. The shaft bottom 35 is formed by an inlay sole laminate 69
which is also a three layer laminate whose one outer layer, the
upper outer layer 63 in the depicted variant, consists of a stable
and rigid material such that this inlay sole laminate 69 can assume
the function of an inlay sole or insole for closure of the lower
shaft end 55. In this variant the shaft functional layer 49 and the
shaft liner 51 have an overhang on the sole sided end beyond the
shaft outer material 47. This overhang is spanned by means of a
mesh band 71, which is permeable to the liquid outsole material
during molding. The mesh band 71 is bonded on one side only to the
shaft outer material 47 but not to the shaft functional layer 49
and on the other side is connected via a Strobel seam 57 to both
the shaft functional layer 49 and the shaft liner 51 and to the
inlay sole laminate 69. The sole unit 15 of this variant has, in
addition to the support layer 25 provided with the fibrous layer 39
and the decor layer 45, only one outsole layer 29 in which the
support layer 25 equipped with the fibrous layer 39 and the decor
layer 45 is embedded during molding of the outsole layer 29 in the
manner depicted in FIG. 5, During molding of the outsole layer 29
onto shaft 13, liquid outsole material penetrates through the mesh
band 71, on the one hand, to the overhang of the sole sided lower
end of the shaft functional layer 49 and to the Strobel seam 57
and, on the other hand, to the bottom of the peripheral edge area
of the inlay sole laminate 69, where it can penetrate its lower
textile layer and reach the shaft bottom functional layer 37 there.
In this way, by means of outsole material, the transition between
the shaft functional layer 49 and the shaft bottom functional layer
37 is sealed.
[0120] In both variants depicted in FIGS. 4 and 5 the support layer
25 is preferably produced by injection molding. The decor layer 45
and the fibrous layer 39 can be inserted into the injection mold
before the injection process. During the injection process,
material of the support layer 25 penetrates through the outer
peripheral area of decor layer 45 and into the outer peripheral
area of fibrous layer 39 so that the support layer 25, the decor
layer 45 and the fibrous layer 39 are fastened to each other by the
molding process.
[0121] In a modification of the variant depicted in FIGS. 4 and 5
the fibrous layer 39 and the decor layer 45 are combined with each
other into a unit before they are joined to the sole unit 15. This
unit can form an insert that is produced separately from the
remaining components of the sole unit 15 and is inserted during
production of the sole unit 15. This insertion occurs into the sole
layer with which the unit of decor layer 45 and fibrous layer 39 is
to be provided.
[0122] In the variants depicted in the figures, this insert is
inserted into support layer 25. In other variants not shown, in
which the sole layer provided with decor layer 45 and fibrous layer
39 is not formed by a support layer but by an outsole or a midsole
of a different type from the support layer, for example, the insert
can be inserted into the corresponding sole layer. This means the
insert is produced separately and is then inserted into an
appropriate sole layer according to the design and/or desired
appearance of the specific sole unit 15. Inserts with visually
different decor layers 45 can be kept in stock and a
correspondingly selected insert inserted into the sole unit 15
depending on the shoe type for which it is intended.
[0123] In the variant depicted in FIG. 5, at least one of the
stabilization connectors is formed as a support connector 73 within
the through hole 27 of the support layer 25. For this purpose the
support connector 73 is designed such that it extends to the
contact surface 75 of the outsole layer 29 and is therefore
supported during walking with the shoe on floor 77, just like the
outsole
layer 29. A particularly good stabilization of the sole unit 15
even during walking is therefore achieved with the support
connector 73 depicted in FIG. 5.
[0124] Such a support connector is not present in the variant
depicted in FIG. 4 at least in the cross-sectional plane in the
through hole 27 of the support layer 25 depicted there.
* * * * *