U.S. patent application number 13/820241 was filed with the patent office on 2013-06-27 for method for manufacturing a sole assembly and for manufacturing a shoe.
The applicant listed for this patent is Christian Bier, Thorger Hubner, Frank Jensen, Jakob Moller Hansen, Stane Nabernik, Tore Stromfors. Invention is credited to Christian Bier, Thorger Hubner, Frank Jensen, Jakob Moller Hansen, Stane Nabernik, Tore Stromfors.
Application Number | 20130160223 13/820241 |
Document ID | / |
Family ID | 43984150 |
Filed Date | 2013-06-27 |
United States Patent
Application |
20130160223 |
Kind Code |
A1 |
Bier; Christian ; et
al. |
June 27, 2013 |
Method For Manufacturing A Sole Assembly and For Manufacturing A
Shoe
Abstract
The invention relates to a method for manufacturing a shoe,
comprising the steps of providing an upper assembly with an upper
portion comprising an outer material and with a bottom portion;
providing a ventilating sole element (161) having a structure or
material allowing for air flow through it; placing the ventilating
sole element in a mould (220), said mould having pins (221)
projecting in a lateral direction; positioning the ventilating sole
element and the upper assembly such that an upper part of the
ventilating sole element contacts the bottom portion of the upper
assembly; closing the mould such that the pins contact a side wall
of the ventilating sole element, and injection moulding so as to
form a surrounding sole element (195) being fixed to the upper
assembly and to the ventilating sole element, said surrounding sole
element comprising lateral passages (50) from the outside of the
surrounding sole element to the side wall of the ventilating sole
element formed by the pins; and after injection moulding,
connecting the lateral passages of the surrounding sole element to
the structure or material of the ventilating sole element. The
invention is also related to a method for manufacturing a
corresponding sole assembly.
Inventors: |
Bier; Christian; (Miesbach,
DE) ; Nabernik; Stane; (Kranj, SI) ; Hubner;
Thorger; (Flintsbach, DE) ; Stromfors; Tore;
(Lindome, SE) ; Jensen; Frank; (Bredebro, DK)
; Moller Hansen; Jakob; (Aabenraa, DK) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Bier; Christian
Nabernik; Stane
Hubner; Thorger
Stromfors; Tore
Jensen; Frank
Moller Hansen; Jakob |
Miesbach
Kranj
Flintsbach
Lindome
Bredebro
Aabenraa |
|
DE
SI
DE
SE
DK
DK |
|
|
Family ID: |
43984150 |
Appl. No.: |
13/820241 |
Filed: |
September 3, 2010 |
PCT Filed: |
September 3, 2010 |
PCT NO: |
PCT/EP10/62976 |
371 Date: |
March 1, 2013 |
Current U.S.
Class: |
12/146B |
Current CPC
Class: |
A43B 3/0078 20130101;
A43B 23/022 20130101; B29D 35/061 20130101; A43B 7/125 20130101;
A43B 13/12 20130101; A43B 13/32 20130101; B29D 35/122 20130101;
A43B 7/088 20130101; A43B 7/087 20130101 |
Class at
Publication: |
12/146.B |
International
Class: |
A43B 13/14 20060101
A43B013/14 |
Claims
1. Method for manufacturing a breathable sole assembly, comprising
the steps of: providing a ventilating sole element having a
structure or material allowing for air flow through it, placing the
ventilating sole element in a mould, said mould having pins (221)
projecting in a lateral direction; closing the mould such that the
pins contact a side wall of the ventilating sole element, and
injection moulding so as to form a surrounding sole element being
fixed to the ventilating sole element, said surrounding sole
element comprising lateral passages from the outside of the
surrounding sole element to the side wall of the ventilating sole
element formed by the pins; and after injection moulding,
connecting the lateral passages of the surrounding sole element to
the structure or material of the ventilating sole element.
2. Method for manufacturing a breathable shoe, comprising the steps
of: providing an upper assembly with an upper portion comprising an
outer material and a breathable bottom portion; providing a
ventilating sole element having a structure or material allowing
for air flow through it; placing the ventilating sole element in a
mould, said mould having pins projecting in a lateral direction;
positioning the ventilating sole element and the upper assembly
such that an upper part of the ventilating sole element contacts
the bottom portion of the upper assembly; closing the mould such
that the pins contact a side wall of the ventilating sole element,
and injection moulding so as to form a surrounding sole element
being fixed to the upper assembly and to the ventilating sole
element, said surrounding sole element comprising lateral passages
from the outside of the surrounding sole element to the side wall
of the ventilating sole element formed by the pins; and after
injection moulding, connecting the lateral passages of the
surrounding sole element to the structure or material of the
ventilating sole element.
3. Method of claim 1, wherein the lateral passages of the
surrounding sole element are connected to the structure or material
of the ventilating sole element by making at least one opening
through the side wall of the ventilating sole element through the
lateral passages of the surrounding sole element, particularly by
drilling, puncturing, lasering or other thermal removal.
4. The method of claim 1, wherein the ventilating sole element has
a channel structure at least at an upper side thereof allowing for
communication of air between the channels and the lateral passages
of the surrounding sole element.
5. The method of claim 1 wherein the ventilating sole element is
made as a container element having a bottom part and a side wall so
as to form an inner space of the container element, wherein in the
inner space there is positioned a structure or material allowing
for air flow through it.
6. The method of claim 2 wherein the ventilating sole element has a
functional layer attached to the surface facing the bottom portion
of the upper assembly.
7. The method of claim 2, wherein the upper assembly comprises a
breathable outer material and a waterproof, breathable functional
layer arrangement extending over said upper portion and said bottom
portion.
8. The method of claim 7, wherein a side end area of a bottom
functional layer of said functional layer arrangement and a lower
end area of an upper functional layer of said functional layer
arrangement are connected to one another with a waterproof seal
being provided at the connection.
9. The method of claim 8, wherein the side end area of said bottom
functional layer and the lower end area of said upper functional
layer are stitched to one another to form a stitched seam.
10. The method of claim 9, wherein said surrounding sole element is
moulded so as to penetrate to the upper functional layer so as to
form a seal at the stitched seam by material of the surrounding
sole element formed by the injection moulding.
11. The method of claim 8, wherein a netband is provided, said
netband connecting a lower end area of the breathable outer
material with the side end area of the bottom functional layer, and
wherein said netband is penetrated by material of the surrounding
sole element in the moulding step.
12. The method of claim 7, wherein said bottom functional layer is
provided with supporting members, particularly knobs, at its lower
surface.
13. The method of claim 1, wherein the ventilating sole element
comprises at least one lip protruding from the side wall of the
ventilating sole element.
14. The method of claim 13, wherein positioning of the ventilating
sole element is done with a bottom piston pressing and deforming
said protruding lip of the ventilating sole element against the
bottom portion of the upper assembly.
15. The method of claim 1 wherein the ventilating sole element is
attached to the bottom portion of the upper assembly in a first
injection-moulding step, and connected to the surrounding sole
element formed in a second injection-moulding step.
16. The method of claim 1, wherein a comfort layer is provided on
top of said ventilating sole element towards the upper
assembly.
17. The method of claim 16, wherein the comfort layer is attached
to the top of said ventilating sole element, in particular by
spotwise or circumferential gluing.
18. The method of claim 1, wherein the underside of said
ventilating sole element forms at least a part of an outer
sole.
19. The method of claim 1, wherein the undersides of said
surrounding sole element and of said ventilating sole element form
at least a part of an outer sole.
20. The method of claim 1, wherein the underside of said
ventilating sole element is arranged at a higher position as
compared to the underside of said surrounding sole element.
21. The method of claim 1, wherein an additional sole element is
provided forming at least a part of an outer sole, said additional
sole element being arranged below said ventilating sole
element.
22. The method of claim 21, wherein said additional sole element is
arranged below said surrounding sole element and said ventilating
sole element.
23. The method of claim 1, wherein said surrounding sole element
extends below said ventilating sole element.
24. The method of claim 23, wherein said surrounding sole element
forms at least a part of an outer sole.
25. The method of claim 23, wherein an additional outer sole
element forming at least a part of an outer sole is arranged below
said surrounding sole element.
26. The method of claim 23, wherein supporting members are formed
in portions of said surrounding sole element below said ventilating
sole element, said supporting members extending substantially
vertically through said surrounding sole element.
27. The method of claim 2, wherein a comfort layer is provided on
top of said ventilating sole element towards the upper assembly,
wherein the comfort layer has an upper side and a lower side, where
the upper side is facing the bottom portion of the upper assembly,
and the lower side is facing the ventilating sole element, wherein
the lower side is stiffer than the upper side, particularly the
lower side being stiff and the upper side being soft.
Description
[0001] The present invention is related to a method for
manufacturing a breathable sole assembly and a method for
manufacturing a breathable shoe.
[0002] It is known in the art to equip shoes with breathable soles.
An example of such a breathable sole is known from EP 1 033 924 B1.
Therein, a safety shoe is described, whose outsole comprises
horizontal air vents at the sides of the sole for ventilation. The
shoe is also provided with a honeycomb structure lying within the
outsole and a perforated insole, such that water vapour is
discharged from the inside of the shoe through these vapour
permeable layers and the horizontal air vents to the outside
atmosphere. The honeycomb may be made of an air-permeable material
such as a fibre structure. Alternatively, the honeycomb may be made
of a mouldable material such as polyurethane (PU) into which a set
of canals has been formed. If the shoe is not worn in totally dry
conditions, such as a paper mill, then a waterproof breathable
membrane may be provided below the insole.
[0003] EP 1 033 924 B1 also discloses a method for manufacturing a
sole assembly and a shoe. To manufacture the shoe the honeycomb is
attached to the insole of the upper structure or assembly which is
lasted. An injection mould is provided with pins on both sides
extending parallel to the plane of the sole member. The last closes
the mould from above. Then sole material is injected into the mould
forming a sole with horizontal air vents and at the same time
attaching it to the upper structure or assembly. In case the
honeycomb has a duct structure and is surrounded by an intact edge,
the pins penetrate through the edge of the honeycomb forming canals
or openings between the air vents and the duct structure. If no
intact edge exists then the pins extend into close contact with the
sides of the honeycomb to form air vents between the honeycomb and
the outside atmosphere.
[0004] Alternatively, a sole structure or assembly is manufactured
separately by inserting a body the size of the honeycomb into the
mould to form a cavity for the honeycomb and injecting the sole
material. The honeycomb is then fitted into the cavity and the sole
structure or assembly together with the honeycomb is attached to
the insole of the upper structure or assembly preferably by
gluing.
[0005] Particularly with a honeycomb which has a duct or channel
structure, the pins of the mould need to be aligned and correspond
very precisely with this duct or channel structure to ensure that
the canals or openings are in the right place and to achieve a
smooth transition from the ducts or channels to the air vents. In
case of the use of a membrane in the shoe the pins must furthermore
be placed such that they will not damage the delicate membrane,
which makes alignment even more difficult.
[0006] It is an object of the invention to provide a method for
manufacturing a sole assembly and a method for manufacturing a shoe
which are suitable for manufacturing the sole assembly and shoe,
respectively, for a wide variety of usage scenarios overcoming the
disadvantages of the prior art solution.
[0007] According to an aspect of the invention, there is provided a
method for manufacturing a sole assembly according to the features
of claim 1 and a method for manufacturing a shoe according to the
features of claim 2.
[0008] In particular, in an aspect of the invention there is
provided a method for manufacturing a sole assembly, comprising the
steps of providing a ventilating sole element having a structure or
material allowing for air flow through it, placing the ventilating
sole element in a mould, said mould having pins projecting in a
lateral direction, closing the mould such that the pins contact a
side wall of the ventilating sole element, and injection moulding
so as to form a surrounding sole element being fixed to the
ventilating sole element, said surrounding sole element comprising
lateral passages from the outside of the surrounding sole element
to the side wall of the ventilating sole element formed by the
pins, and after injection moulding, connecting the lateral passages
of the surrounding sole element to the structure or material
allowing for air flow through it of the ventilating sole
element.
[0009] In another aspect of the invention there is provided a
method for manufacturing a shoe, comprising the steps of providing
an upper assembly with an upper portion comprising an outer
material and with a water vapour permeable bottom portion,
providing a ventilating sole element having a structure or material
allowing for air flow through it, placing the ventilating sole
element in a mould, said mould having pins projecting in a lateral
direction, positioning the ventilating sole element and the upper
assembly such that an upper part of the ventilating sole element
contacts the bottom portion of the upper assembly, closing the
mould such that the pins contact a side wall of the ventilating
sole element, and injection moulding so as to form a surrounding
sole element being fixed to the upper assembly and to the
ventilating sole element, said surrounding sole element comprising
lateral passages from the outside of the surrounding sole element
to the side wall of the ventilating sole element formed by the
pins, and after injection moulding, connecting the lateral passages
of the surrounding sole element to the structure or material
allowing for air flow through it of the ventilating sole
element.
[0010] According to the invention, a method for manufacturing a
sole assembly and a method for manufacturing a shoe are provided
which are suitable for manufacturing the sole assembly and shoe,
respectively, for a wide variety of usage scenarios. The different
components such as upper assembly, ventilating sole element,
surrounding sole element, outsole, etc., may be manufactured for a
wide variety of usage scenarios in a way that they fulfil the
particular demands. The interconnection between the structure or
material allowing for air flow through it of the ventilating sole
element and the lateral passages in the surrounding sole element is
made in a manufacturing step in which openings or apertures are
made in side wall of the ventilating sole element through the
lateral passages to interconnect the structure or material of the
ventilating sole element with the lateral passages. In other words
the lateral passages in the surrounding sole element are formed at
the time of forming the surrounding sole element. The openings or
apertures are made in later step, at a time in which the passages
already exist. In this way, air and water vapour may effectively be
transferred out of the shoe via the ventilating sole element and
the lateral passages. The open parts of the structure or material
of the ventilating sole element and the lateral passages in the
surrounding sole element formed by the pins are interconnected by
making apertures or openings in the ventilating sole element
through the lateral passages, which have already been formed
previously. In that way there is a reliable path for air to
communicate between the structure or material and an outside of the
surrounding sole element regardless of the exact position of the
moulding pins.
[0011] The method is beneficial since it is not necessary that the
pins of the mould are exactly aligned with any channels or open
parts in the structure or material of the ventilating sole element
prior to injection moulding. Further, no injected material can
enter into the channels or open part of the structure or material
of the ventilating sole element. According to the invention, the
pins for forming the lateral passages can have any geometric shape.
They do not need to correspond exactly to the position or shape or
size of the channels or open parts of the ventilating sole
element.
[0012] According to an embodiment of the invention, the lateral
passages of the surrounding sole element are connected to the
structure or material of the ventilating sole element by drilling,
puncturing or lasering into a portion of the side wall of the
ventilating sole element or otherwise removing some of the material
of the side wall, through the lateral passages of the surrounding
sole element.
[0013] According to an embodiment of the invention, the upper
assembly comprises a breathable outer material and a waterproof,
breathable functional layer arrangement extending over said upper
portion and said bottom portion. For example, according to a
further embodiment, a side end area of a bottom functional layer of
said functional layer arrangement and a lower end area of an upper
functional layer of said functional layer arrangement are connected
to one another with a waterproof seal being provided at the
connection. In this way, a shoe may be provided which allows for an
excellent protection against water entering the inner part of the
shoe containing the foot, while ensuring high breathability through
the upper as well as the sole of the shoe. The waterproof upper
assembly, comprising the functional layer arrangement, e.g. in the
form of a bootie or a three dimensional sock or in the form of the
upper functional layer and the bottom functional layer, whose
connection is sealed in a waterproof manner, ensures that no water
enters the shoe from the outside, such that the wearer will not get
wet feet in any wet conditions, e.g. rainy, muddy or snowy
environments. The functional layer arrangement extends over
substantial parts of the upper portion and the bottom portion of
the upper assembly, particularly it extends over substantially the
entire inner extension of the upper assembly. In this way, the
upper assembly forms a waterproof bag around the wearer's foot,
which allows for a 360.degree. water protection for the wearer's
foot, i.e. it completely surrounds the wearer's foot (with the
exception of the shoe opening for receiving the wearer's foot, of
course). The functional layer arrangement may be arranged towards
the inner space of the upper assembly, in particular it may form at
least substantial parts of the inner surface of the upper assembly.
For example, the functional layer arrangement may be comprised of
one or more functional layer pieces or of one or more functional
layer laminate pieces. These pieces may be sealed with respect to
each other in any suitable way, e.g. via the application of sealing
tapes, via injection-moulding of sealing material, via welding them
together, via heating the pieces in an overlap region and pressing
them with sufficient force against each other that a waterproof
seal is formed, etc.
[0014] The functional layer arrangement, particularly, the
waterproof, breathable upper functional layer laminate ensures that
no water enters the shoe from the outside through the outer
material. At the same time, it is ensured that the upper portion is
breathable and therefore helps in transporting water vapour from
the inside of the shoe to the outside. Water vapour can be
effectively transferred out of the shoe both via the upper portion
of the upper assembly as well as the bottom portion of the upper
assembly, the structure or material of the ventilating sole element
and the lateral passage. Accordingly, a high level of water vapour
discharge is achieved, particularly because air flow can take place
in the lateral passage and the ventilating sole element in a static
environment, e.g. when sitting or standing. This flow may be
enhanced by the movement of the shoe when the wearer is walking or
running. Two favourable effects take place during a walking or
running motion, each of which is predominantly associated with one
of the two phases of the gait cycle, namely the actual stance phase
and the shoe swinging phase in between the actual steps. During the
shoe swinging phase, an air flow in and out of the ventilating sole
element through the at least one lateral passage is generated, with
the lateral passages being very suitable to develop such air flow
therein. This is particularly the case, because the outside end of
the lateral passage is in air connection with the environment
during all phases of the walking motion, allowing for water vapour
discharge along with the air discharge at all times. The bending of
the shoe sole during the walking or running motion and additionally
the application of the wearer's weight on the ventilating sole
element during the stance phase also forces air flow within the
ventilating sole element and the at least one lateral passage. The
air pushed out of the ventilating sole element takes water vapour
from the inside of the shoe with it. The ambient air coming back
into the ventilating sole element can then be recharged with water
vapour.
[0015] Any water, dirt, soil etc., that may enter through the
passages will be discharged through those passages over time by
gravity and movement of the shoe. Therefore, there will be no
build-up of these undesirable materials over time. The functional
layer lying above the ventilating sole element will therefore also
not be affected e.g. by such dirt particles.
[0016] The term breathable material refers to materials that are
water vapour permeable. They may also be air permeable. In a
particular embodiment, the functional layer arrangement, in
particular the upper functional layer laminate and the bottom
functional layer laminate are waterproof and breathable, but not
air permeable. The term breathable shoe refers to a shoe through
which water vapour in the form of sweat may pass from the inside of
the shoe to the outside.
[0017] The term ventilating sole element is not intended to imply
that the ventilating sole element comprises an active,
self-propelled mechanism for ventilating the sole. Instead, the
structure of the ventilating sole element allows for an airing or
ventilating of the ventilating sole element in a static environment
and also particularly due to the wearer's motion during use of the
shoe. Accordingly, the ventilating sole element may also be
referred to as ventilated sole element or ventilation sole element.
It is explicitly pointed out, however, that the invention does not
rule out that an active mechanism, such as a self-propelled pump or
the like, is present in addition to the particular inventive
structure.
[0018] A shoe according to the invention always features a sole or
sole assembly which comprises at least the ventilating sole element
and a surrounding sole element, but may also comprise further
elements such as a separate outsole. The bottom or lower surface of
the sole or sole assembly may contain a tread, i.e. a profile or
contour or pattern in a vertical and/or horizontal direction but
does not have to. The sole or sole assembly may be attached to the
upper assembly of the shoe in a number of ways, including but not
limited to moulding or injection moulding the sole or parts of the
sole assembly on to the upper assembly and gluing parts or all of
the sole on to the upper assembly.
[0019] According to a further embodiment, the ventilating sole
element comprises a plurality of openings.
[0020] According to a further embodiment, at least one opening
connected to at least one lateral passage extends from the
structure or material of the ventilating sole element, allowing for
air flow through it, through a side wall of the ventilating sole
element. The at least one lateral passage extends from the opening
through said surrounding sole element, said opening and lateral
passage allowing for communication of air between said structure or
material of said ventilating sole element and an outside of said
surrounding sole element. Describing the path the other way around,
the passage passes from the outer lateral surface of the
surrounding sole element through the surrounding sole element and
the opening passes through the side wall of the ventilating sole
element to the structure or material of the ventilating sole
element allowing for air flow through it. The passage in the
surrounding sole element forms the last piece in the water vapour
discharge chain. The water vapour, generated by the wearer's foot
perspiration, reaches the lateral outside of the sole of the shoe,
that is the ambient air, via the bottom functional layer laminate,
the ventilating sole element and the at least one opening and
lateral passage. A path for water vapour to be discharged
effectively via airflow and gradient driven diffusive forces is
established.
[0021] The lateral passages may be placed anywhere in the
surrounding sole element. Particularly, they may be situated in the
back (heel region) of the surrounding sole element and/or in the
front (toe area). This allows the air with the water vapour to be
more easily pushed through the ventilating sole element and out of
the lateral passages due to the rolling motion of the sole assembly
during walking.
[0022] According to a further embodiment, the surrounding sole
element and ventilating sole element may comprise at least one
lateral passage and opening connected thereto extending straight
through the surrounding sole element and the ventilating sole
element from the outside on one side to the outside of the other
side. Such opening(s) may e.g. be created by using a laser or a
drill to pass right through the ventilating sole element.
[0023] According to a further embodiment, the ventilating sole
element does not comprise vertical passages extending through the
ventilating sole element from the bottom side thereof to an upper
side thereof. Not having vertical passages allows for a high
flexibility of the sole design, particularly for the provision of
stable, waterproof and non water vapour permeable sole layers
across the complete extension of the underside of the foot. This
may provide high comfort to the wearer, because the load bearing of
the sole may be distributed over the whole area of the sole, such
that less stiff materials may be used. The sole may feel more
uniform and therefore more comfortable for the user than soles with
vertical holes. An additional advantage is that a
dirt/soil/mud/sand build-up on the underside of the sole does not
compromise the water vapour discharge capability of the shoe. The
lateral openings and passages ensure breathability of the shoe in a
wide variety of usage scenarios, in particular also in highly
adverse usage environments.
[0024] In a further embodiment however, the ventilating sole
element comprises at least one vertical passage in addition to the
at least one opening allowing for additional air flow. This also
allows for additional drainage of liquids and/or dirt from the
ventilating sole element.
[0025] According to a further embodiment, said ventilating sole
element has a channel structure. This channel structure forms said
structure allowing for air flow through it, which is provided in
the ventilating sole element. Such a ventilating sole element
comprising a channel structure provides for an effective collection
and transport of air and moisture resulting from the water vapour
being discharged via diffusion through the breathable bottom
portion of the upper assembly which is positioned above the
ventilating sole element, when the completed shoe comprising the
ventilation sole element is worn.
[0026] According to a further embodiment, said ventilating sole
element comprises a side wall, a channel structure is formed in the
ventilating sole element, and said channel structure comprises a
plurality of channels. These channels may be either transverse or
longitudinal channels. At least some of the channels comprise air
and moisture discharging ports. At least one of the channels is a
peripheral channel, i.e. a channel that lies on the periphery or
circumference of the ventilating sole element, but inside the side
wall. This peripheral channel intersects with a plurality of the
other channels. The channels and the side wall form functional
pillars. The ratio of the top surface area of the functional
pillars (Ap) to the top surface area of the channels (Ac) of the
channel structure is between 0.5 and 5.0.
[0027] The peripheral channel does not have to be closed or run
along the entire circumference of the ventilating sole element. The
first kind of functional pillars is surrounded completely by
channels, e.g. by two transverse channels and the left and right
portions of a peripheral channel or by two transverse channels, one
longitudinal channel and one peripheral channel or by two
transverse channels and two longitudinal channels. The second kind
of functional pillars is formed by respective upper portions of the
ventilating sole element surrounded by the inner end of the side
wall and by the channel portions that are located closest to said
inner end of the side wall. Such second kind of functional pillars
can for example extend in longitudinal direction of the shoe
between two adjacent transverse channels and in a transverse
direction between the inner end of the side wall and the adjacent
portion of the peripheral channel. The side wall extends between
the outer surface of the side wall and an imaginary line drawn
between those channel walls or channel ends or channel ports which
are located closest to the outer surface of the side wall. The side
wall does not have to be thick or load-bearing. It provides a
boundary of the ventilating sole element to the outside of the
sole.
[0028] The channel structure may be formed in the top or upper part
of the ventilating sole element, i.e. starting at the upper surface
facing towards the upper assembly and extending some way down into
the ventilating sole element. The channel structure may also be
formed throughout the ventilating sole element or in any other part
thereof.
[0029] All or a subset of the air and moisture discharging ports
are connected to the outside of the ventilating sole element by
openings and lateral passages passing through the side wall of the
ventilating sole element and through the surrounding sole element,
such that air can pass from the channel structure of the
ventilating sole element to the outside of the shoe and vice
versa.
[0030] The functional pillars that are formed by the channel
structure and the side wall of the ventilating sole element serve
the first purpose of a good distribution of the pressure as imposed
on the ventilating sole element structure by the underside of the
foot, and the second purpose of providing an efficient air and
moisture collecting and transferring channel structure formed
around the functional pillars to allow for good ventilation.
[0031] Moreover, the ventilating sole element having a channel
structure, as described above, has good flexing properties and is
wear resistant. It can easily be manufactured, particularly in one
moulding step, wherein the outer shape of the ventilating sole
element including the channel structure in the ventilating sole
element is formed by the moulds. The ventilating sole element can
be cast, injected or vulcanized.
[0032] By the relationship of the top surface area of the pillars
to the top surface area of the channels being between 0.8 and 5.0 a
good compromise between comfort, durability, supporting and
pressure distribution properties on the one hand and the
ventilation effect on the other is attained.
[0033] The inventors have discovered that a particularly good
compromise between supporting and pressure distribution properties,
leading to a high degree of comfort for a wearer, and ventilation
is attained when the top surface area formed by the pillars is
equal to or greater than the top surface area defined by the
channels. A particularly good compromise is attained when this
ratio is between 1.0 and 3.0 and more particularly between 1.4 and
2.2.
[0034] This relationship can better be understood by having a look
at the extremes: From a comfort point of view no channels in the
ventilating sole element at all are desired. From a ventilation
point of view the open space in the ventilating sole element that
is created by the channel structure, should be as large as
possible.
[0035] On the other hand the width of the channels is not
arbitrary. Channels which are too narrow are not suitable, since
they do not allow for enough collection and transport of air and
moisture. Channels that are too wide do not feel comfortable
because the wearer will feel the edges of the pillars. The wider
the channels are, the more their edges will imprint on the above
layers, in particularly the functional layer at the bottom.
[0036] Taking all these points into account, the inventors of the
present application have discovered that the relationship as
described above is particularly advantageous.
[0037] According to a further embodiment of the invention, the
functional pillars have a minimum upper edge length of 4
millimetres. All edges should be at least 4 mm long, both in the
longitudinal and in the transverse direction.
[0038] According to a further embodiment of the invention, at least
some of the lateral ends of said channels are formed as air and
moisture discharging ports.
[0039] The channels may follow the shape of the ventilating sole
element. At least the bottom surface of the transverse channels may
be substantially horizontal, when seen in the main direction of the
transverse channels. In this case the channel depth varies
throughout the ventilating sole element. In another embodiment the
bottom surface of the transverse channels is inclined downwards
towards the centre of the ventilating sole element. The channels
may also be inclined downwards towards the outside of the
ventilating sole element.
[0040] According to a further embodiment of the invention, the
width of the channels at the upper side of the ventilating sole
element lies between 2 and 5 millimetres, particularly between 2
and 3.5 millimetres.
[0041] According to a further embodiment of the invention, the
channel structure has a first portion with a first channel width,
and a second portion with a second channel width. By providing such
portions with different channel widths different flexing and
bending conditions occurring in such portions can be matched.
[0042] In a further embodiment of the invention such portions
having a different channel width can be positioned under a heel
portion of the foot and/or a forefoot portion of the foot,
particularly a ball portion of the forefoot.
[0043] According to an embodiment of the invention, the channel
width in such special portions can be smaller than the channel
width in the other portions of the channel structure.
[0044] According to a further embodiment of the invention, the
distances between adjacent trans-verse channels in the forefoot
portion can be smaller than in the heel portion, in order to
increase the effect of actively moving air and moisture to the
outside. In the forefoot portion of the ventilating sole element
the flexing that occurs is greater than in the heel portion.
Furthermore, the foot produces more sweat in this region than e.g.
in the heel region.
[0045] By such flexing the cross section of the channel is reduced
and widened again which forces the air out of such channels. By
providing a higher transverse channel density in the forefoot
portion, such active effects can be increased which leads to a
further improved ventilation effect.
[0046] The shape of the channels can be of different kinds.
According to a further embodiment of the invention, the channels
comprise channel walls and a channel bottom, wherein the distance
between the walls of a channel, when seen in the sectional view,
increases in an upwards direction. Such channel form provides for a
good air and moisture collecting and transport function.
[0047] According to a further embodiment of the invention the
channel bottom is formed as a substantially horizontal plane. By
the provision of this feature, the channels, when seen in a
sectional view, have an essentially isosceles trapezoid shape and,
more particularly the form of an isosceles trapezoid.
[0048] According to a further embodiment of the invention, oblique
bottom transition faces are provided between the substantially
horizontal channel bottom and the channel walls.
[0049] In an alternative embodiment of the present invention, the
channel bottom has a rounded, concave form, giving the channels a
U-like shape, when seen in a sectional view.
[0050] The channels may be formed in a way that they do not have
sharp corners and/or edges, such as corners or edges having acute
angles. Due to the lack of 90.degree. angles in the embodiments of
the channel bottom, air and moisture cannot be trapped in any
corners where no air/moisture movement can take place, as may be
the case in rectangular shaped channels.
[0051] None of the above described channel forms are prone to
mechanical failure, e.g. in the form of breakage as is the case for
example with a plane V-shaped channel. Furthermore, due to the
width of the channel bottoms in comparison to a simple V-shape the
channels can take up far more air and moisture.
[0052] Any sharp edges reduce airflow due to friction and
turbulence created and induce cracks and failure of the sole. This
is particularly the case at the intersections of the channels. In a
preferred embodiment at least the vertical edges of the channels
are rounded, preferably having a radius of between 0.25 and 5
mm.
[0053] The horizontal edges of the channel/pillar tops may be
rounded in a further embodiment, preferably having a radius between
0.5 and 5 mm. This leads to less imprinting on the layers in the
shoe above the ventilating sole element and a more comfortable
feeling for the wearer.
[0054] According to a further embodiment of the invention, one
continuous peripheral channel is provided extending from a front
portion to a rear portion of the ventilating sole element.
[0055] By such single continuous peripheral channel, a good
collection and transport of air and moisture can be attained.
[0056] According to an alternative embodiment, at least two
peripheral channels are provided extending over different portions
of the ventilating sole element. Such peripheral channels can
intersect with each other or they can be formed separately from
each other. By the provision of at least two peripheral channels, a
good air and moisture collecting and trans-porting function can be
attained as well.
[0057] According to a further embodiment of the invention, the
peripheral channel runs in a zig-zag line, seen from a front
section to a rear section of the ventilating sole element. By using
such a zigzag shaped peripheral channel, a particularly efficient
transport of air and moisture to the air and moisture discharging
ports can be achieved.
[0058] The zigzag form of the peripheral channel can be such that
the outer points of such zig-zag peripheral channel intersect with
those transverse channels the ends of which are formed as air and
moisture discharging ports, at a position just inside of those air
and moisture discharging ports.
[0059] The channel structure as a whole, that is the arrangement of
the various channels to each other is such that in a preferred
embodiment, the maximum length that a water molecule has to travel
from the inside of the ventilating sole element to the nearest air
and moisture discharging port is 60 mm.
[0060] According to a further embodiment of the invention, the air
and moisture discharging ports have a greater depth, and in
addition or instead they can be broadened as compared to the other
channel portions. Thus, enough air and moisture can be received and
transported further outwards by the air and moisture discharging
ports.
[0061] As described above, the openings of the ventilating sole
element may be connected to the air and moisture discharging ports
of the ventilating sole element. Such openings can be drilled or
lasered or punctured and/or melted, e.g. with a hot needle into the
ventilating sole element in a subsequent manufacturing step. During
this step an increased depth or broadness of the ports allows for a
much more reliable, safer and easier connection process of the
passages to the channel system of the ventilating sole element.
[0062] According to a further embodiment of the invention the upper
surface of the ventilating sole element has a curved form with a
lower front region and a higher rear portion, so as to accommodate
the underside of the foot to be supported. The shape of the
ventilating sole element follows the shape of the anatomical last,
which is ergonomically customized to the feet to be supported by
the ventilating sole element.
[0063] In order to make the sole assembly light weight it is
preferred to use low density polyurethane (PU) e.g. having a
density of 0.35 g/cm.sup.3 for the ventilating sole element.
[0064] Such a polyurethane ventilating sole element has high
stability to support/transfer at least a portion of the weight of
the user during use, such as during walking, while having some
flexibility in order to enhance the wearer's comfort during
walking. Depending on the preferred use of the shoe, a suitable
material can be chosen. Examples of such material are Elastollan
from the company Elastogran Gmbh, Germany. This material is
preferred due to its low density. Alternatively for injection
moulding the ventilating sole element, TPU (Thermoplastic
Polyurethane), EVA (Etylene Vinyl Acetate), PVC (Polyvinyl
Chloride) or TR (Thermoplastic Rubber), etc. may be used.
[0065] It is further preferred to use PU on a polyethylene (PE)
basis for the ventilating sole element.
[0066] It is further preferred to use a material that is not too
hard for the ventilating sole element for shock absorption reasons.
Thus, a polyurethane material with a shore A hardness between 38
and 45 is preferred for the ventilating sole element. Shore
hardness is measured by the durometer test. A force is applied onto
a spot of the polyurethane, whereby the force creates an
indentation. The time taken for the indentation to disappear is
then measured.
[0067] According to another embodiment of the invention the
material of the ventilating sole element is porous, such that it
has a high rate of water vapour diffusion through it. This enhances
the ventilating effect of the ventilating sole element.
[0068] In a further embodiment of the invention the depth of the
channels is less than 20 mm, preferably between 2 and 10 mm. This
avoids the wearer of the shoe experiencing a rolling movement when
walking which would badly influence the comfort sensed by the
wearer and which would effect a tilting torque on the functional
pillars which over time may cause breakage of the functional
pillars.
[0069] The functional pillars formed by the channel structure can
have different sizes, especially length, depth and surface area,
that can vary across the surface of the ventilating sole
element.
[0070] The functional pillars can also have different shapes, when
seen in a plan view, for example a rectangular shape, a triangular
shape or a rounded shape.
[0071] The inventors have found out that there is a relationship
between the depth of the channels and the surface area of the
functional pillars facing the upper assembly above. The less deep
the channels are the smaller the surface area can be. A typical
value of a functional pillar surface is 0.6 to 1 cm.sup.2.
[0072] According to a further embodiment, said ventilating sole
element comprises a container element having a bottom part and a
side wall so as to form an inner space of said container element,
wherein said inner space is filled with a filler material allowing
for air flow through it. Instead of a filler material allowing for
air flow through it, there may also be provided a filler structure
allowing for air flow through it, such as a channel structure. The
container element forms a tub for receiving the filler material or
filler structure allowing for air flow through it.
[0073] According to a further embodiment, the filler structure or
material is a three-dimensional spacer. The three-dimensional
spacer may be configured so that the structure or material
maintains a spacing between layers situated beneath it and above
it, in particular between the lower portion of the upper assembly
and the bottom part of the container element. In this way, the air
flow through the structure or material is retained. Particularly,
such a spacer structure or material may allow for a very low air
flow resistance, while ensuring high stability of the combination
of the container element and the spacer structure or material. In
another embodiment, the spacer structure or material is made to be
at least partially elastic. Because of this, the walking comfort of
the shoe is increased, as the spacer structure or material allows
for cushioning and an easier rolling process during the stance
phase of the gait cycle. In another embodiment, the spacer
structure or material is designed so that during maximal stress
with the maximum weight of the shoe user to be expected
corresponding to the shoe size in the corresponding shoe, it yields
elastically at most to the extent that, even during such maximum
stress, a significant part of the air flow of the spacer structure
or material is still retained. The spacer may be made of materials
such as e.g. polyester, polyolefins or polyamides.
[0074] In another embodiment, the air permeable spacer has a flat
structure forming a first support surface and a number of spacer
elements extending away from the flat structure at right angles
and/or at an angle between 0 and 90.degree.. The ends of the spacer
elements lying away from the flat structure then together define a
surface by means of which a second support surface, facing away
from the flat structure, can be formed. In another embodiment, the
spacer elements of the spacer are designed as knobs, the free knob
ends together forming the second support surface mentioned. In
another embodiment, the spacer has two flat structures arranged
parallel to each other, the two flat structures being joined to
each other via the spacer elements in a manner allowing for air
flow through and between them and holding them spaced apart from
each other. Each of the flat structures then forms one of the two
support surfaces of the spacer. All the spacer elements need not
have the same length in order to make the two support surfaces
equidistant over the entire surface extent of the spacer structure.
For special applications, it can be advantageous to make the spacer
have different thickness in different zones or at different
locations along its surface extent, in order to form a surface
anatomically compatible with the foot. The spacer elements can be
formed separately, i.e., not joined to each other between the two
support surfaces. However, there is also the possibility of
allowing the spacer elements to touch between the two support
surfaces and the possibility of joining them at at least some of
the contact sites, for example, with an adhesive or by the fact
that the spacer elements consist of materials that can be welded to
each other, such as a material that becomes adhesive from heating.
The spacer elements can be rod- or thread-shaped individual
elements or sections of a more complex structure, for example, a
truss or lattice. The spacer elements can also be connected to each
other in a zigzag or in the form of a cross-grating. In another
embodiment, the spacer structure or material is formed by two
air-permeable flat structures arranged substantially parallel to
each other, which are joined to each other and spaced apart by
means of mono- or multifilaments in a manner allowing for air flow
through and between them.
[0075] In another embodiment the filler material or structure is
porous.
[0076] The filler structure or material may also be discontinuous
in an additional embodiment. According to a further embodiment, the
filler comprises a number of filler elements, which are spherical
in shape, e.g. filler balls. These filler elements are received by
the container element. The filler elements themselves may be made
of a material which does not allow for an air flow or water vapour
to pass through it. However, with the filler elements having voids
therebetween, an overall structure may be formed which does allow
for air flow and thus water vapour transport through it. The filler
elements may be selected based on their stability and comfort
characteristics. The air flow through the filler structure may be
adjusted by adjusting the size of the filler elements.
[0077] According to a further embodiment, the filler structure is
at least partly comprised of channels. The channel structure allows
for a distributed air connection between the underside of the lower
portion of the upper assembly and at least portions of the side
wall and/or bottom part of the container element. Water vapour can
pass from the inside of the shoe to the channel structure provided
inside the container element through the bottom functional layer
laminate.
[0078] Air communication between the filler structure or material
and the outside of the container element is established through the
at least one opening, which extends through the side wall of the
container element, such that water vapour can pass to the outside
of the container element together with the air flow out of the
container element. The at least one opening may also extend through
the filler structure or material insofar that air flow from the
filler structure or material to the outside of the container
element is established. The container element may also be provided
with openings in its bottom part.
[0079] It is pointed out that the side wall and/or bottom part of
the container element does not have to be load bearing and/or be a
structurally crucial part, but can also merely serve as a border
structure between the inside and the outside of the container
element in order to help a functional separation of the individual
components and the manufacturing of the shoe.
[0080] The ventilating sole element may be the container element
filled with the air flow permitting material or structure. In this
case, the side wall of the ventilating sole element may be formed
by the side wall of the container element and the surrounding sole
element surrounding the ventilating sole element.
[0081] In a separate embodiment the structure or material allowing
for air flow through it may be inherently stable, such that no
container element may be necessary to support this structure or
material. It may be directly attached to the bottom of the upper
assembly. It may also be wrapped at least on its lateral surface
with a tape, which may be attached to the upper assembly, e.g. by
sewing or gluing. The tape may serve the purpose of preventing
surrounding sole material or outer sole material from entering the
open structure during injection or else may prevent other fluid
material from entering which is used to connect the structure or
material to the upper assembly.
[0082] According to a further embodiment, said side end area of
said bottom functional layer laminate is attached by a sewn seam to
said lower end area of said upper functional layer laminate. Said
seam may be sealed by sealing adhesive, the application of a
waterproof seam tape or by fluid material of the surrounding sole
element having penetrated into and around said sewn seam during
injection moulding of the surrounding sole. The penetrated
surrounding sole material, i.e. the penetrated material of the
surrounding sole element, allows for a tight sealing between the
two laminates and for the provision of a waterproof upper
assembly.
[0083] In a further embodiment, said ventilating sole element is
positioned below said bottom portion of the upper assembly, such
that an upper perimeter of said ventilating sole element is located
within said bond, in particular within said sewn seam. In other
words the ventilating sole element is placed some distance away
from the bond towards the middle of the shoe. In particular, said
upper perimeter may have a minimum distance from said sewn seam,
particularly 1 mm to 4 mm, more particularly 2 mm to 3 mm. In this
way, the surrounding sole material may penetrate freely into and
around the sewn seam. The injected or moulded on surrounding sole
material reaches the bond between the functional layer laminates
and seals it. The ventilating sole element may be attached to the
bottom portion of the upper assembly before said surrounding sole
material is applied.
[0084] According to a further embodiment, a lower portion of said
breathable outer material allows for penetration of surrounding
sole material therethrough, said waterproof seal being formed at
least partially by surrounding sole material having penetrated
through said lower portion of said breathable outer material to
said upper functional layer laminate, said bottom functional layer
laminate and said sewn seam. The surrounding sole element seals the
upper assembly. It accounts for a waterproof seal between the upper
portion and the bottom portion of the upper assembly.
[0085] According to a further embodiment, said lower portion of
said breathable outer material comprises a netband, with the side
end area of said bottom functional layer laminate being attached by
said sewn seam to said netband, particularly to a lower end area of
said netband, and to said lower end area of said upper functional
layer laminate, with said surrounding sole material having
penetrated through said seam. The netband provides a highly
efficient way of ensuring a high level of sole material penetration
to the sewn seam. The netband may be positioned substantially only
horizontally at the underside of the upper assembly or
substantially only vertically at the side portions of the upper
assembly. It may also be positioned partly horizontally and partly
vertically, wrapping around the corner region of the upper assembly
between the underside and the side portions. The netband and the
remaining end of the breathable outer material may be positioned
end-to-end or may have an overlap or may both be folded over at the
connection point. Accordingly, the netband may also in part be
positioned laterally to the remainder of the breathable outer
material.
[0086] According to a further embodiment, said surrounding sole
element is formed by a material moulded or injected on at least
parts of a lower portion of said upper assembly and onto said
lateral surface of said ventilating sole element. In this way, the
upper assembly and the ventilating sole element are permanently
fixed with respect to each other. In exemplary embodiments, the
provision of the surrounding sole element may be achieved in one of
the following two manners. In the first alternative, a first
injection-moulding step provides for a localized application of
surrounding sole material onto the upper assembly and the
ventilating sole element resulting in an attachment of the two
components. This first injection-moulding step may also provide for
the sealing between the upper functional layer laminate and the
bottom functional layer laminate, as described above. The
surrounding sole element may be completed in a second
injection-moulding step, which also provides for the sealing if the
sealing has not been achieved in the first injection-moulding step.
In the second alternative, only one injection-moulding step is
performed, through which the attachment between the upper assembly
and the ventilating sole element, the sealing between the upper
functional layer laminate and the bottom functional layer laminate
and the forming of the entire surrounding sole element is achieved.
The surrounding sole element may therefore perform three functions,
namely attaching the ventilating sole element to the upper
assembly, ensuring airflow through the provision of the at least
one lateral passage, and sealing the connection region between the
upper portion and the bottom portion of the upper assembly.
[0087] According to a further embodiment, said ventilating sole
element is glued to said upper assembly in a breathable way.
[0088] According to a further embodiment, said bottom functional
layer laminate is a two layer laminate comprising an upper
supporting textile layer and a lower breathable and waterproof
functional layer, also referred to as bottom membrane or lower
membrane. This embodiment is preferable for use in shoes with
injected soles. The injected material may penetrate directly onto
the lower membrane.
[0089] According to a further embodiment, said bottom functional
layer laminate is a two layer laminate comprising an upper
breathable and waterproof functional layer, and a lower supporting
textile layer. This embodiment is preferable for use in shoes with
cemented/glued soles.
[0090] According to a further embodiment, said ventilating sole
element comprises a circular lip protruding from said ventilating
sole element. According to a further embodiment, said ventilating
sole element comprises a circular lip arranged in the vicinity of
an upper circumferential edge of said ventilating sole element,
said circular lip protruding in a direction between and including
upwards, that is vertical, and laterally outwards, that is
horizontal, from said ventilating sole element. The circular lip
provides a means for attaching the (inner) ventilating sole element
to the upper assembly. Such attachment gives advantages during
manufacturing of the shoe because the upper assembly and the
(inner) ventilating sole element can be handled as a unit which is
easily transported from one manufacturfing station to the next
inside the factory. Additionally/alternatively, the circular lip
provides a barrier against surrounding sole material, such that
said surrounding sole material may be kept to the desired
locations, for example during injection-moulding of the surrounding
sole element.
[0091] In a further embodiment, said ventilating sole element
comprises lip sections. These lip sections may be provided for a
portion-wise attachment and/or sealing. The lip sections may be
positioned on the ventilating sole element as discussed above with
regard to the circular lip. In a particular embodiment, said
ventilating sole element comprises a first lip section in the
vicinity of an upper circumferential edge in a heel area and a
second lip section in the vicinity of an upper circumferential edge
in a forefoot area. Said first and second lip sections may extend
vertically upwards from an upper surface of said ventilating sole
element.
[0092] In a particular embodiment, the circular lip/the lip
sections may be provided on the upper surface of the ventilating
sole element, in particular in a position spaced from the lateral
edge of the ventilating sole element. This spacing between lateral
edge and the circular lip/lip portions allows for a penetration of
surrounding sole material around the upper lateral edge of the
ventilating sole element. In embodiments where the upper lateral
edge is aligned with the bond between the upper functional layer
laminate and the bottom functional layer laminate, the surrounding
sole material may still penetrate around said bond and provide for
an effective seal covering respective portions of both laminates.
The spacing may be in the range of 1 to 5 mm, more particularly in
the range of 2 to 3 mm. The height of the circular lip/lip sections
may be between 0.5 and 3 mm, particularly around 1 mm.
[0093] In a further embodiment, the circular lip may be stitched to
a lower portion of said upper assembly, particularly in a strobeled
or zig-zag fashion. The circular lip may also be glued or attached
via an injection-moulded material to a lower portion of said upper
assembly.
[0094] In an exemplary embodiment where the ventilating sole
element comprises a circular lip, the circular lip may be attached
to the upper assembly in a first injection-moulding step, with the
first injection-moulding step also sealing the connection between
the upper functional layer laminate and the bottom functional layer
laminate. The surrounding sole element having at least one lateral
passage may then be formed in a second injection-moulding step.
[0095] According to a further embodiment, said bottom functional
layer laminate is provided with supporting members, particularly
dots or knobs, at its underside. The dots ensure that the
functional layer of the bottom functional layer laminate does not
come to lie directly on top of the sole or a sole element, in
particular the ventilating sole element, which is arranged below
the bottom functional layer laminate. The dots lie on top of the
sole element and ensure maintaining a distance between the sole
element and the bottom functional layer laminate. The dots enhance
the grip between the bottom functional layer laminate and the sole
element underneath. The dots may be arranged in a particular
pattern or grid that is matched to the sole element and prevents
the bottom functional layer laminate from being displaced during
use. The dots may also be shaped and distributed over the underside
of the bottom functional layer laminate in an arbitrary fashion.
Moreover, the dots may compensate for a potentially uneven surface
of the sole element. They may prevent edges/recesses in the sole
element from pushing through the bottom functional layer laminate,
such that the wearer's comfort is enhanced. In embodiments where
the sole element, i.e. the (inner) ventilating sole element,
comprises a channel structure, a suitable arrangement of the dots
prevents a forcing of the bottom functional layer laminate into the
channels of the channel structure during use. Moreover, the dots
and the channel structure may form a functional unit in such a way
that the dots assist in the air exchange in the channel structure
below the dots. In a particular embodiment, the pattern of the dots
may at least partially correspond to the channel system of the
(inner) ventilating sole element, such that water vapour discharge
from the inside of the shoe to the channel system is maximized.
[0096] Particularly, there may be provided a plurality of discrete
abrasion-resisting polymeric dots forming a discontinuous
lining-forming pattern on the surface of said bottom functional
layer laminate. In a particular embodiment, the polymeric dots have
a smooth, rounded, non-angular external surface. The may be
substantially circular in plan view and partspherical in
cross-section. This contributes to providing a smooth and
comfortable feel of the shoe to the wearer. The dots may be
arranged in a repeat regular pattern, such as in a plurality of
parallel rows, or in a random pattern. In a particular embodiment,
the polymeric dots cover 20-80% of the area of the bottom
functional layer laminate, more particularly 30-70% and even more
particularly 40-60%.
[0097] In a particular embodiment, each dot is preferably of a
maximum cross-dimension or width in the plane of the substrate
which is less than 5000 microns, for example in the range of 100 to
1000 microns, preferably 200-800, particularly 400-600 microns. The
dots may be spaced apart centre-to-centre by 200-2000 microns,
particularly 300-1500, especially 400-900 microns. Each dot may
have a height in the range of 10-200 microns, preferably 70-140,
particularly 80-100 microns.
[0098] According to a further embodiment, a water vapour permeable
comfort layer is provided on top of at least parts of said
ventilating sole element. Particularly, the comfort layer may be
provided on top of the ventilating sole element. The comfort layer
may have a larger lateral extension than the ventilating sole
element, particularly projecting between 0.5 mm and 2 mm over the
ventilating sole element, more particularly projecting
approximately 1 mm over the ventilating sole element. It is also
possible that the comfort layer is provided only on top of the
filler structure or material described above. The comfort layer may
be provided to compensate for an uneven upper surface of the
ventilating sole element. As a structure or material allowing for
air flow through it, the ventilating sole element may have a
heterogeneous or jagged structure. In particular, a channel system
or channel grid may cause alternating portions of voids and sole
material of the ventilating sole element. The comfort layer allows
for the discomfort potentially caused to the wearer of the shoe by
these inhomogeneous portions to be greatly reduced or prevented.
The water vapour permeable comfort layer may be of any suitable
material that provides a highly comfortable feel to the wearer and
that is able to withstand the loads and forces applied thereto
during use. Exemplary materials are open cell polyurethanes. For
example, the material may be POLISPORT (trademark) from company Jin
Cheng Plastic, China. According to an embodiment, before assembling
the comfort layer on the ventilating sole element, mechanical
pressure is applied to the material of the comfort layer, which is
pressed, e.g., from 2 mm to 1 mm in thickness. This may be done to
make the material more compact and hence to lower the amount of
water absorbed. This advantageously prevents the material to act as
sponge which nurtures growth of fungus and the like.
[0099] The water vapour permeable comfort layer may be attached to
the top of said ventilating sole element, in particular by spotwise
or circumferential gluing or by gluing across the entire surface
with a breathable glue. Enhanced air flow characteristics in the
(inner) ventilating sole element may be achieved by spotwise gluing
or gluing across the entire surface, as channels enclosed at their
upper side may be formed.
[0100] According to a further embodiment, said comfort layer has an
upper side and a lower side, where the upper side is facing the
bottom portion of the upper assembly, and the lower side is facing
the ventilating sole element, the lower side being flexurally rigid
or stiff and the upper side being soft. The lower stiff side can be
made of a woven or non woven fabric and the upper side of any
smooth and soft material, for example a non-woven or a foamed
polyurethane. The comfort layer may consist of two discrete layers.
With the lower layer being comparably stiff or hard, the comfort
layer may be prevented from being pressed into the channel
structure of the ventilating sole element more than 1 mm. Stiffness
or flexural rigidity is defined e.g. in German DIN Norm 53864 with
respect to textiles. In this way, the comfort layer characteristics
are preserved as desired, with the comfort layer being very durable
during use of the shoe. The soft upper layer may provide for a very
comfortable feel of the sole for the wearer's foot. In an
embodiment of the invention the soft upper layer has a smooth
surface with the difference between peaks and valleys of no more
than 0.1 mm.
[0101] In a particular embodiment, both the upper layer and the
lower layer of the comfort layer are made of polyester. The upper
and lower layers may be joined via a hot melt adhesive. In a
particular embodiment, the material properties of the upper layer
and the lower layer as as follows. The stiff lower layer has the
following properties: a tensile strength in the lengthwise
direction between 400 N/5 cm and 700 N/5 cm (UNI EN 29073/3),
particularly between 500 N/5 cm and 600 N/5 cm; and a tensile
strength in the crosswise direction between 500 N/5 cm and 800 N/5
cm (UNI EN 29073/3), particularly between 600 N/5 cm and 700 N/5
cm. The soft upper layer has the following properties: a tensile
strength in the lengthwise and the crosswise direction between 50
N/5 cm and 200 N/5 cm (UNI EN 29073/3), particularly between 100
N/5 cm and 150 N/5 cm.
[0102] In a further embodiment the comfort layer has a thickness of
less than or equal to 2.0 mm, a water absorption of <45% by
weight and an MVTR (Moisture Vapour Transmission Rate) of >5000
g/m2/24 h, preferably about 8000 g/qm/24 h. In an embodiment a
functional layer or membrane may be attached to the ventilating
sole element above the comfort layer. The combination of comfort
layer and membrane has an MVTR>2000 g/m2/24 h, preferably about
4500 g/m2/24 h. MVTR was measured according to the potassium
acetate test described in DIN EN ISO 15496.
[0103] A comfort layer as described in the paragraphs above may be
used in any kind of sole or shoe construction, not limited to the
constructions described herein. In particular, the invention also
generally proposes the provision of such a comfort layer in a shoe
or shoe sole construction. This aspect is to be seen and may be
applied independently from the other aspects as described herein.
Accordingly, this aspect and its embodiments may form a separate
part of the invention claimed independently from other aspects
described herein.
[0104] According to a further embodiment, the underside of said
ventilating sole element forms at least a part of an outer sole.
Particularly, the undersides of said surrounding sole element and
said ventilating sole element may form at least a part of an outer
sole. This outer sole may or may not have a tread. The underside of
said ventilating sole element may be arranged at a higher position
as compared to the underside of said surrounding sole element. So
in this case, although both the ventilating sole element and the
surrounding sole element form a part of the outer sole, only the
surrounding sole element part of this outer sole touches the
ground.
[0105] According to a further embodiment, the surrounding sole
element consists of a first polyurethane and the ventilating sole
element consists of a second polyurethane, the second polyurethane
being softer than the first polyurethane. Particularly, said second
polyurethane may have a Shore A value of 35-45. In this way, the
ventilating sole element may not be too hard and provides good
shock absorption properties. It is also possible that the
surrounding sole element and the ventilating sole element consist
of the same polyurethane, but that they are produced in separate
manufacturing steps. Shore hardness is measured by the durometer
test. A force is applied onto a spot of the polyurethane, whereby
the force creates an indentation. The time taken for the
indentation to disappear is then measured.
[0106] According to a further embodiment, an additional sole
element is provided forming at least a part of an outer sole, said
additional sole element being arranged below said ventilating sole
element. Portions of said additional sole element may also be
arranged laterally outside of the container element. The additional
sole element is not necessarily arranged directly adjacent to the
ventilating sole element.
[0107] According to a further embodiment, supporting members are
formed in portions of said additional sole element below said
ventilating sole element, said supporting members extending
substantially vertically through said additional sole element.
[0108] According to a further embodiment, a sole comfort layer is
provided. In particular, the sole comfort layer may be provided in
the form of an additional sole layer arranged above the outer sole.
More particularly, the sole comfort layer may be arranged between
the ventilating sole element and the additional sole element
forming at least a part of an outer sole. The sole comfort layer
does not necessarily extend over the whole lateral extension of the
sole.
[0109] According to a further embodiment, said surrounding sole
element extends below said ventilating sole element. Particularly,
said surrounding sole element may form at least a part of an outer
sole. It is possible that an additional sole element is arranged
under said surrounding sole element, thus forming an outer sole
element. The additional sole element is not necessarily arranged
directly adjacent to the surrounding sole element. For example, a
further layer, such as an additional sole comfort layer, may be
positioned in between.
[0110] According to a further embodiment, supporting members are
formed in portions of said surrounding sole element below said
ventilating sole element, said supporting members extending
substantially vertically through said surrounding sole element.
Supporting members may also be formed in any other element or layer
arranged below said ventilating sole element.
[0111] According to a further embodiment, at least one hollow
insert is provided in the at least one lateral passage. The at
least one hollow insert may be removable. It may have a covering
with an opening in it, such as an insert head with a hole in its
centre. It is also possible that at least one removable solid
insert is provided in the at least one lateral passage.
Alternatively, a partially hollow insert may have a solid
covering/head.
[0112] According to a further embodiment, a breathable inner sole
or footbed is removably provided above the bottom functional layer
laminate, i.e, between the wearer's foot and the top of the bottom
functional layer laminate during use of the shoe or between the
wearer's foot and an insole. The inner sole may account for a
better adaptation of the shoe to the wearer's foot and may
therefore increase the wearer's comfort. Such an inner sole may be
made of leather, fibre, polyurethane, etc. Perforations in these
materials may ensure the necessary breathability. However, the
inner sole may also be made of a material which is breathable per
se.
[0113] According to a further embodiment, the ventilating sole
element may be glued to the upper assembly. It is also possible
that the ventilating sole element is attached to the upper assembly
through injection-moulding, in particular through the application
of an injection-moulded surrounding connection element.
[0114] According to a further embodiment, the step of providing the
upper assembly comprises providing said upper portion of said upper
assembly with a waterproof, breathable upper functional layer
laminate having a lower end area, providing said bottom portion of
said upper assembly with a waterproof, breathable bottom functional
layer laminate having a side end area, joining said side end area
of said bottom functional layer laminate to said lower end area of
said upper functional layer laminate, and providing a waterproof
seal between said bottom functional layer laminate and said upper
functional layer laminate.
[0115] According to a further embodiment, the opening(s) in the
ventilating sole element is at least partly created by lasering or
drilling or puncturing or otherwise thermally removing (melting
away) some material so as to form a passage. The at least one
lateral passage is formed during injection-moulding by providing
the mould with respective pins for forming the at least one lateral
passage. Lasering provides for extremely accurate results, while
drilling and puncturing can be performed more cheaply.
[0116] The methods for manufacturing a breathable shoe or sole
assembly may be modified corresponding to the modifications
discussed above with respect to the breathable shoe. In other
words, manufacturing steps corresponding to additional shoe
elements/features may be included in the methods for manufacturing
a breathable shoe or sole assembly. It is explicitly pointed out
that the steps of attaching, given for the methods in accordance
with above aspects of the invention, may be the only steps of
attachment. It is, however, also possible that additional
attachments between the given elements are present.
[0117] According to another aspect, the invention also generally
proposes the use of a laser for creating openings in an element of
a shoe, particularly a shoe sole or removing shoe sole material.
This aspect is to be seen and may be applied independently from the
other aspects as described herein before, particularly
independently from a method for manufacturing a shoe or sole
assembly using a ventilating sole element as described herein
before.
[0118] Accordingly, this aspect in connection with the following
embodiments may form a separate part of the invention claimed
independently from other aspects described herein.
[0119] Particularly, according to an embodiment there is provided a
method for making openings in an element of a shoe, particularly a
shoe sole, characterized in that a robot is adapted to hold the
element, such as the sole or part thereof, in front of a laser
apparatus and that the laser apparatus through a series of
repetitive shots at the element (e.g., sole or part thereof) burns
away material of the element for making at least one opening or a
design in the element. The at least one opening may have a length
of between approx. 0.5 to 50 mm. The opening may be formed as an
air channel or guide for supporting an air flow therein from one
end of the opening to the other.
[0120] For such use, different types of lasers can be used as,
e.g., diode lasers, infrared lasers and CO2 lasers. In the
following an embodiment of the invention will be described which
makes use of a CO2 laser. CO2 lasers work with a wave length in the
range of 9.4-10.6 micrometers. Usually, a laser is controlled by
way of three parameters, such as speed (of the beam), quantity of
energy and wavelength.
[0121] Making openings or patterns with a laser, particularly a CO2
laser, is possible in elastomeric, i.e. meltable materials such as
polyurethane (PU), thermoplastic polyurethane (TPU), ethylene vinyl
chloride (EVA), polyvinyl chloride (PVC) or rubber. In these
materials the laser will, using a sufficient amount of energy, burn
away the targeted sole material which will disappear without
leaving debris.
[0122] Use of a laser for roughening of a shoe upper is described
in DE 10 2009 049 776 A1.
[0123] When roughing shoe uppers of leather, techniques exist
according to which the laser beam is swept across the surface of
the upper in a predetermined time and with a predetermined amount
of energy. The beam is swept by a mirror in the laser apparatus
that deflect the laser beam in order to reach the surface of the
shoe to be roughened while the robot holds the shoe upper in a
fixed position during sweeping of the beam. The robot places the
shoe in front of the laser and then the mirrors move the beam
through the leather. During this process the robot is stopped. If
the curvature of the shoe upper becomes too great, i.e. if the
focus point of the laser beam is removed too much from the targeted
spot, the shoe upper is repositioned anew by the robot. After
repositioning, the new target spot is again in focus, and the laser
sweeps across one or more spots.
[0124] A problem occurs, however, when deep openings in a
(elastomeric) sole or element thereof shall be made. Such openings
have a depth which is by far larger than the relatively shallow
roughing made on leather uppers by the laser. For example, a
lasered channel in a leather upper has a depth of 0.5 mm, whereas
an opening in the sole may extend from the medial side of the sole
to the lateral side, i.e. has a length of 50 mm. If the
mirror-solution, which is used for roughing of the upper, with
deflecting the laser beam is used for making openings in an element
of a shoe, a problem may occur in opening any borders, such as the
side wall of the ventilating sole element which may need to be
provided with deep and narrow channels.
[0125] When using the mirror-solution the deflection of the beam
may create an acute angle between the beam itself and the surface
of the element. When applied for connecting narrow and elongated
channels of the lateral passages of the surrounding sole element to
the structure or material of the ventilating sole element, such
acute angle drives the beam sideways into the channel side wall of
the lateral passages and it does not reach the bottom thereof
facing the ventilating sole element.
[0126] On the other hand, according to the invention, the opening
is made in the element of the shoe or sole, such as in the side
wall of the ventilating sole element, by keeping the beam of the
laser in a fixed direction (i.e. no sweeping of the laser beam) and
letting the robot position the target spot of the element aligned
with the center of the laser lens. This means that the laser beam
will not be swept as when roughening a shoe upper. Instead we only
move the robot arm holding the sole. However, there may be
applications in which a mirror may be used when making openings in
an element of a sole.
[0127] This method is thus especially useful if the laser beam
shall be shot through a cylindrical passage already present in the
sole as is the case if e.g. the end of a passage in a sole, such as
in the surrounding sole element, has to be opened.
[0128] According to an example a number of openings shall be made
in a polyurethane sole. The sole material is Elastollan.TM. from
manufacturer Elastogran GmbH. Elastollan has a relatively low
density (0.35 g/cm.sup.3) and is often used for shoe midsoles. The
following steps may be applied in various ways, in combination or
individually depending on the particular implementation and needs.
The terms "first, second . . . " are used only for designation
purposes and shall not impose any limitations as to sequence or
numbers of steps.
(1) In a first step a sole is placed in front of the laser by a
robot. (2) In a second step the target spot on the sole or element
thereof is placed orthogonally to the laser beam by the robot. (3)
In a third step the laser beam hits the sole material at an angle
to the sole (element) surface of approximately 90 degrees. (4) In a
fourth step the focus of the laser is kept constant, i.e.
unchanged. (5) In a fifth step a series of laser shots towards the
target spot is performed (e.g., multiple shots in the same place).
The number of shots may be between 1 and 10 depending on the power
of the laser and material and depth of entry. Duration per shot may
be approx. 1 ms.
[0129] When applied for connecting the lateral passages of the
surrounding sole element to the structure or material of the
ventilating sole element, the laser shots may result in a diameter
of the openings in the side side wall of the ventilating sole
element which equals the diameter of the passages made by the pins
in the surrounding sole element during injection. In order to get
the desired diameter the number of shots can be varied as can the
relative position of the shots. During a shot cycle the target can
be moved a few millimeters (e.g., the robot moves), and the
diameter will increase. In a further step, the robot moves the sole
to the next target spot, i.e. the process goes to the second step
(2) above.
[0130] In relation to the ventilating sole element, the opening of
the side wall of the ventilating sole element with laser leaves no
debris. Everything is burned away. Hereby any clogging of the air
channels caused during manufacturing of the openings is prevented.
The method further has the advantage that it is very fast compared
to drilling out the openings.
[0131] In the following, particular embodiments and/or variations
of the process making use of a laser for creating openings in a
shoe sole are described:
[0132] In order to get a cylindrical opening with a clean edge the
amount of energy per shot may be increased. The focus point may be
kept constant. The first laser shots start with a low energy for
making a first opening with a diameter of say 2 mm. The next series
of shots has an energy increase of 50% per shot. The opening now
has a diameter of 4 mm. The third series of shots has again an
increase of energy by 50%, increasing the diameter at the beginning
of the opening to 6 mm.
[0133] Alternatively, or simultaneously, the point of focus of the
laser beam can be amended per shot or per series of shots. After a
first series of shots the depth of the opening may be 3 mm. Now the
focus has to be changed and moved 3 mm further inwards in the
sole.
[0134] Change of focus is made via software which controls the
movement of the lenses in the laser apparatus.
[0135] Further, in order to ensure a well defined opening with a
well defined edge, the laser beam can be moved in a spiral shape.
Such spiral shape can be elliptical or circular. This functions the
following way: [0136] A first series of shots in the centre of the
target spot. [0137] The next series of shots in a neighbouring
spot. [0138] And continuing in a spiral shape until an opening with
the desired shape is achieved.
[0139] Ideally, in order to create a clean cut in a polyurethane
sole, the diameter of the point of focus (spot size) may be between
0.5 mm and 2 mm and the power between 150 watt and 250 watt. It
should be noted that these values are to be understood as pure
examples without imposing any limitations in connection with the
invention.
[0140] The combination of a robot and laser is considered part of
this aspect of the invention because something is needed to
position precisely the channels in front of a laser. The robot is
one of the preferred solutions because the openings are always in
different positions--for instance, the position of a shoe with size
40 is different of the same shoe in size 41. A shoe sole is
characterized by 3D-curvatures. It is not only a 2D surface, and
therefore the focus point of the laser beam is changed along the 3D
surface of the sole.
[0141] Aspects of the invention and further embodiments thereof are
disclosed in the following description with reference to the
drawings, in which:
[0142] FIG. 1 is an exploded three-dimensional view of the main
components of a shoe in accordance with a first embodiment of the
invention.
[0143] FIG. 2a is a schematic cross-sectional view of a shoe in
accordance with a second embodiment of the invention.
[0144] FIG. 2b is a schematic cross-sectional view of a shoe in
accordance with a third embodiment of the invention.
[0145] FIG. 2c is a schematic cross-sectional view of a shoe in
accordance with a fourth embodiment of the invention.
[0146] FIG. 2d is a schematic cross-sectional view of a shoe in
accordance with a fifth embodiment of the invention.
[0147] FIG. 3a is a schematic cross-sectional view of a shoe in
accordance with a sixth embodiment of the invention.
[0148] FIG. 3b is a schematic cross-sectional view of a shoe in
accordance with a seventh embodiment of the invention.
[0149] FIG. 3c is a schematic cross-sectional view of a shoe in
accordance with an eighth embodiment of the invention.
[0150] FIG. 3d is a schematic cross-sectional view of a shoe in
accordance with a ninth embodiment of the invention.
[0151] FIG. 3e is a schematic cross-sectional view of a shoe in
accordance with a tenth embodiment of the invention.
[0152] FIG. 3f is a schematic cross-sectional view of a sole in
accordance with the eighth embodiment of the invention.
[0153] FIG. 4a is a schematic cross-sectional view of a shoe in
accordance with an eleventh embodiment of the invention.
[0154] FIG. 4b is a schematic cross-sectional view of a shoe in
accordance with a twelfth embodiment of the invention.
[0155] FIG. 5 is a schematic cross-sectional view of a shoe in
accordance with a thirteenth embodiment of the invention.
[0156] FIG. 6a is a schematic cross-sectional view of a shoe in
accordance with a fourteenth embodiment of the invention.
[0157] FIG. 6b is a schematic cross-sectional view of a shoe in
accordance with a fifteenth embodiment of the invention.
[0158] FIG. 6c is a schematic cross-sectional view of a shoe in
accordance with a sixteenth embodiment of the invention.
[0159] FIG. 7 is a schematic cross-sectional view of a shoe in
accordance with a seventeenth embodiment of the invention.
[0160] FIG. 8 is a schematic cross-sectional view of a shoe in
accordance with a twentieth embodiment of the invention.
[0161] FIG. 9a-c show an embodiment of a mould and of a
semimanufactured product formed in the process of manufacturing a
shoe in accordance with aspects of the present invention, the
semimanufactured product comprising an exemplary outsole and
ventilating sole element attached to the outsole,
[0162] FIG. 10 shows a semimanufactured product of FIG. 9 in a
process step with a comfort layer disposed on the ventilating sole
element,
[0163] FIG. 11 shows the semimanufactured product of FIG. 10 placed
in a mould for injection moulding prior to the moulding step,
[0164] FIG. 12 shows a process step in which the upper portion of
the shoe placed on a last is positioned to contact the ventilating
sole element in the mould prior to the moulding step,
[0165] FIG. 13 shows an example of a drilling apparatus, which may
be used to interconnect the lateral passages in the surrounding
sole element and the ventilating sole element,
[0166] FIG. 14 shows an example of a finished shoe with lateral
passages formed in the surrounding sole element
[0167] In the following, exemplary embodiments of a shoe in
accordance with principles of the invention will be described. The
skilled person will be aware that various changes or adaptations
may be made as far as appropriate and depending on the particular
needs of the respective shoe construction.
[0168] FIG. 1 shows an exploded three-dimensional view of the main
components of a shoe 300 according to an embodiment of the
invention. The shoe 300 comprises a sole assembly 7 and an upper
assembly 8. The sole assembly 7 in turn comprises, from bottom to
top in the exploded view, an outsole 90, a shank 172, a ventilating
sole element 60, a comfort layer 40, and a surrounding sole element
80.
[0169] The primary purpose of FIG. 1 is to provide context for the
following Figures. The position of a vertical plane including
horizontal line Y-Y corresponds to the positions of the
cross-sectional planes depicted in the following Figures. It is
pointed out that the embodiments of the following Figures are
different from the shoe 300, but that the position and viewing
direction of the respectively depicted vertical cross-sectional
planes can be inferred from the line Y-Y and the associated arrows,
which represent the viewing direction.
[0170] The outsole 90 comprises a tread or corrugated structure on
its lower surface for improving the grip characteristics of the
shoe during walking. The shank 172 is provided in the shoe 300 to
give it additional stability. The shank 172 may be made of metal or
any other suitable material. Due to the illustrative nature of FIG.
1, the shank 172 is shown as a separate element. However, in most
embodiments, the shank 172 is positioned within the ventilating
sole element 60. It is pointed out that the shank 172 is an
optional component, which is not shown in most embodiments.
[0171] The ventilating sole element 60 comprises a channel
structure, in particular a channel grid, at its upper side. The
channel structure comprises transverse channels, generally
designated with reference numeral 181. Channels 184 cross the
transverse channels 181.
[0172] A distinction is made between at least one peripheral
channel being formed in a peripheral region of the channel
structure and longitudinal channels. For the sake of simplicity in
describing different shoe constructions by presenting
cross-sectional views in FIGS. 2 to 10, the channels 184 are
generally referred to as longitudinal channels, although one or
more of the channel cross-sections shown may belong to one or more
peripheral channels.
[0173] The ventilating sole element 60 has an upper surface 606, a
lower surface 604 and a lateral surface 602. In an assembled state
of the shoe 300, the lower surface 604 of the ventilating sole
element 60 is partly adjacent the shank 172 and partly adjacent the
outsole 90, the upper surface 606 of the ventilating sole element
60 is adjacent the comfort layer 40, and the lateral surface 602 of
the ventilating sole element 60 is adjacent a lateral inner surface
802 of the surrounding sole element 80. Regarding the
engagement/connection of the individual components, more details
are given below.
[0174] The channel structure, in particular the transverse channels
181, is in air communication with a plurality of openings 55. The
openings 55 extend through a side wall of the ventilating sole
element 60, particularly they extend from the channel structure of
the ventilating sole element 60 to lateral passages 50 of the
surrounding sole element 80.
[0175] The surrounding sole element 80 has a varying height across
its circumference, with the lateral passages being arranged at
different heights. In this way, the positions of the lateral
passages account for the uneven surface structure of the
ventilating sole element 60, which takes into account the wearer's
foot and its positioning during walking. Exemplary embodiments of
the components are described in greater detail below.
[0176] FIG. 2a is a schematic cross-sectional view of a shoe 301a
in accordance with an embodiment of the invention. FIGS. 2 to 8 are
in particular schematic in that they show a u-shaped shoe portion.
It is apparent to a person skilled in the art that the shoe is
closed on top, in particular in a forefoot region.
[0177] The shoe 301a comprises an upper assembly 8 and a sole
assembly 7. The upper assembly 8 has an upper portion 10 and a
bottom portion 20. The upper portion 10 comprises, from outside to
inside, a breathable outer material 11, also referred to as upper
material, a mesh 12, an upper membrane 13, and a textile lining 14.
The mesh 12, the upper membrane 13 and the textile lining 14 are
provided as a laminate, also referred to as upper functional layer
laminate 17. The upper membrane 13 is breathable and waterproof.
With all of the upper material 11, the mesh 12 and the textile
lining 14 being breathable, i.e. water vapour permeable, the upper
portion 10 as a whole is breathable and waterproof.
[0178] The upper material 11 may be any breathable material
suitable for forming the outside of a shoe, such as leather, suede,
textile or man made fabrics, etc.
[0179] The upper functional layer laminate (i.e. mesh 12, upper
membrane 13 and textile lining 14) may be any suitable waterproof
and breathable laminate, such as commercially available
GORE-TEX.RTM. laminate from W.L. Gore & Associates.
[0180] A lower portion of the outer material 11 is comprised of a
netband 15. The netband 15 may be attached to the remainder of the
outer material 11 through any suitable way of connection, for
example stitching or gluing. In the exemplary embodiment of FIG.
2a, the netband 15 is attached to the remainder of the outer
material 11 via stitching 16, as illustrated by a connecting line.
As the term netband suggests, this portion of the outer material is
not a continuous material, but comprises voids in the material that
allow for the penetration of fluid sole material therethrough, as
will be explained later. Instead of providing a netband, the lower
portion may also be comprised of the same material as the remainder
of the outer material, with the voids being generated by puncturing
or perforating the outer material in the lower portion.
[0181] The bottom portion 20 comprises, from bottom to top, a lower
membrane 21 and a supporting textile 22. The textile may be a
woven, non-woven or knitted textile, for example Cambrelle.RTM..
The lower membrane 21 and the supporting textile 22 are provided as
a laminate, also referred to as bottom functional layer laminate
24. The lower membrane 21 is waterproof and breathable. With the
supporting textile 22 being breathable, an overall breathable and
waterproof bottom functional layer laminate 24 is provided. The
bottom functional layer laminate 24 may be any suitable laminate,
for example commercially available GORE-TEX.RTM. laminate from W.L.
Gore & Associates.
[0182] The upper portion 10 and the bottom portion 20 are connected
to each other at their respective end areas. Particularly, a lower
end area of the upper functional layer laminate 17 is connected to
a side end area of the bottom functional layer laminate 24. In the
embodiment of FIG. 2a, this connection also connects an end area of
the netband 15 to the upper functional layer laminate 17 and the
bottom functional layer laminate 24. The bottom functional layer
laminate 24, the upper functional layer laminate 17 and the netband
are stitched together, for example by a strobel stitch or a zigzag
stitch. Accordingly, a connection 30, also referred to as bond 30,
in the form of a sewn or stitched seam is formed connecting the
bottom functional layer laminate 24, the outer material 11 (via the
netband 15) and the upper functional layer laminate 17. This seam
30 is sealed in a waterproof manner by sole material, as will be
explained later, such that a waterproof structure is formed by the
upper portion 10 and the bottom portion 20.
[0183] The upper functional layer laminate 17 and the bottom
functional layer laminate 24 may be positioned end-to-end before
being connected and sealed together, as shown in FIG. 2a.
[0184] Both laminates may also be bent downwards, such that
respective portions of the upper sides of the laminates are
positioned adjacent each other. In these different positions, the
laminates may be connected, for example through stitching as shown,
and the connection region may be sealed. The netband 15 of the
outer material 11 may be positioned corresponding to the upper
functional layer laminate 17, i.e. in an end-to-end or overlap or
bent relation with respect to the bottom functional layer laminate
24, such that the connection 30 also connects the netband 15 to the
bottom functional layer laminate 24 and the upper functional layer
laminate 17. The netband 15 may also extend through the connection
30, which is uncritical due to its porous structure. These
different options for forming the connection 30 may be applied to
all embodiments described herein.
[0185] In the embodiment of FIG. 2a, the connection 30 between the
upper functional layer laminate 17 and the bottom functional layer
laminate 24 is located at the substantially horizontal portion of
the inside of the shoe 301a, which is intended to support the
underside of the wearer's foot. In the cross-sectional plane of
FIG. 2a, the connection 30 is close to the lateral end of said
substantially horizontal portion, i.e. close to the point where the
portion for supporting the weight of the foot transitions into the
side wall of the shoe. Due to the nature of the shoe 301a, the
bottom functional layer laminate 24 is a substantially foot-shaped
structure, with the upper functional layer laminate 17 being
connected thereto perimetrically. It is pointed out that the terms
horizontal and vertical refer to the horizontal and vertical
directions present when the shoe is placed with the sole on an even
ground. For an easier understanding, the shoes are depicted in that
orientation throughout the Figures.
[0186] The sole or sole assembly 7 of the shoe 301a, i.e. the
portion of the shoe 301a below the upper assembly 8, which consists
of the upper portion 10 and the bottom portion 20, is comprised of
a ventilating sole element 61, a comfort layer 40 and a surrounding
sole element 81.
[0187] The ventilating sole element 61 comprises a channel
structure 160 that allows for air communication between the upper
side of the ventilating sole element 61 and openings 55. Lateral
passages 50 extend through a side wall 702 of the surrounding sole
element 81 and the openings 55 extend through a side wall 608 of
the ventilating sole element 61. For an easier reading of the FIGS.
2 to 8, the reference numerals 608 and 702 are provided with
brackets illustrating lateral extensions of the side wall of the
ventilating sole element and side wall of the surrounding sole
element, respectively. It is, however, understood that the
reference numerals 608 and 702 are meant to denote the side wall of
the ventilating sole element and the side wall of the surrounding
sole element themselves. The channel system 160 of the embodiment
of FIG. 2a comprises a plurality of longitudinal channels 184,
arranged in the longitudinal direction of the shoe 301a, and a
plurality of transverse channels 181, arranged in the transverse
direction of the shoe 301a, i.e. in the direction orthogonal to the
longitudinal direction of the shoe.
[0188] The cross-sectional view of FIG. 2a cuts through a
transverse channel 181 of the channel structure 160 along the
horizontal line Y-Y of FIG. 1. Therefore, the transverse channel
181 of the ventilating sole element 61 is not shown in a shaded
manner, as the cross-sectional cut reaches through the open
channel. In contrast thereto, the portions of the ventilating sole
element 61 surrounding the channel structure 160 and the
surrounding sole element 81 are shown in a shaded manner
illustrating that the cross-section of FIG. 2a slices through these
shoe elements in the depicted cross-sectional plane.
Correspondingly, the upper assembly 8 and the comfort layer 40 are
shown in a shaded manner.
[0189] In the cross-sectional view of FIG. 2a, the longitudinal
channels 184 are seen in their cross-sectional shape, which is a
u-shape reaching from the upper surface 606 of the ventilating sole
element 61 some distance towards the lower surface 604 of the
ventilating sole element 61. The transverse channel 181 cut in the
cross-section of FIG. 2a is confined by a surface made of the
portions between the longitudinal channels lying behind the
cross-sectional plane. Accordingly, the transverse channel 181
depicted extends longitudinally behind the cross-sectional plane of
FIG. 2a, with the non-shaded portions of the ventilating sole
element 61, which surround the u-shaped longitudinal channels 184,
forming a trans-verse boundary surface. Only the u-shaped
longitudinal channels 184 form a longitudinal air flow permitting
connection to further transverse channels behind and in front of
the cross-sectional plane of FIG. 2a.
[0190] The u-shape of the longitudinal and transverse channels
allows for a good compromise between providing sufficient channel
volume for fluid communication and providing a strong ventilating
sole element structure for supporting the wearer's foot and
transferring the wearer's weight to the ground and/or the
surrounding sole element 81. Also, the u-shaped channels can be
manufactured easily and quickly, particularly in the case of an
injection-moulded ventilating sole element 61, because the rounded
channel side walls allow for an easy parting of the ventilating
sole element 61 and the mould after the moulding operation.
[0191] It is pointed out that the channels of the ventilating sole
element 61 may have any suitable cross-section that allows for an
efficient transfer of water vapour from the upper side of the
ventilating sole element 61 to the lateral passages 50 in the
surrounding sole element 81. At the same time, the ventilating sole
element 61 should provide a stable structure for the sole of the
shoe. It is also pointed out that the channels may have varying
cross-sections along their length in order to form a channel system
having desired properties.
[0192] The exemplary embodiment of FIG. 2a comprises five
longitudinal channels 184, which are distributed across the width
of the ventilating sole element 61 in a uniform manner. It is also
possible that the longitudinal channels have varying widths and/or
are distributed non-uniformly across the width of the ventilating
sole element 61. Further, it is possible that these channels are at
an angle with respect to the longitudinal direction of the shoe
301a, such that any suitable channel structure 160 may be
formed.
[0193] The transverse channel 181 connects the longitudinal
channels 184 to each other and to the openings 55 and lateral
passages 50 in the surrounding sole element 81. At its lateral
ends, the transverse channel is equipped with air and moisture
discharging ports 182. The air and moisture discharging ports 182
are arranged laterally outside from the laterally outmost
longitudinal channel. In particular, the air and moisture
discharging ports 182 are arranged directly adjacent the side wall
608 of the ventilating sole element 61. The air and moisture
discharging ports 182 are formed by recesses in the floor of the
transverse channels 181. In other words, the floor of the
transverse channels 181 extends deeper down into the ventilating
sole element 61 in the region of the air and moisture discharging
ports 182 than throughout the remainder of the transverse channels
181. The air and moisture discharging ports 182 allow for an
efficient collection of moisture/water vapour from the inside of
the shoe, from where the water vapour can be carried away
effectively through the openings 55 and lateral passages 50. All or
only a subset of the transverse channels may 181 have air and
moisture discharging ports.
[0194] All or only a subset of the transverse channels 181 may
provide for the connection with openings 55 and lateral passages
50. There may also be transverse channels 181 that are not in air
communication with openings 55 and lateral passages 50, but end in
dead ends.
[0195] The transverse channels of the ventilating sole element 61,
one of which is being shown in FIG. 2a, allow for air communication
between the channel system 160 of the ventilating sole element 61
and the openings 55 and lateral passages 50 extending through the
side walls 608 and 702, respectively. With the bottom functional
layer laminate 24 being breathable, water vapour transport from the
inside of the shoe to the lateral outside of the sole 7 is ensured
through the ventilating sole element structure, which allows the
water vapour containing air to pass through it.
[0196] It is pointed out that the transverse channels 181 may have
the same, a smaller or greater height than the longitudinal
channels 184. They may be channels that reach from the top of the
ventilating sole element towards the inside of the ventilating sole
element, such that they can also be seen as grooves or tranches. It
is also possible that the transverse channels lie below a portion
of the ventilating sole element 61 and are therefore not readily
visible from the top of the ventilating sole element 61. Also, the
longitudinal channels may be grooves, as shown, or channels
concealed from the upper surface of the ventilating sole element
61.
[0197] In the present embodiment, the channel system 160 of the
ventilating sole element 61 is a channel grid. The channels of the
channel grid extend from the top of the ventilating sole element 61
to the inside thereof. The channels may be longitudinal channels
184 and transverse channels 181, which intersect for allowing air
communication therebetween. The channels may also be diagonal
channels, when seen from the top of the ventilating sole element.
In general, such a channel grid may have any combination of
longitudinal, transverse and diagonal channels.
[0198] It is pointed out that any channel structure may be embodied
in all other constructions of the remainder of the shoe, in
particular in combination with all other upper assembly
constructions and all other constructions relating to the remainder
of the sole 7.
[0199] The lateral passages 50 extend through the side wall 702 of
the surrounding sole element 81 and the openings 55 extend through
a side wall 608 of the ventilating sole element 61 of the shoe
301a, allowing for air communication between the channel structure
of the ventilating sole element 61 and the lateral outside of the
shoe 301a. In the exemplary embodiment of FIG. 2a, the lateral
passages 50 and openings 55 are depicted as transverse passages and
openings being horizontal. However, the terms lateral passage and
openings may not be understood in such a restricting manner. A
lateral passage or opening may be any passage or opening,
respectively, that allows for an air communication between the
inside of the ventilating sole element and a lateral outside of the
surrounding sole element, i.e. the outside of the surrounding sole
element that is not the underside of the shoe 301. In particular,
the lateral passages 50 and/or openings 55 may be inclined with
respect to the horizontal direction, in particular with the outer
end lower than the inner end of the ventilation passage. This
inclination has the advantage that water can drain out more easily
from the ventilating sole element and surrounding sole element.
However, horizontal lateral passages and openings have the
advantage of providing a favourable path for air or water vapour
flow, particularly if a continuous passage from the right side of
the ventilating sole element to the left side of the ventilating
sole element or vice versa is present. The lateral passages 50
and/or openings 55 may also be inclined with the outer end being
higher than the inner end of the ventilation passage. This allows
for creating the openings, for example through drilling or by laser
operation, without any danger of damaging the delicate membrane 21
of the bottom functional layer laminate 24. Moreover, water vapour,
which is warm due to the wearer's body temperature, may effectively
exit the ventilating sole element through such inclined lateral
passages in a chimney-like manner. When viewed from the top of the
ventilating and surrounding sole element, the lateral passages 50
may be in a longitudinal direction of the shoe, in a transverse
direction of the shoe, or in any direction therebetween. For
example, in the front or the back of the shoe, the ventilation
channels may be substantially in a longitudinal direction of the
shoe. The orientation options described for the lateral passages 50
may be applied to all embodiments described.
[0200] The ventilating sole element 61 of the shoe 301a also
comprises a circular lip 101. The circular lip 101 is arranged at
the upper lateral edge of the ventilating sole element 61. As the
ventilating sole element 61 is a three-dimensional structure, the
circular lip 101 surrounds the perimetric upper edge of the
remainder of the ventilating sole element 61. In other words, the
circular lip 101 is arranged at the periphery of the upper lateral
portion of the ventilating sole element 61. Accordingly, the term
circular is not intended to be understood as referring to the shape
of a circle. Instead, it is understood as referring to a structure
surrounding an inner space or as referring to a loop structure.
However, the term is also not intended to require a closed lip or
collar structure. The lip may be continuous around the perimeter of
the ventilating sole element 61, but is may also be made of a
plurality of spaced apart lip sections distributed around the
perimeter of the ventilating sole element 61. The lip also does not
need to be arranged right at the upper lateral edge of the
ventilating sole element 61. It may also be attached to the lateral
surface 602 or the upper surface 606 thereof. However, a
positioning in the vicinity of an upper circumferential edge of the
ventilating sole element may be beneficial, as will be discussed
below.
[0201] The circular lip 101 may perform one or more of the
functions described as follows. As shown in FIG. 2a, the circular
lip 101 extends to the position of the connection 30. The
connection 30 includes the circular lip 101, such that it connects
the upper portion 10, the bottom portion 20 as well as the
ventilating sole element 61. In particular, the strobel stitch 30
connects the upper functional layer laminate 17, the netband 15 of
the upper material 11, the bottom functional layer laminate 24 and
the circular lip 101 of the ventilating sole element 61. Hence, the
circular lip 101 allows for an attachment of the ventilating sole
element 61 to the upper assembly 8. This attachment is independent
from the attachment of the ventilating sole element 61 to the upper
assembly 8 via the surrounding sole element 81. During the
manufacture of the shoe 301a, the ventilating sole element 61 may
be attached to the upper assembly 8 in a fixed position through the
connection 30 along the circular lip 101, which may also leave the
comfort layer 40 in a fixed position. This allows for a more
accurate production of the shoe 301a, as the fixed position of the
ventilating sole element 61 ensures that the surrounding sole
element 81 surrounds the ventilating sole element 61 in the desired
manner and location.
[0202] The ventilating sole element 61 and the circular lip 101 may
be made of one piece or more pieces. In other words, the circular
lip 101 may be an integral part of the ventilating sole element 61
or it may be a part attached in a separate manufacturing step to
the remainder of the ventilating sole element 61. Particularly, the
ventilating sole element 61--including the circular lip 101--may be
produced in one manufacturing step, for example through injection
moulding. In this way, a strong connection between the circular lip
101 and the remainder of the ventilating sole element 61 is
ensured, which results in a strong attachment of the whole
ventilating sole element 61 to the upper assembly 8. For example,
the lip extends 2 millimetres horizontally from the ventilating
sole element; extensions will typically be between 1 and 5
millimetres.
[0203] It is also possible that the ventilating sole element 61,
comprising the circular lip 101, is attached to the upper assembly
by gluing the circular lip 101 onto the upper assembly 8 or by
effecting an attachment between the circular lip 101 and the upper
assembly 8 through a local injection-moulding operation in the
region of the circular lip 101, particularly only in the region of
the circular lip 101.
[0204] The circular lip 101 may additionally/alternatively have the
function of providing a barrier for the sole material of the
surrounding sole element 81 during its injection-moulding onto the
ventilating sole element 61 and the upper assembly 8. The circular
lip may be positioned such that the sole material of the
surrounding sole element 81 does not penetrate through to the
comfort layer 40 and/or the upper side of the ventilating sole
element 61. The circular lip 101 may also be designed and
positioned in such a way that some sole material of the surrounding
sole element 81 may penetrate onto the bottom functional layer
laminate 24, particularly onto the bottom membrane 21. The sealing
between the bottom functional layer laminate 24 and the upper
functional layer laminate 17 may be effected via the surrounding
sole element material. However, the circular lip may prevent excess
sole material from penetrating into the area between the
ventilating sole element and the bottom functional layer laminate.
In this way, the water vapour permeability of a large area of the
bottom functional layer laminate 24 is ensured.
[0205] The ventilating sole element 61 may be placed in a mould
with a suitable pressure/fixation, such that the circular lip 101
can fulfil this function during injection-moulding of the
surrounding sole element 81. In particular, a piston may exert
pressure on the ventilating sole element 61, through which it is
pressed against the upper assembly 8. The circular lip may be
pressed against the upper assembly 8, in the process of which a
deformation of the protruding lip may occur, such that a tight
barrier for the subsequent injection-moulding step is formed. The
circular lip 101 may in this way help to keep a large portion of
the lower surface of the bottom functional layer laminate 24 from
getting into contact with the sole material of the surrounding sole
element 81, such that a large area with breathable characteristics
is maintained. The circular lip 101 may also be positioned at any
position on the upper surface 606 of the ventilating sole element
61, such that a barrier for the injection-moulding is established
at a desired location. Also, the circular lip 101 may be attached
to the lateral surface 602 of the ventilating sole element 61, with
the barrier effect being achieved through an attachment of the far
end of the circular lip 101 to the upper assembly 8, for example
through the strobel stitch 30.
[0206] The circular lip 101 may extend from the ventilating sole
element in any direction between a lateral direction towards the
outside of the ventilating sole element and a vertical direction
upwards from the ventilating sole element.
[0207] It is explicitly pointed out that, albeit the circular lip
101 is only shown for the embodiments of FIG. 2a, the ventilating
sole elements of the other embodiments of the invention may also
comprise a lip or collar structure, in particular a circular lip or
a plurality of lip sections as described above.
[0208] The upper portion of the surrounding sole element 81 is
located above the circular lip 101 of the ventilating sole element
61, i.e. below a part of the bottom functional layer laminate 24,
as well as underneath the circular lip 101 and underneath a part of
the upper portion 10 of the upper assembly 8 as well as adjacent a
part of the upper portion 10 of the upper assembly 8 that is
arranged in a substantially vertical direction. In other words, the
surrounding sole element 81 wraps around the corner of the upper
assembly 8 where the inside of the shoe is patterned to match a
wearer's foot. In yet other words, the surrounding sole element 81
covers a part of the underside of the upper assembly 8 as well as
parts of the lower lateral sides of the upper assembly 8. Sole
material of the surrounding sole element 81 is penetrated through
the netband 15, through the strobel stitch 30, through the mesh 12,
onto the upper material 11, onto the upper membrane 13, around at
least a portion of the circular lip 101 and onto the bottom
membrane 21. This penetrated sole material seals the strobel stitch
30 in a waterproof manner on the one hand and attaches the
ventilating sole element to the upper assembly 8 on the other hand.
The sealing provides a completely waterproof upper assembly 8 made
up of the upper functional layer laminate 17 and the lower
functional layer laminate 24 surrounding the interior of the shoe
and being sealed in a waterproof manner to each other. The sealed
upper functional layer laminate 17 and bottom functional layer
laminate 24 form a waterproof, breathable functional layer
arrangement. Thus the upper assembly 8 is waterproof, which allows
the sole assembly to be nonwaterproof. The surrounding sole
material also penetrates through the connection 30 to the upper
sides of the bottom functional layer laminate 24 and the upper
functional layer laminate 17, which is illustrated by the circle
sector covering the upper side of the strobel stitch 30 and
extending onto the bottom functional layer laminate 24 and the
upper functional layer laminate 17 in FIG. 2a. In particular, the
surrounding sole material penetrates through the space between the
two laminates upwards. The surrounding sole material also
penetrates somewhat in between the circular lip 101 and the bottom
functional layer laminate 24. In this way, the whole region of the
strobel stitch 30 is penetrated with surrounding sole material,
such that all holes generated in the upper membrane 13 and the
bottom membrane 21 through the strobel stitching operation are
reliably sealed by surrounding sole material. However, the
penetrating surrounding sole material is kept to such a low volume
that the comfort for the wearer as well as the breathability of the
upper assembly 8 is essentially unimpeded.
[0209] Above the ventilating sole element 61, the comfort layer 40
is provided in the shoe 301a. The comfort layer 40 is positioned on
top of the ventilating sole element 61. The comfort layer 40 may be
loosely positioned there or may be attached before further
manufacturing of the shoe. Such attachment may be achieved by a
spot-gluing or circumferential gluing or by gluing making use of
breathable glue, such that the flow of water-vapour from the inside
of the shoe to the ventilating sole element 61 is not prevented.
Also, the full surface of the ventilating sole element 61 can be
glued, and in order to prevent glue to enter the channels a highly
thixotropic glue should be used. The comfort layer 40 is inserted
for increasing the soft walking feel for the wearer, particularly
for ensuring that the wearer does not feel bothered by the channel
system 160 of the ventilating sole element 61. In the exemplary
embodiment of the shoe 301a, the comfort layer 40 has a greater
lateral extension than the channel system 160 of the ventilating
sole element 61 and extends somewhat above the region of the
circular lip 101. However, the comfort layer does not extend to the
lateral edges of the circular lip 101 where it is attached to the
upper assembly 8. In general, the comfort layer may have the same
or smaller or larger lateral dimensions as/than the ventilating
sole element.
[0210] The comfort layer 40 is provided directly on top of the
ventilating sole element 61. However, it could also be spaced apart
somewhat from the ventilating sole element 61. Such a spacing may
be the result of using a gluing layer for attaching the comfort
layer 40 to the ventilating sole element 61 that has a sizeable
vertical extension. The comfort layer may still provide the
beneficial properties discussed, when not provided directly on top
of the ventilating sole element.
[0211] The ventilating and surrounding sole elements are produced
and attached to the upper assembly 8 in a several stage process. As
a first step, the ventilating sole element 61 is produced, for
example through injection-moulding of a polyurethane (PU) into an
accordingly shaped mould. Polyurethane is one of a plurality of
suitable materials that can be used in order to form a ventilating
sole element 61 that has high stability to support at least a
portion of the weight of the wearer during use, such as during
walking, while having some flexibility in order to enhance the
wearer's comfort during walking. Depending on the preferred use of
the shoe, a suitable material can be chosen. Examples of such
materials besides polyurethane is EVA (Ethylene Vinyl Acetate).
etc.
[0212] As a next step, the comfort layer 40 is placed on top of the
ventilating sole element 61 and attached to it using an adhesive.
The ventilating sole element 61 and the comfort layer 40 are then
placed in the desired position with respect to the upper assembly 8
in a mould, wherein the surrounding sole element material is
injection-moulded onto the upper assembly 8 and the ventilating
sole element 61. In this way, the surrounding sole element 81
adheres to the upper assembly 8 as well as to the sole ventilating
element 61, such that a lasting, integral joint of these elements
is achieved through the sole material of the surrounding sole
element 81. Suitable materials for the surrounding sole element are
polyurethane, EVA, PVC or rubber, etc.
[0213] In the embodiment of FIG. 2a, the netband 15 wraps around
the corner of the upper portion 10, i.e. the part of the upper
portion 10 where the upper functional layer laminate 17 and the
netband 15 of the upper material 11 are bent from a substantially
horizontal orientation to a substantially vertical orientation. The
part having a substantially vertical orientation forms the side
walls for the wearer's foot. Accordingly, the sole material of the
surrounding sole element 81 may penetrate through the netband 15
and onto the upper membrane from the underside and from the lateral
sides of the upper assembly 8. In this way, a strong,
multi-directional attachment between the surrounding sole element
81 and the upper functional layer laminate 17 is achieved, as well
as a good seal provided between the laminates 17, 24.
[0214] In the exemplary embodiment of FIG. 2a, the surrounding sole
element 81 reaches further down than the ventilating sole element
61, which leads to a supporting of the wearer's weight by only the
surrounding sole element 81 on a plane surface. This may be
desired, as only a portion of the sole needs to be designed for
continuous load bearing of the wearer, whereas the material used
for the ventilating sole element 61 may be chosen based on the
manufacturing characteristics for producing the channel system 160
and/or based on a minimisation of weight of the ventilating sole
element 61 and therefore of the centre portion of the sole 7 of the
shoe 301a in which the ventilating sole element 61 is situated.
[0215] Even though, according to the exemplary embodiment of FIG.
2a, the sole 7 of the shoe 301a is not shown to have an outer sole,
it is pointed out that such an additional sole element could be
provided therewith as well as with all other embodiments described.
Also, the undersides of the ventilating sole element 61 and the
surrounding sole element 81 are not provided with a tread structure
for improving the grip of the sole assembly 7 on the ground during
use of the shoe. It is, however, pointed out that tread elements
may be provided at the underside of the sole in all embodiments
described. Exemplary tread structures/elements will be described
below.
[0216] FIG. 2b shows a cross-section through a shoe 301b according
to another embodiment. Many elements of the shoe 301b are identical
to the corresponding elements of the shoe 301a shown in FIG. 2a.
Like or similar elements are denoted with like reference numerals,
and a description thereof is omitted for brevity.
[0217] The channel structure 160 of the ventilating sole element 61
of the shoe 301b is shown to have a plurality of longitudinal
channels 184, which are rectangular in cross-section. The
longitudinal channels 184 are connected to each other and to the
openings 55 and lateral passages 50 by a plurality of transverse
channels 181, one of which being positioned and shown in the
cross-sectional plane of FIG. 2b. Each of the lateral ends of the
transverse channel 181 coincides with a longitudinal channel 184,
and no air and moisture discharging ports are provided in the
transverse channels 181. The positioning of these lateral ends is
adapted to the positioning of the openings 55 and lateral passages
50, which extend through the side wall 608 of the ventilating sole
element 61 and through the surrounding sole element 81, such that
the openings 55, lateral passages 50 and the transverse channel 181
allow for air flow therethrough. The small cross-sectional area of
the openings 55 and lateral passages 50 through the side walls 702
and 608 as compared to the cross-sectional area of the transverse
channel 181 at its lateral ends has the advantage that a large
connection area between the lateral surface 602 of the ventilating
sole element 61 and the inner lateral surface 802 of the
surrounding sole element 81 is provided, such that a strong
attachment can be achieved.
[0218] The longitudinal channels 184 of the channel structure 160
of the shoe 301b extend deeper into the ventilating sole element 61
than the transverse channels 181. The provision of channels with
different heights is one measure of achieving a desired compromise
between channel volume and ventilating sole material volume, i.e. a
desired compromise between air flow volume and sole stability.
Accordingly, different height channels may also be used in the
other embodiments described.
[0219] In addition to the differences in the channel structure 160,
a number of further differences between the embodiment of FIG. 2a
and the embodiment of FIG. 2b exist.
[0220] The ventilating sole element 61 of the shoe 301b does not
comprise a circular lip. The surrounding sole element 81 is
arranged below a portion of the upper functional layer laminate 17
as well as below a portion of the bottom functional layer laminate
24. In this way, the surrounding sole element 81 allows for a
strong attachment and sealing of these laminates to each other.
Moreover, the comfort layer 40 is extended over the full width of
the ventilating sole element 61, such that the wearer benefits from
the comfortable feel thereof over a large portion of the underside
of the foot.
[0221] In the exemplary embodiment of FIG. 2b, the ventilating sole
element 61 and the surrounding sole element 81 are provided with
tread elements, in particular with a pattern of protruding and
receding portions, for improving the walking characteristics of the
shoe 301b.
[0222] It is pointed out that it is possible that the upper
material 11, the mesh 12, the upper membrane 13 and the textile
lining 14 are formed as a four-layer laminate in the embodiment of
FIG. 2b as well as in the other embodiments described.
[0223] FIG. 2c shows a cross-section through a shoe 301c according
to another embodiment. Many elements of the shoe 301c are identical
to the corresponding elements of the shoe 301b shown in FIG. 2b and
shoe 301a shown in FIG. 2a, with a description thereof omitted for
brevity. However, the ventilating sole element 61 of the shoe 301c
is different from the ventilating sole element 61 of the shoe 301b.
The ventilating sole element 61 of the shoe 301c comprises
longitudinal channels 184 and transverse channels 181 that extend
from the upper surface 606 of the ventilating sole element 61 to
the lower surface 604 of the ventilating sole element 61. In other
words, the channels in the ventilating sole element 61 extend along
the whole height of the ventilating sole element 61. In this way,
water vapour is communicated from the underside of the bottom
functional layer laminate 24 to the underside of the shoe 301c
through the channels in addition to being communicated to the
lateral sides of the shoe 301c through the openings 55 and lateral
passages 50. Accordingly, water vapour can be discharged from the
inside of the shoe into all directions.
[0224] The cross-sectional view of FIG. 2c cuts through a
transverse channel 181 of the channel system 160 of the ventilating
sole element 61 of the shoe 301c. The water vapour entering the
ventilating sole element 61 from the inside of the shoe 301c
partially exits the shoe at its underside via the longitudinal
channels 184 and the transverse channels 181 of the channel
structure 160 and partially through the openings 55 and lateral
passages 50, wherein the transverse channels 181 allow for the air
communication between the channel system 160 of the ventilating
sole element 61 and the lateral passages 50. The transverse
channels 181 extend across the full width of the ventilating sole
element 61. When seen from the bottom, the ventilating sole element
61 of the shoe 301c is comprised of a plurality of individual inner
ventilating sole element blocks separated by the longitudinal and
transverse channels.
[0225] Again, the transverse channels 181 and/or the longitudinal
channels 184 may extend over any portion of the height of the
ventilating sole element 61, particularly over the whole height, as
shown, or over a portion of the height extending from the top of
the ventilating sole element 61 to the inside thereof. Also, the
channels in the ventilating sole element 61 may have any direction
between the longitudinal direction of the shoe 301c and the
trans-verse direction of the shoe 310c, when seen from its top or
bottom. In other words, the channels may be oriented in any
direction in the ventilating sole element 61, when looking at a
horizontal cross-section through the sole of the shoe.
[0226] It is pointed out that the individual components of the
ventilating sole element may be injection-moulded onto the upper
assembly 8 in separate injection-moulding steps.
[0227] The comfort layer 40 of the shoe 301c extends across the
entire lateral extension of the ventilating sole element 61 and an
adjacent portion of the surrounding sole element 81. In this way,
any discontinuities between the ventilating sole element 61 and the
surrounding sole element 81, which may be present due to a
particular design, such as a lip or collar at the lateral edges of
the ventilating sole element 61, or due to manufacturing process
imperfections, may be covered with the comfort layer 40, such that
these discontinuities are not detrimental to the wearer's comfort
or to the bottom membrane 21. It is pointed out that the comfort
layer 40 may also extend beyond the ventilating sole element 61 in
other embodiments shown.
[0228] FIG. 2d shows a cross-section through another embodiment of
a shoe 301d in accordance with the invention. Again, all elements
of the shoe 301d are identical to the corresponding elements of the
shoe 301a shown in FIG. 2a, with the exception of the ventilating
sole element 61. The ventilating sole element 61 of the shoe 301d
comprises channels 184 that extend through the whole height of the
ventilating sole element 61. The channels are diagonal, meaning
that their open ends at the upper surface 606 of the ventilating
sole element 61 are offset from their open ends at the lower
surface 604 of the ventilating sole element 61. This has the
advantage that sharp objects that might enter into these diagonal
channels, e.g. tacks or nails lying on the ground will normally not
pass up the channel, but get stuck in the material of the
ventilating sole element 61 and therefore will not damage the
functional layer lying above the channels. In the embodiment of
FIG. 2d, the diagonal channels 184 are longitudinal channels, with
their open ends at the upper surface 606 of the ventilating sole
element 61 being offset in a transverse direction from their open
ends at the lower surface 604 of the ventilating sole element 61.
The diagonal longitudinal channels are connected by horizontal
channels 181 in the transverse direction of the shoe 301d, i.e. by
transverse channels 181. The transverse channels 181 allow for
fluid communication between the diagonal channels 184 and the
lateral passages 50. Again, the trans-verse channels 181 may have
any vertical extension. They may extend the whole height of the
ventilating sole element 61 as well as only portions of it. They
may be covered by sole material of the ventilating sole element 61
when viewed from the top of the ventilating sole element 61, as
shown, but they may also extend from the top of the ventilating
sole element 61 to the inside thereof. It is also possible that the
transverse channels are diagonal channels and that the longitudinal
channels have a vertical orientation, as for example shown in FIG.
2b. Also, both the longitudinal and the transverse channels may be
diagonal, intersecting and forming a particular fluid communication
channel structure. In the embodiment of FIG. 2d again, water vapour
is communicated from the inside of the shoe to the underside of the
upper assembly 8 and from there together with the air through the
channels and passages out of the sole, allowing for a water vapour
discharge from the foot in all directions.
[0229] Again, the comfort layer 40 is shown to be provided directly
on top of the ventilating sole element 61.
[0230] FIG. 3a shows a cross-section through a shoe 302a according
to another embodiment. Many components of the shoe 302a are similar
or identical to the corresponding elements of the shoe 301b
depicted in FIG. 2b. A description thereof is therefore omitted for
brevity. However, the shoe 302a comprises a ventilating sole
element 62 and a surrounding sole element 82 that are different
from the corresponding elements of the shoe 301b. The ventilating
sole element 62 has a varying lateral extension from the upper
surface 606 to the lower surface 604. On the upper surface 606 and
for approximately the upper two thirds of the ventilating sole
element 62, the lateral extension is constant and corresponds to
the extension of the ventilating sole element 61 of the shoe 301b.
Throughout a lower portion of the ventilating sole element 62, the
ventilating sole element 62 extends over the complete lateral
extension of the sole assembly 7. The ventilating sole element 62
comprises the entire contact area between the sole assembly 7 and
the ground. The ventilating sole element 62 extends underneath the
surrounding sole element 82, such that the surrounding sole element
82 does not touch the ground when the shoe is positioned on its
sole. The surrounding sole element 82 fills the lateral pocket
between the ventilating sole element 62 and the upper assembly 8.
It also covers a lower part of the side walls of the upper assembly
8, i.e. it is also adjacent a part of the upper portion 10 of the
upper assembly 8 that is arranged in a substantially vertical
direction. The ventilating sole element 62 comprises five
longitudinal channels 184 in the depicted cross-sectional plane,
the longitudinal channels 184 extending approximately one third
into the ventilating sole element 62 from the upper surface 606
thereof. The longitudinal channels 184 of the shoe 302a are
connected by transverse channels 181 to each other and to the
openings 55 and lateral passages 50, with the cross-section of FIG.
3a cutting through one of the transverse channels 181. The
transverse channels 181 have the same height extension as the
longitudinal channels 184 and also extend from the upper surface
606 of the ventilating sole element 62 thereinto. The longitudinal
channels 184 and the transverse channels 181 may be seen as grooves
extending into the ventilating sole element 62 from its upper
surface 606. Again, many other channel structures are also possible
to effect fluid communication between the top of the ventilating
sole element 62 and the lateral passages 50, as described with
respect to the other Figures.
[0231] The design of the shoe 302a allows for a small amount of
sole material being needed for the surrounding sole element 82. The
ventilating sole element 62, which takes up most of the volume of
the sole assembly 7, may be produced separately, and the
surrounding sole element 82 may be produced in a quick,
well-controlled injection-moulding step. This step may be the last
step in finishing the shoe manufacturing.
[0232] FIG. 3b shows a cross-section through a shoe 302b according
to another embodiment. The shoe 302b is identical to the shoe 302a
of FIG. 3a, with the exception of the sole assembly 7. The shoe
302b comprises a ventilating sole element 62 and a surrounding sole
element 82. An outsole 92 is provided below the ventilating sole
element 62 and the surrounding sole element 82. The surrounding
sole element 82 of the shoe 302b is identical to the surrounding
sole element 82 of the shoe 302a, shown in FIG. 3a. The ventilating
sole element 62 of the shoe 302b extends between the inner lateral
surface 802 of the surrounding sole element 82. The outsole 92
extends across the entire width of the sole assembly 7 of the shoe
302b. It covers both the undersides of the ventilating sole element
62 and the surrounding sole element 82. The outsole 92 is the only
element of the shoe 302b coming into contact with the ground during
normal use of the shoe 302b on an even surface. This design has the
advantage that a particularly suitable material for the outsole 92
can be chosen independently from any requirements for the
ventilating sole element 62 and the surrounding sole element 82.
For example, a thermoplastic polyurethane (TPU) or rubber or
leather can be used. Also, the materials of the ventilating sole
element 62 and the surrounding sole elements 82 may be chosen
purely based on factors such as comfort for the wearer, stability
of the sole, bonding properties during the manufacture of the shoe
302b, without having to worry about the wear and tear of the sole
through the continuous contact of the sole to the ground during
use.
[0233] The channel structure 160 of the ventilating sole element 62
has four longitudinal channels 184 in the cross-sectional plane of
FIG. 3b. The channel structure also comprises transverse channels
181, one of which being shown in the cross-sectional plane of FIG.
3b. The laterally outermost longitudinal channels 184 are not
positioned at the lateral ends of the trans-verse channel 181. At
the lateral ends of the transverse channels 181, air and moisture
discharging ports 182 are provided. The air and moisture
discharging ports comprise recesses in the floor of the transverse
channel 181, with the floor having an inclined shape in the
exemplary embodiment of FIG. 3b. The lateral ends of the transverse
channel 181 are in air communication with the openings 55 and
lateral passages 50, which extend through the side walls 608 and
702 of the ventilating sole element 62 and the surrounding sole
element 82, respectively. It is apparent that the channel structure
160 may be modified in various different ways as described
above.
[0234] FIG. 3c shows a cross-section through a shoe 302c according
to another embodiment. Many elements of the shoe 302c are identical
to the corresponding elements of the shoes 302a and 302b shown in
FIGS. 3a and 3b, with a description thereof omitted for
brevity.
[0235] The bottom functional layer laminate 24 of the bottom
portion 20 of the upper assembly 8 of the shoe 302c is a
three-layer laminate, which comprises--from bottom to top--a mesh
23, a bottom waterproof and breathable membrane 21 and a supporting
textile 22. The mesh 23 may give the bottom functional layer
laminate 24 enhanced stability. It is pointed out that the bottom
functional layer laminate 24 of the other embodiments may also be
the three-layer laminate, as comprised in the shoe 302c.
[0236] FIG. 3d shows a cross-section through a shoe 302d according
to another embodiment. Many elements of the shoe 302d are identical
to the corresponding elements of the shoe 302b shown in FIG. 3b,
with a description thereof being omitted for brevity. The
ventilating sole element 62 of the shoe 302d extends in between the
surrounding sole element 82 in an upper portion of the vertical
extension of the surrounding sole element 82. The height extension
of the ventilating sole element 62 is approximately half the height
extension of the surrounding sole element 82 underneath the upper
assembly 8. The channel system 160 of the ventilating sole element
62 is similar to the channel system 160 of the ventilating sole
element 62 of the shoe 302a, shown in FIG. 3a. Below the
ventilating sole element 62, there is provided a sole comfort layer
122, also referred to as midsole 122. The sole comfort layer 122 is
co-extensive with the ventilating sole element 62 in the lateral
dimension. The sole comfort layer 122 does not comprise air
communication channels in the embodiment shown in FIG. 3d, but may
also comprise air communication channels in other embodiments. The
three-layered design over a large portion of the lateral extension
of the sole assembly 7, i.e. the arrangement of ventilating sole
element 62, the sole comfort layer 122 and the outsole 92 on top of
each other, allows for selecting a plurality of materials highly
suitable for certain tasks. In particular, the material for the
outsole 92 may be selected based on its grip and abrasion
properties, the material for the sole comfort layer 122 may be
selected based on its comfort and cushioning capabilities, and the
material for the ventilating sole element 62 may be selected based
on its ability to provide stability while having a channel
structure therein. These elements may be attached to each other
through gluing, injection-moulding or other suitable
techniques.
[0237] FIG. 3e shows a cross-section through a shoe 302e according
to another embodiment. Many elements of the shoe 302e are identical
to the corresponding elements of the shoe 302d shown in FIG. 3d,
with a description thereof being omitted for brevity.
[0238] In contrast to the shoe 302d, the shoe 302e does not
comprise a comfort layer and a channeled ventilating sole element.
It is, however, pointed out that a comfort layer, as discussed
above, may also be present in the embodiment of the shoe 302e. It
is also pointed out that the comfort layer may be dispensed with in
the other embodiments described.
[0239] The shoe 302e comprises a container element 113. The
container element 113 is filled with a structure or material 112
allowing for air flow through it. The structure or material 112
extends through the whole volume of the container element 113,
which is confined by a bottom part 113a and a side wall 113b. The
structure or material 112 allows for air communication between the
underside of the bottom functional layer laminate 24 and the
openings 55 and lateral passages 50. The openings 55 extend through
the side wall 113b of the container element 113 and the lateral
passages 50 extend through the side wall 702 of the surrounding
sole element 82. It is also possible that the material of the side
wall 113b of the container element 113 is made of a material which
allows for air flow through it, e.g. a porous material.
[0240] The container element 113 comprises a circular lip 113c at
its upper lateral edge. The circular lip 113c is attached to the
upper assembly 8 via the strobel stitch 30, such that at least the
container element 113, including the structure or material 112, is
fixed with respect to the upper assembly 8, before the surrounding
sole element 82 is injection-moulded. It is also possible that the
container element 113, the sole comfort layer 122, also referred to
as midsole 122, and the outsole 92 are attached to each other,
before this composite sole structure is attached to the upper
assembly 8 via strobel stitch 30.
[0241] The container element 113 forms the ventilating sole element
of the shoe 302e. Its placement underneath the bottom functional
layer laminate 24 of the upper assembly 8 establishes an air
communication between the inside of the shoe, the container element
113 and the openings 55 and lateral passages 50 provided in the
side wall of the container element 113 and the surrounding sole
element 82.
[0242] The structure or material 112 may be any such structure or
material suitable for allowing air communication and for supporting
a desired portion of the wearer's weight during use of the shoe.
The structure or material 112 may be comprised of a number of
filler elements placed in the container element 113, such that air
flow can occur through the voids in between the filler elements.
Examples for such a structure or material are man made fabrics with
open cell structure or other suitable materials, as described
above.
[0243] The structure or material 112 allowing for air flow through
it may be continuous, threedimensionally formed such as a spacer or
else a porous structure or material, having inherent air flow
permitting properties.
[0244] It is pointed out that the ventilating sole element of other
embodiments may also be substituted by the structure or material
112 allowing for air flow through and, if necessary, the container
element 113. It is also possible that the whole ventilating sole
element is made from an air flow permitting material, such as a
porous material, which allows the water vapour discharge from the
underside of the upper assembly 8 through lateral passages in the
material.
[0245] FIG. 3f shows a cross-section through a sole 202b in
accordance with another embodiment. The sole 202b corresponds
substantially to the sole of the shoe 302c, shown in FIG. 3c, with
the exception of a slightly different channel structure 160.
Accordingly, a detailed description is omitted for brevity. The
sole 202b may be manufactured as a separate element and may be
attached to the upper assembly 8 of the shoe 302c or any other
upper assembly described herein. The attachment may be achieved by
gluing, injection-moulding or any other suitable attachment
technique.
[0246] FIG. 4a shows a cross-section through a shoe 303a according
to another embodiment. The upper assembly 8, comprising the upper
portion 10, the lower portion 20 and the connection 30 thereof, and
the comfort layer 40 of the sole assembly 7 are identical to the
upper assembly 8 and the comfort layer 40 of the shoe 302d, shown
in FIG. 3d. Also, regarding its outer dimensions, the ventilating
sole element 63 of the shoe 303a is identical to the ventilating
sole element 62 of the shoe 302d. Regarding the channel structure
160, the ventilating sole element 63 of the shoe 303a is fairly
similar to the ventilating sole element 62 of the shoe 302a.
However, the channel structure of the ventilating sole element 63
is less wide, and the side wall 608 of the ventilating sole element
63 has a greater lateral extension. A detailed description of these
elements is omitted for brevity. The shoe 303a comprises the
ventilating sole element 63 and the surrounding sole element 83.
Again, openings 55 and lateral passages 50 are provided, which
extend through the side wall 608 of the ventilating sole element
and side wall 702 of the surrounding sole element for effecting air
communication between the channel structure of the ventilating sole
element 63 and the lateral outside of the sole assembly 7 of the
shoe 303a.
[0247] The surrounding sole element 83 not only surrounds the
ventilating sole element 63 laterally, but also passes underneath
or is arranged below it in the exemplary embodiment of shoe 303a.
The surrounding sole element 83 comprises supporting members 133.
The supporting members 133 extend vertically through the
surrounding sole element 83. They are positioned below the
ventilating sole element 63. In the present embodiment, the
surrounding sole element 83 comprises four supporting members 133
equally spaced below the ventilating sole element 63. Depending on
their extension in the longitudinal direction of the shoe 303a, the
supporting members 133 may be ribs or stilts. In other words, the
supporting members 133 may have longitudinal extensions
substantially equal to their transverse extensions, shown in FIG.
4a, or may have longitudinal extensions substantially larger than
their transverse extensions. In another embodiment, the supporting
members may be formed as transverse ribs.
[0248] The supporting members 133 may be manufactured as follows.
The supporting members 133 may be made from the same material as
the ventilating sole element 63. In this case the ventilating sole
element 63 and the supporting members 133 may be injection-moulded
integrally in one injection-moulding step. Accordingly, the
surrounding sole element 83 may then be injection-moulded around
the ventilating sole element 63, parts of the upper assembly 8 and
the supporting members 133 in a subsequent injection-moulding step.
It is also possible that the supporting members 133 are
manufactured separately. In this case, they may either be attached
to the ventilating sole element 63 or may be kept in a fixed
position with respect to the ventilating sole element 63 in a
mould, before the surrounding sole element 83 is
injection-moulded.
[0249] The supporting members 133 contribute to the stability of
the sole, in particular of the ventilating sole element of the shoe
303a. Their positioning underneath the ventilating sole element 63
may offset stability disadvantages that may arise from the
channeled structure of the ventilating sole element 63. Moreover,
the supporting members 133 allow for a less restricted selection of
the material for the surrounding sole element 83, because sole
stability is less of a concern. The supporting members 133 also
keep the ventilating sole element 63 elevated to allow the
surrounding sole element material 83 to flow underneath the
ventilating sole element 63 during injection moulding.
[0250] FIG. 4b shows a cross-section through a shoe 303b according
to another embodiment. Many elements of the shoe 303b are identical
to the corresponding elements of the shoe 303a, shown in FIG. 4a,
such that a description thereof is omitted for brevity. The
ventilating sole element 63 of the shoe 303b comprises the channels
given in the ventilating sole element 63 of the shoe 303a. Also,
the openings 55 and lateral passages 50, extending through the side
walls 608 and 702 of the ventilating sole element 63 and the
surrounding sole element 83, are identical to the openings 55 and
lateral passages 50 of the shoe 303b. Additionally, vertical
passages 52 are provided, which extend vertically from the channel
structure of the ventilating sole element 63 through the
ventilating sole element 63 to its lower surface 604 and further
through the surrounding sole element 83. The vertical channels 52
allow for air flow between the channel structure of the ventilating
sole element 63 and the underside of the sole assembly 7. In this
way, vertical water vapour and air discharge channels are provided
in the shoe 303b, such that a higher breathability is achieved. The
supporting members 133 of the surrounding sole element 83 are
arranged around the vertical channels 52 in the surrounding sole
element 83. In other words, the supporting members 133 of the
surrounding sole element 83 of the shoe 303a are hollow structures,
through which the vertical channels 52 extend. It is pointed out
that the surrounding sole element 83 may also be provided without
hollow supporting members 133, but may still have vertical
channels. In general words, vertical channels may extend through
the surrounding sole element 83 in its portion below the
ventilating sole element 63. Such vertical channels can be made by
having vertical pins fixated in a bottom piston of the mould.
[0251] The shoe 303b additionally comprises inserts 51 arranged in
at least a portion of the lateral passages 50 of the surrounding
sole element 83. The inserts 51 are pin-shaped. They comprise
pin-heads with the pin-head extension being greater than the
diameter of the lateral passages 50. The inserts 51 have a hollow
structure, such that air and water vapour discharge from the
ventilating sole element 63 through the lateral passages 50 is
effected through the inside of the inserts 51. The diameter of the
lateral passages 50 may be enlarged so as to accommodate the
inserts and ensure an adequate air flow through them.
[0252] Without the inserts 51, the walls of the lateral passages 50
may be rough or uneven from the manufacturing process, giving rise
to turbulences in the air flow therethrough and diminished air and
water vapour discharge capabilities. The hollow inserts 51 ensure
that the air flow through the lateral passages 50 flows along
smooth surfaces and is highly efficient in transporting air and
water vapour from the ventilating sole element 63 to the outside of
the sole of the shoe 303b. An unimpeded air and water vapour flow
through the lateral passages may be achieved by the inserts 51 in a
cheaper way than by optimizing manufacturing processes, such as
injection-moulding processes for the surrounding sole element
83.
[0253] The inserts 51 may be removable inserts, allowing the wearer
to insert them as desired to account for different usage scenarios.
Being removable, the inserts 51 are also a way of making the
appearance of the shoe adjustable by the wearer.
[0254] The inserts 51 may also be solid, i.e. not hollow, and
removable. In this case, the wearer may insert the inserts 51 in
extremely adverse usage environments, such as during heavy
rainfalls or hiking through puddles or muddy terrain. In this way,
an entering of water, mud, etc. into the sole may be completely
prevented, such that the lateral passages 50 and the ventilating
sole element 63 may not be clogged up or made impermeable to air
flow in any other way for later use. Also, these solid inserts may
be used in low temperature conditions, such that no flow of cold
air through the lateral passages 50 and the ventilating sole
element 63 causes discomfort to the wearer. In order to save
material and weight, it is also possible to only make the heads of
the pins solid, with the portions of the pins received by the
lateral passages being hollow. Another measure against the
discomfort of cold air flow is to provide an insulating comfort
layer 40 or an insulating bottom functional layer laminate 24.
[0255] The inserts 51 may be made of metal or plastic or any other
suitable material.
[0256] It is pointed out that the provision of the inserts 51 and
the provision of the hollow supporting members 133 are independent.
While they both may enhance the water vapour characteristics of the
shoe 303b, one feature may also be provided without the other.
Also, both features may be provided in the other embodiments
discussed, separately or in combination.
[0257] FIG. 5 shows a cross-section through a shoe 304 according to
another embodiment. Many elements of the shoe 304, particularly the
whole upper assembly 8, are identical to the shoe 303a, as shown in
FIG. 4a. Also, the ventilating sole element 64 of the shoe 304 is
similar to the ventilating sole element 63 of the shoe 303a. The
surrounding sole element 84 of the shoe 304 is modified as compared
to the surrounding sole element 83 of the shoe 303a. The
surrounding sole element 84 of the shoe 304 does not extend to the
bottom of the shoe 304, i.e. to the surface area of the shoe 304
that gets into contact with the ground during normal use. The
vertical extension of the surrounding sole element 84 of the shoe
304 is smaller than the vertical extension of the surrounding sole
element 83 of the shoe 303a.
[0258] An outsole 94 is arranged underneath the surrounding sole
element 84 of the shoe 304. The outsole extends over substantially
the whole lateral extension of the surrounding sole element 84. In
the cross-sectional view of FIG. 5, the outsole 94 extends over the
whole width of the surrounding sole element 84. The outsole 94 is
provided with a tread in order to increase traction for the wearer
on a variety of surfaces. The outsole 94 does not comprise
supporting members. Supporting members 134 are present in the
surrounding sole element 84. Providing a separate outsole 94 for
the shoe 304 has the same advantages as providing the outsole 92
for the shoe 302b, as discussed in connection with FIG. 3b.
[0259] FIG. 6a shows a cross-section through a shoe 305a according
to another embodiment. The upper assembly 8 and the comfort layer
40 of the shoe 305a correspond to the upper assembly 8 and the
comfort layer of the shoe 304, as described with reference to FIG.
5. The shoe 305a comprises a ventilating sole element 65 and a
surrounding sole element 85. The ventilating sole element 65 has a
channel structure 160 identical to the channel structure 160 of the
ventilating sole element 64 of the shoe 304 of FIG. 5. The
surrounding sole element 85 has lateral passages 50, which are in
fluid communication with openings 55 and the channel system 160 of
the ventilating sole element 65.
[0260] The lateral extension of the ventilating sole element 65
changes somewhat below the height of the lower end of the lateral
passages 50. Approximately half way from the upper surface 606 of
the ventilating sole element 65 to its lower surface 604, the
ventilating sole element 65 extends across almost the entire width
of the transverse extension of the ventilating sole element. The
surrounding sole element 85 forms a sole element surrounding the
lateral surface 602 of the wider portion of the ventilating sole
element 65. It also covers the lower surface 604 of the ventilating
sole element 65, thereby forming the contact surface of the shoe
305a with the ground. The surrounding sole element 85 also fills
the pocket between the ventilating sole element 65 and the upper
assembly 8, thereby effecting an attachment between these two
components and a waterproof seal between the upper portion 10 and
the lower portion 20.
[0261] The surrounding sole element 85 comprises supporting members
135 arranged below the ventilating sole element 65. The design of
the ventilating sole element of the shoe 305a ensures that the
cushioning and comfort capacities of the ventilating sole element
65 are taken advantage of over a large volume of the ventilating
sole element, while the complete surrounding of the ventilating
sole element 65 by the surrounding sole element 85 allows for a
uniform optical appearance of the shoe and for the provision of a
durable outer material across all outer walls of the sole assembly
7. The surrounding sole element 85 is provided with a tread
structure.
[0262] FIG. 6b shows a cross-section through a shoe 305b according
to another embodiment. As compared to FIG. 6a, the surrounding sole
element 85 is modified in that is does not comprise a portion that
gets into contact with the ground during regular use of the shoe
305b. In other words, the surrounding sole element 85 surrounds the
ventilating sole element 65 only laterally, not from the bottom
side. An outsole 95 is provided below the undersides of the
ventilating sole element 65 and the surrounding sole element 85.
The outsole 95 comprises supporting members 135. The supporting
members 135 are comparable to the supporting members 135 shown in
the lower layer of the surrounding sole element 85 of FIG. 6a.
Moreover, the outsole 95 comprises a tread structure on its
underside. The advantages of having a separate outsole 95 element
are the same as described with the outsole 92 of the shoe 302b
shown in FIG. 3b.
[0263] FIG. 6c shows a cross-section through a shoe 305c according
to another embodiment. The upper assembly 8 of the shoe 305c
comprises an upper portion 10, comprising an upper material 11 and
an upper functional layer laminate 17, and a bottom portion 20,
comprising a bottom functional layer laminate 24. The bottom
functional layer laminate 24 extends across the entire horizontal
portion of the upper assembly 8. It also extends somewhat up the
side portions of the upper assembly 8. The upper functional layer
laminate 17 does not extend all the way down to the transition from
the horizontal portion to the side portions of the upper assembly
8. The upper material 11, including the netband 15, may extend as
far down as the upper functional layer laminate 17 or further down
than the upper functional layer laminate 17. In the exemplary
embodiment of FIG. 6c, the netband 15 extends down to the bottom
end of the lateral sides of the upper assembly 8. The upper
functional layer laminate 17 and the bottom functional layer
laminate 24 are brought close together with the respective edges,
with a strobel stitch 30 connecting these components in the
exemplary embodiment of FIG. 6c. The strobel stitch 30 also
attaches the netband 15 to these components.
[0264] A ventilating sole element 65, which is arranged below the
bottom functional layer laminate 24 and a comfort layer 40, extend
across most of the horizontal portion of the bottom functional
layer laminate 24. In fact, the ventilating sole element 65 may
extend over the entire horizontal portion of the bottom functional
layer laminate 24. This is possible because the seam 30, joining
the netband 15 of the upper material 11, the bottom functional
layer laminate 24 and the upper functional layer laminate 17, is
situated at a lower lateral side of the upper assembly 8 rather
than at the underside of the upper assembly 8. The surrounding sole
element 84 may thus only be applied outside the horizontal lateral
extension of the bottom functional layer laminate 24, rather than
also underneath the bottom functional layer laminate 24 (which is
the case in FIG. 6c), whilst still being able to seal the seam
30.
[0265] The ventilating sole element 65 in FIG. 6c has a constant
width along its vertical extension in the cross-sectional plane of
FIG. 6c. It may have a constant width in all transverse
cross-sections throughout the entire longitudinal direction of the
shoe 305c. It is also possible, however, that the width of the
ventilating sole element 65 may vary in the vertical dimension in
other transverse cross-sections at different longitudinal points
throughout the shoe 305c, as shown for example in FIG. 1. The
channel structure 160 of the ventilating sole element 65 of the
shoe 305c corresponds to the channel structure 160 of the
ventilating sole element 65 of the shoe 305b, shown in FIG. 6b.
[0266] Providing the ventilating sole element 65 over all or almost
the entire lateral dimension of the sole assembly 7 has the
advantage that the high water vapour discharge capabilities of the
bottom functional layer laminate 24 and the ventilating sole
element 65 receiving the water vapour therefrom may be taken
advantage of over a large area. This feature may also be applied to
all of the other embodiments.
[0267] The surrounding sole element 85 surrounds the lateral
surface 602 of the ventilating sole element 65. It has a constant
width throughout the vertical extension of the ventilating sole
element 65. Above that vertical extension, the surrounding sole
element 85 laterally surrounds a lower portion of the upper
assembly 8. The sole material of the surrounding sole element 85 is
penetrated through the netband 15 and through the strobel stitch
30, thereby sealing the connection region between the upper portion
10 and the lower portion 20 of the upper assembly 8. Underneath the
ventilating sole element 65 and the surrounding sole element 85, an
outsole 95 is provided. Again, the outsole 95 is provided with
supporting members 135 and a tread structure on its underside.
[0268] FIG. 7 shows a cross-section through a shoe 306 according to
another embodiment. The upper assembly 8 of the shoe 306 is
identical to the upper assemblies of both the shoe 301b of FIG. 2b
and the shoe 302b of FIG. 3b, with the exception of the bottom
functional layer laminate 24 used, which will be discussed below.
The shoe 306 does not comprise a comfort layer on top of the
ventilating sole element 66. The surrounding sole element 86 of the
shoe 306 is identical to the surrounding sole element 81 of the
shoe 301b. The ventilating sole element 66 of the shoe 306 has a
channel structure 160 similar to the channel structure 160 of the
ventilating sole element 62 of the shoe 302c, but comprising only 4
longitudinal channels 184. The lateral extension of the ventilating
sole element 66 of the shoe 306 is identical to the lateral
extension of the ventilating sole element 62 of the shoe 302c. The
ventilating sole element 66 extends between the surrounding sole
element 86 with a constant width along the vertical dimension. The
ventilating sole element 66 extends all the way down to the bottom
of the sole, particularly as far down vertically as the surrounding
sole element 86. The ventilating sole element 66 and the
surrounding sole element 86 form a flush surface (with the
exception of the tread structures) for getting into contact with
the ground during use of the shoe 306. Therefore, the weight of the
wearer may be evenly distributed between the two components of the
ventilating sole element.
[0269] The bottom functional layer laminate 24 of the shoe 306 is
provided with dots 29, also referred to as knobs, on its lower
side. Accordingly, the dots 29 are provided on the lower surface of
the bottom membrane 21. The dots 29 are polymeric dots distributed
over the lower surface of the bottom functional layer or membrane
in a regular pattern, particularly in parallel rows extending in
the transverse direction of the shoe, with one such row being shown
in the cross-sectional view of FIG. 7. The dots 29 have a
cushioning effect, such that the wearer's comfort is ensured
despite the non-uniform nature of the top surface of the
ventilating sole element 66. The dots 29 have been found to be so
efficient that the comfort layer may be dispensed with. A bottom
functional layer laminate 24 having polymeric dots 29 may be
applied to all other embodiments as well. Due to the spaces present
between the discrete dots 29, the water vapour permeability of the
bottom functional layer laminate 24 is not compromised. As the
bottom functional layer laminate 24 may be readily manufactured
including the dots 29, such a laminate may reduce the number of
components needed for manufacturing the shoe, such that gains in
the manufacturing efficiency may be achieved.
[0270] FIG. 8 shows a cross-section through a shoe 308 according to
another embodiment. The upper assembly 8 is similar to the upper
assembly 8 of the shoe 305c shown in FIG. 6c, and a comfort layer
40 is disposed between the bottom functional layer laminate 24 and
a ventilating sole element 68. The shoe 308 comprises the
ventilating sole element 68 and a surrounding sole element 88. The
ventilating sole element 68 extends vertically from the comfort
layer 40 to the lower end of the shoe 308 forming an outer sole of
the shoe 308. The ventilating sole element 68 is equipped with a
tread structure at its underside. The ventilating sole element 68
extends across the entire lateral dimension of the shoe 308 in its
lower portion. In its upper portion, the lateral dimension of the
ventilating sole element 68 is reduced as compared to the lower
portion. The lateral extension of the upper portion of the
ventilating sole element 68 corresponds approximately to the
lateral extension of the upper assembly 8. The surrounding sole
element 88 surrounds the upper portion of the ventilating sole
element 68 and a lower portion of the upper assembly 8, covering
the connection region 30 between the upper portion 10 and the lower
portion 20 of the upper assembly 8. Openings 55 and lateral
passages 50 are provided, which extend through the side wall 608 of
the ventilating sole element 68 and the side wall 702 of the
surrounding sole element 88, respectively, and which are in air
communication with the channel structure 160 of the ventilating
sole element 68. The ventilating sole element 68 comprises a
channel structure 160 corresponding to the channel structure 160 of
the ventilating sole element 65 of the shoe 305c.
[0271] The surrounding sole element 88 has a small lateral
extension, which allows for a very uniform design of the
ventilating sole element 68, as the vast majority of the sole
volume is provided by the ventilating sole element 68. Again, the
small volume of the surrounding sole element 88 allows for a quick
and well-controlled injection-moulding of the surrounding sole
element 88, while the attachment between ventilating sole element
68 and upper assembly 8 as well as the sealing of the connection
between the upper portion 10 and the lower portion 20 of the upper
assembly 8 as well as the water vapour discharge capabilities
through the lateral passages 50 can be ensured.
[0272] In the embodiments described, a number of modifications may
be made, as is apparent to a person skilled in that art. Further,
the embodiments can be combined in different ways.
[0273] For example, instead of injection-moulding, other techniques
can be used for manufacturing the sole elements of the embodiments
described above. For example, the ventilating sole element may also
be poured into a mould in a casting process. Vulcanizing is another
well-known sole production process.
[0274] Another exemplary modification relates to the two-layer
bottom functional layer laminate described. It is also possible to
provide a three-layer bottom functional layer laminate, having a
third layer below the lower membrane. The third layer may be a mesh
or another suitable material that allows penetration of sole
material therethrough during injection-moulding, such that a
sealing of the lower membrane to the upper membrane may be
effected.
[0275] Another exemplary modification is that the at least one
lateral passage 50 can be provided with inserts that can be removed
before the first use. In particular, the inserts may be connected
to the material around the lateral passages, in particular to the
surrounding sole element. However, such attachment may be weak, for
example only comprising local attachment points, such that a user
may remove the inserts by hand. In this way, it is ensured that the
lateral passages remain free of dirt during the shipping and
selling process, but that the lateral passages can be easily
completed by the wearer of the shoe.
[0276] In the following, an exemplary method for manufacturing a
shoe in accordance with principles of the invention will be
described. The skilled person will be aware that various changes or
adaptations may be made in manufacturing the shoe as far as
appropriate and depending on the particular needs of the respective
shoe construction.
[0277] The manufacturing method described in the steps below is
described by way of polyurethane injection of the ventilating sole
element. However, any other suitable material for forming the
ventilating sole element may be used, e.g Ethylene Vinyl Acetate
(EVA) Alternatively, the ventilating sole element can be made in a
casting process where the ventilating sole element material is
poured (i.e. not injected) into a mould where it is formed and
cured or in a vulcanization process.
[0278] In a process of forming an upper assembly, a bottom portion
20 of the upper assembly is attached to an upper portion 10
thereof. This can be done in any suitable way, for example using
commonly known methods such as gluing, stitching etc. For example,
the bottom portion may comprise a breathable insole or a
waterproof, breathable functional layer laminate with a membrane
being waterproof and water vapour permeable. The bottom portion may
extend between lower end areas of the upper portion such as shown
in the examples of FIGS. 1 to 8. Particularly, the bottom portion
may be seen as the lower part of the upper assembly extending
between the seams 30. Accordingly, it may encompass also parts of
the side portions of the upper assembly.
[0279] In the examples of FIGS. 1-8 as described above, the bottom
portion 20 of the upper assembly comprises a waterproof, breathable
bottom functional layer laminate. In an embodiment, a 2-layer
bottom functional layer laminate is stitched ("strobeled") to a
waterproof, breathable upper functional layer laminate at a
stitched seam 30 according to the Strobel method as described
above. For example, the laminate may have a textile layer 22 on top
towards the foot and a membrane, which is waterproof and
breathable, below towards the sole.
[0280] In the process of forming a sole assembly, an outsole, e.g.
of rubber, is made in a respective manufacturing step as commonly
known. The rubber is vulcanized and shaped into an outsole.
Afterwards, the outsole may optionally be chemically primed by
brushing "TFL Primer" (commercially available from the company
Forbo Adhesives) on the surface facing the foot. Priming is carried
out on open rubber cells in a well known manner to improve the
connection to the polyurethane of the ventilating sole element
which is later injected. After such priming, glue (for example,
Helmipur.RTM. GPU from Forbo Adhesives) is applied to that area of
the outsole where the ventilating sole element is to be placed
later. The outsole is dried for a particular period of time as
necessary, for example half an hour at 25-40.degree. C.
[0281] Thereafter, optionally a shank (not shown in FIG. 9b) as
commonly known may be mounted on the outsole on the side facing the
foot. The shank may be adhered to the outsole and may be elevated,
e.g., by 3-5 millimetre high protrusions which are arranged on the
side of the shank facing the outsole. This elevation allows the
material of the ventilating sole element to enter between shank and
outsole during the injection taking place later.
[0282] In a further step, the outsole is then placed on a piston of
a mould, which is in the present embodiment a first injection form
or mould and is shaped to mould the ventilating sole element. An
exemplary injection mould 210 is shown in FIG. 9a. It comprises
side frames 211 which are shown in a closed position surrounding a
bottom portion 213 of the mould. The structure visible on top of
the bottom portion 213 is arranged to form the channel structure in
the ventilating sole element, as can been seen in FIG. 9c with
channel structure 162. The outsole may be placed on another part of
the mould 210, for example on a top piston as the top part of the
mould. For example, as shown in FIG. 9b, an outsole 191 is placed
on top of a top piston 212 of the mould 210. In a subsequent step,
the side frames 211 of the mould 210 close from an opened state
into the state as shown in FIG. 9a, wherein the top piston 212 with
the outsole 191 facing the inner space of the mould is lowered and
seals the mould 210 from the top (not shown).
[0283] Afterwards, the material forming the ventilating sole
element, such as polyurethane, is injected into the mould 210
(e.g., conventional polyurethane of the type such as MS18 from
Elastogran GmbH (BASF)). In an embodiment of the invention, this
may be the same polyurethane which is used for a surrounding sole
element (which may also be seen as a midsole) later on. In another
embodiment the polyurethane of the ventilating sole element is
softer (Shore A value of e.g. 30-45) than a polyurethane used for
the surrounding sole element (Shore A value of e.g. 45-65). This
increases comfort for the wearer. During injection the formed
ventilating sole element is bonded to the outsole. After completion
of the injection process, these two components now form a
monolithic entity, as can be seen in FIG. 9c. Subsequently, the
edges of the ventilating sole element may be manually treated for
superfluous material, if any.
[0284] The manufacturing steps as described above may be performed
and finished in a particular manufacturing site independently from
other parts of the shoe, for example by a sub-supplier, who will
deliver to the shoe manufacturer, for instance, a finished
semimanufactured product comprising the ventilating sole element
attached to an outsole. An embodiment of a ventilating sole element
161 attached to an outsole 191 is shown in FIG. 9c. In other
embodiments, according to the aspects as described with reference
to FIGS. 1 to 8, a semimanufactured product comprising any type of
ventilating sole element with or without an outsole component
and/or stilts may be manufactured in a first stage of a
manufacturing process, e.g. by a sub-supplier.
[0285] As illustrated in FIG. 10, a breathable comfort layer 40 is
fixed on the surface of the ventilating sole element, e.g. by glue
being manually spread on the edge of the ventilating sole element
or over parts of or the full surface of the ventilating sole
element. According to an embodiment, before assembling the material
on the ventilating sole element, mechanical pressure is applied to
the material, which is compressed, e.g., from 2 mm to 1 mm in
thickness. This may be done to make the material more compact and
hence to lower the amount of water absorbed. This advantageously
prevents the material from acting as sponge which nurtures growth
of fungus and the like.
[0286] The ventilating sole element with the outsole and the
comfort layer is then placed in an injection mould, such as a
second injection mould 220 (which in this embodiment is different
from the first injection mould 210 for forming the ventilating sole
element), as shown in FIG. 11. For example, the outsole 191 with
the ventilating sole element 161 and the comfort layer 40 is placed
on top of a bottom piston 222. The second injection mould 220
incorporates pins 221 in the side frames for making lateral
passages in a surrounding sole element which if formed during the
following injection process.
[0287] At the beginning of the moulding process, the last with the
upper portion 10 of the shoe is lowered into the second injection
mould 220. The bottom piston 222 is then raised until the
ventilating sole element has firm contact with the bottom portion
20 of the shoe upper assembly placed on the last. The contact
between ventilating sole element with comfort layer and the bottom
portion 20 must be so tight that polyurethane from the upcoming
injection does not enter between bottom portion 20 and comfort
layer. In order to achieve a tight sealing a lip extends vertically
from the surface of the ventilating sole element. The lip could be
arranged around the full upper circumferential edge of the sole
element, but preferably a U-shaped lip of approx 2 mm height is
made in the heel area, and a 1 mm high lip is made in the forefoot
area. When raising bottom piston 222 against bottom portion 20 an
extra mechanical pressure is exerted on the lip in order to deform
it a bit. Due to the force impact the lip will bend outside and
away from the ventilating sole element, and with the aid of the
comfort layer make a tight seal which prevents entry of
polyurethane. After raising the bottom piston the side frames with
pins 221 close the mould 220, as shown in FIG. 12. The pins 221
contact the side wall of the ventilating sole element so as to form
lateral passages 50 in the surrounding sole element to be injected,
but do not penetrate them.
[0288] Thereafter, an injection with surrounding sole material,
particularly PU, is made, hereby creating a surrounding sole
element. After a certain curing time (e.g. 3.5 minutes) the side
frames are opened and last with the shoe is lifted. Any remaining
sprue is manually removed from the surrounding sole element with a
knife.
[0289] In a subsequent step, openings 55 are made in the side wall
of the ventilating sole element, e.g. with a laser or a drill or
puncturing e.g. with a hot needle or other thermal means of
removing wall material. In this regard, FIG. 13 shows a drilling
apparatus 230 with a drill 231 suitable for entering into the
lateral passages 50.
[0290] The creation of openings 55 in the side wall of the
ventilating sole element connects the lateral passages 50 of the
surrounding sole element to the structure or material of the
ventilating sole element, so that water vapour can flow and/or
diffuse through the bottom portion of the upper assembly and then
flow through the structure or material of the ventilating sole
element together with the air flowing therethrough and then through
the lateral passages in the surrounding sole element to the outside
of the shoe, that is the ambient air. It is not necessary that pins
of the mould for forming the surrounding sole element are exactly
aligned with any channels or open parts in the ventilating sole
element prior to injection moulding, to ensure there is a safe
connection between the passages and openings with a smooth
transition and that no injected material can enter into the
channels or openings of the ventilating sole element. Rather,
according to the invention, the pins for forming the lateral
passages do not penetrate into any channels or open parts of the
ventilating sole element. They can have a position in which they
are adjacent to or in contact with the side wall of the ventilating
sole element. The pins can have a position which is not aligned
with any channels or open parts, if any, formed in the ventilating
sole element. The structure or material of the ventilating sole
element and the lateral passages in the surrounding sole element
are interconnected by making apertures or openings in the
ventilating sole element through the lateral passages, so that
thereafter there is a reliable path for air to communicate between
the structure or material of the ventilating sole element and an
outside of the surrounding sole element, that is the ambient air,
regardless of the exact position of the moulding pins.
[0291] FIG. 14 shows a finished shoe with a surrounding sole
element 181 having lateral passages 50 formed therein. According to
an embodiment, the process of drilling starts with high speed and
then switches to a lower speed of the drill.
[0292] A functional layer/membrane as described herein is a water
vapour-permeable and/or waterproof layer, for example, in the form
of a membrane or a correspondingly treated or finfished material,
for example, a textile with plasma treatment. Both the lower
functional layer, also referred to as lower membrane, and the upper
functional layer, also referred to as upper membrane, can be parts
of a multilayer, generally a two-, three- or four-layer laminate;
the lower functional layer and the upper functional layer are
sealed so as to be waterproof in the lower area of the shaft
arrangement on the sole side; the lower functional layer and the
upper functional layer can also be formed from one material.
[0293] Appropriate materials for the waterproof,
water-vapour-permeable functional layer are especially
polyurethane, polyolefins, and polyesters, including polyether
esters and laminates thereof, 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, and
expanded polytetrafluoroethylene provided with hydrophilic
impregnation agents and/or hydrophilic layers; see, for example,
document U.S. Pat. No. 4,194,041. Microporous functional layers are
understood to mean functional layers whose average effective pore
size is between 0.1 and 2 .mu.m, preferably between 0.2 .mu.m and
0.3 .mu.m.
[0294] A laminate as described herein is a composite consisting of
several layers permanently joined together, generally by mutual
gluing or sealing. In a functional-layer laminate, a waterproof
and/or water vapour-permeable functional layer is provided with at
least one textile layer. The at least one textile layer mostly
serves to protect the functional layer during its processing. Here,
we speak of a two-layer laminate. A three-layer laminate consists
of a waterproof, water-vapour-permeable functional layer embedded
in two textile layers. The connection between the functional layer
and the at least one textile layer occurs by means of a
discontinuous glue layer or a continuous water-vapour-permeable
glue layer. In one variant, a glue can be applied spot-wise between
the functional layer and the one or two textile layers. Spot-wise
or discontinuous application of glue occurs because a fullsurface
layer of a glue that is not water vapour-permeable itself would
block the water-vapour permeability of the functional layer.
[0295] A functional layer/functional-layer laminate is considered
"waterproof," optionally including the seams provided on the
functional layer/functional-layer laminate, if it guarantees a
water-entry pressure of at least 1.times.10.sup.4 Pa. The
functional-layer material preferably withstands a water-entry
pressure of more than 1.times.10.sup.5 Pa. The water-entry pressure
is then 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
concerning the procedure are stipulated in ISO standard 0811 from
the year 1981.
[0296] Whether a shoe is watertight can be tested, for example,
with a centrifuge arrangement of the type described in U.S. Pat.
No. 5,329,807.
[0297] A functional layer/functional-layer laminate is considered
"water-vapour permeable" or "breathable" if it has a
water-vapour-permeability number Ret of less than 150
m.sup.2.times.Pa.times.W.sup.-1. Water-vapour permeability is
tested according to Hohenstein skin model. This test method is
described in DIN EN 31092 (02/94) and ISO 11092 (1993).
* * * * *