WO2024221119A1

WO2024221119A1 - Sport shoe and manufacturing method

Info

Publication number: WO2024221119A1
Application number: PCT/CH2024/050023
Authority: WO
Inventors: Flavio GUARNIER
Original assignee: X Technology Swiss GmbH
Current assignee: X Technology Swiss GmbH
Priority date: 2023-04-27
Filing date: 2024-04-19
Publication date: 2024-10-31
Anticipated expiration: 2025-10-27
Also published as: CH720738B1; CN121013666A; CH720738A1

Abstract

A partly multi-layered upper, comprising a base upper (2) with top opening (21), lacing means (23) and a closed lasting margin, with fixed insole and a partly additional upper (3) with cut-outs for lacing means (30), wherein the partly additional upper (3) surrounds at least a hindfoot region (12) of the base upper (2) forming part of a sports shoe (1), should be created, increasing stability and robustness of the sports shoe (1). This is reached because the partly additional upper (3) comprises a midsole margin and is suitable to be wrapped around a midsole edge (40) of a midsole (4), fastened in a taut manner and glued with its midsole margin at least partly to an undersurface of the midsole (4) in a taut manner.

Description

SPORT SHOE AND MANUFACTURING METHOD

TECHNICAL FIELD

The present invention describes a partly multi-layered upper, comprising a base upper with top opening, lacing means and a closed lasting margin, with fixed insole and a partly additional upper with cut-outs for lacing means, wherein the partly additional upper surrounds at least a hindfoot region of the base upper forming part of a sports shoe, a sports shoe with such upper and a manufacturing method of a sports shoe.

STATE OF THE ART

A typical sport shoe or athletic shoe comprises at least three main components: the upper, midsole, and outsole. Each component has a specific function and is designed with specific materials and features to provide support, comfort, and performance during athletic activities. Sport shoe manufacturers are continually developing new features and technologies to improve the performance and comfort of their shoes, giving athletes a range of options to choose from based on their individual needs and preferences.

The upper of a sport shoe is the part that covers the foot and holds it in place. It is typically made of a variety of materials, such as synthetic fabrics, leather, or mesh, and can be designed to be breathable and flexible for comfort and mobility. The upper may also include features such as laces, straps, or Velcro closures to adjust the fit and provide added support.

The midsole of a sport shoe is the layer of material between the upper and the outsole. An insole layer is defined here as a part of the midsole, which is placed inside the upper or forms a closure of the upper facing other midsole parts. The midsole is typically made of a cushioning material, such as foam or gel, and is designed to absorb shock and provide support and stability during athletic activities. The midsole may also include additional features, such as arch support or special cushioning systems, depending on the type of shoe and the intended use.

The outsole of a sport shoe is the bottom layer of the shoe that comes into contact with the ground. It is typically made of rubber or other durable materials and is designed to provide traction and grip for the athlete. The outsole may also include specialized patterns or treads to provide additional traction and support for specific activities, such as running or hiking.

Sport shoes are designed to meet the specific needs of athletes and their intended activities. In addition to the three main components of the upper, midsole, and outsole, sport shoes may also include additional features or technologies to enhance performance and comfort.

Methods for manufacturing are known as following. The method of attaching the upper to the midsole and outer sole of a sports shoe can vary depending on the design and intended use of the shoe. Generally, sports shoes require a secure attachment between the upper, midsole and outsole to withstand the stresses and strains of athletic activity.

One common method for attaching the upper to the midsole and outsole of sports shoes is cementing or adhesive bonding. This involves applying a special adhesive to the edge of the upper and then attaching it to the midsole and/or outsole. The adhesive is then allowed to cure, creating a strong bond between the upper and sole. This method is popular because it provides a lightweight and flexible bond that is well-suited for athletic activities. Another method commonly used for attaching the upper to the midsole and outsole of sports shoes is stitching. This involves using a heavy- duty sewing machine to sew the upper to the lasting board. The stitching is usually done on the outside of the upper but is not visible because it's covered by the midsole, so it is not visible from the outside. This method is used in conjunction with cementing or adhesive bonding to provide added durability and support. Such combined construction method is called Strobel, where the upper is sewn directly to an insole board, which is then attached to the midsole, forming part of the midsole. This construction method is often used because it allows for greater flexibility and a more natural feel in the shoe, as the upper and insole can move more freely with the foot. Additionally, Strobel construction can help reduce weight and incroaso durability in tho shoo.

Some shoes with a Strobel construction may also have an additional layer of foam or cushioning between the insole board and the midsole, which can provide added comfort and support. Overall, Strobel construction is a popular choice for athletic shoes because it offers a balance of flexibility, comfort, and durability.

Overall, the method used to attach the upper to the midsole and/or outsole of a sports shoe will depend on the type of shoe being made, the materials used, and the desired level of durability, flexibility, and support needed for athletic performance.

The "lasted" method is a construction process used in the manufacturing of shoes, including athletic shoes. In this method, a "last" is used, which is a wooden or plastic mold in the shape of a foot. The closed upper of the shoe is stretched and pulled over the last and then attached to the lasting board and then to the sole. Once the upper is attached, the last is removed, and the shoe is left to dry in the desired shape. The lasted method allows for precise shaping of the shoe, resulting in a more customized precise fit for the wearer. It is often used in higher-end shoe manufacturing, technical and heavy duty shoes like mountain shoes or cycling shoes, as it can be more time-consuming and labor-intensive than other construction methods.

The sports shoes produced so far have placed little emphasis on durability, but have focused primarily on comfort. Today, however, the sports shoes should be durable for a long time and be characterized by increased robustness.

DESCRIPTION OF THE INVENTION

The object of the present invention is to create a sports shoe which has increased stability and robustness, showing increased longtime durability of such novel sport shoes, even if the manufacturing process is slightly more complicated.

The comfort of the sports shoe for the athlete remains at a high level despite the more robust shoe design. Above all, the longevity of the sports shoe should be increased, so that even with frequent use a shoe change is postponed. Here, the manufacturer accepts a more elaborate manufacturing process to allow athletes to enjoy their intact sports shoes for longer.

Variations of combinations of features or minor adaptations of the invention can be found in the detailed description, are illustrated in the figures and are included in the dependent claims.

BRIEF DESCRIPTION OF THE DRAWINGS Further understanding of various aspects of the invention can be obtained by reference to the following detailed description in conjunction with the associated drawings, which are described briefly below.

It should be noted that in the differently described embodiments, the same parts are provided with the same reference symbols or the same component names, the disclosures contained in the entire description being able to be applied analogously to the same parts with the same reference symbols or the same component symbols.

A preferred exemplary embodiment of the subject matter of the invention is described below in conjunction with the attached drawings.

FIG. 1 is side view of a finished sport shoe without an outsole according to the invention, while

FIG. 2a) to 2d) are showing side views, partly as exploded views of single manufacturing steps.

FIG. 3 shows a partly exploded view of single manufacturing steps with a combination of base upper and partly additional upper on a lining.

Description

The finished sport shoe 1, includes a forefoot region 10, a midfoot region 11, and a hindfoot region 12, which extends from the toes T to the heel H of the sports shoe 1. The sports shoe 1 is formed by a multi-layer upper comprising a closed base upper 2 and a partially surrounding additional upper 3. The sports shoe 1 shown here in the figures, does not have an outsole for simplicity.

The base upper 2 has a top opening 21 and can be closed with lacing means 23 on the opposite side of the sports shoe 1 from a bottom region 22, preferably laced. However, a Velcro fastener is also possible.

In the area of the heel H, more precisely spanning the hindfoot region 12 and also at least part of the midfoot region 11, the partially surrounding additional upper 3 is fastened over the closed base upper 2 and spanning the midsole 4. In the area of the midfoot region 11, the partially surrounding additional upper 3 is designed in such a way that the lacing means 23 are accessible and both upper 2, 3 can be laced or closed.

In the area of the bottom region 22, overlapping the midfoot region 11 and the hindfoot region 12, the partly additional upper 3 and therewith the whole upper is partially wrapped around and attached to a midsole edge 40 of the midsole 4. The partially surrounding additional upper 3 thus protects the closed base upper 2 and additionally ensures increased robustness of the entire sports shoe 1. More then robustness the additional upper provide a more stable and precise heel seat thus giving the user more control on the shoe and stability.

Since the way in which the individual parts are fastened is also important, the manufacturing process is described below on the basis of Figure 2 and the later claims include not only physical features but also functional features. The base upper 2, preferably in the form of a knitted fabric, is closed on the side opposite the top opening 21. For this purpose, a lasting margin

24 is provided on the first open side of the base upper 2, which is partially folded over around an insole 25 shown with dots and is gluod er sewn there. To accomplish this, a shoe last, not shown, is used over which the base upper 2 is pulled and the insole 25 is attached at the bottom of the shoe last. The result is a closed base upper 2 with insole

25 as shown in Figure 2a). Preferably, the base upper 2 is most preferred lasted using Strobel technique to the insole 25.

The main advantage of this construction is the have a front flexible part (done with Strobel) that follow the point in which the foot bends and a rear heel part (lasted) that gives more stability and more precise fit to the heel.

In the next step, the partly additional upper 3 is pulled over the closed base upper 2 and the shoe last, as shown with the arrow in Figure 2b), whereby an opening in the partly additional upper 3 and cut-outs for lacing means 30 come to lie at the height of the top opening 21 and the lacing means 23 of the base upper 2 respectively. The partly additional upper 3 must be of suitable size, whereby the partly additional upper 3 only encloses the hindfoot region 12 and partially the midfoot region 11 of the sports shoe 1 and of course remains open towards the top, i.e. towards the top opening 21. This condition is shown in Figure 2c).

Now the midsole 4 with a midsole inner surface 41, as indicated by the arrows, is glued below the shoe last with the surrounding base upper 2 enclosed and closed with the insole 25. The partly additional upper 3 is still open and hangs down over the midsole 4 and the midsole edge 40, loose and separated from the midsole 4, which is shown in Figure 2d).

Subsequently, the midsole margin 31 of the partly additional upper 3 is completely folded over around or wrapped around a lower surface of the midsole 4, whereby only a part of the lower surface of the midsole 4 needs to be covered. The midsole margin 31 and thus the entire partly additional upper 3 is firmly tightened in the area of the hindfoot region 12 and optionally also in the area of the midfoot region 11 of the midsole 4 respectively of the sport shoe 1, thus being folded around respectively wrapped around the midsole 4 under tension and thus being fixed to the undersurface in a non-detachable manner. Sewing, stapling or gluing is possible for this purpose, most preferred is gluing as standard lasting technique.

Neue Figur

According to a slight modification, the base upper 2 and the partly additional upper 3 can also be designed as a single piece or single layer, covering a lining B. A cut E is made in base upper 2 between forefoot region 10 and midfoot region 11 and hindfood region 12, with base upper 2 sewn into forefoot region 10 and also along the cut.

The upper 2 and parly additional upper 3 is covering basically all the user foot and the lining B covering the heel and medial/lateral side of the upper 2 is stitched to the upper 2 along the collar, as usually done in standard shoe construction) and along the cut E positioned in the middle area 11 of the upper 2.

In this way the lining B and the front part of the upper 2 form a continuous surface in contact with the foot while leaving the lower heel edge of the upper A free all along the heel and quarter/medial area defining a lasting margin along the bottom edge. This edge delimiting a space under the heel area of the first base upper/additional upper 2+3.

This first layer 2+3 is lasted using Strobel technique, stitched to a footbed covering the bottom of the base upper 2. The Strobel footbed is stitched to the base upper 2 in the front part 10 while in the rear part 12+11 is stitched to the lining B. The midsole 4 is then glued under the first layer 2+3. Once the midsole 4 is secured to the base upper 2, the lasting margin is glued on heel sidewalls of the midsole 4, then folded and glued under the bottom heel area of midsole 4 according to a standard lasting technique.

Preferably, base upper 2 and/or partly additional upper 3 are made of knitted fabric. In addition to being attached underneath the midsole 4 after pulled tight in direction of the midsole 4, the partly additional upper 3 will be folded over, the partly additional upper 3 can also be attached to the side walls of the base upper 2 and the side walls of the midsole 4 in the area of the heel H by gluing or partial sewing.

Here, the upper is a partly multi-layered upper, comprising the base upper 2 and the partly additional upper 3. The midsole margin 31 of the partly additional upper 3 is partially folded over at least in the hindfoot region 12 around the base upper 2 and the midsole 4 with a midsole edge 40. The partly additional upper 3 is folded over to the undersurface of the midsole 4, wherein the partly additional upper 3 is fastened in a taut manner and secured by bonding before the outsole is bonded to the undersurface of the midsole 3 with folded over midsole margin 31.

The partly additional upper 3 must be tensioned over the base upper 2 and the midsole 4, fastened in a taut manner and glued.

Other features, such as padding or ornaments on the outside of the partly additional upper 3 and/or the base upper 2, can also be applied.

This construction with a partly multi-layered upper 2, 3, partly connected to the midsole 4 has several advantages:

- The sports shoe 1 keeps its softness and fexibility in the forefoot region 10, where it's actually requested when you bend your feet.

- The partly additional upper 3 connects and embrace together the midsole 4 and the heel part of the base upper 2, thus stabilizing the heel while not loosing the cushion effect of the midsole 4 - At a lace of the partly additional upper 3 can be pulled in the lasted part of the sports shoe 1 further locking the heel H and stabilizing the foot.

The outsole, omitted here for simplicity, is glued to the undersurface of the midsole 4 before the sports shoe 1 is completed.

The midsole 4 is advantageously formed of an element shaped to essentially copy the contour of the sole of the user's foot and is made of an advantageously flexible material preferably having a hardness of between 47 and 53 Shore C (according to ISO 868). Preferably, the midsole 4 is made of a polyamide elastomeric material and/or polyehter elastomeric material, such as PEBAX®. Advantageously, in order to provide more comfort and efficiently absorb shocks during use of the shoe structure 1, the thickness of the midsole 4 can be differentiated according to the area of the sole of the foot that it has to support. Here in the heel area, in the hindfoot region 12, the midsole 4 has a greater thickness, e.g. about 15 mm, while in the forefoot region 10 it has a smaller thickness, e.g. about 8 mm.

List of reference signs

1 sports shoe

10 forefoot region

11 midfoot region

12 hindfoot region

2 base upper

21 top opening

22 bottom region

23 lacing means

24 lasting margin

25 insole

3 partly additional upper (partly surrounding, enclosing) surrounding

30 cut-out for lacing means

31 midsole margin

4 midsole

40 midsole edge

41 midsole inner surface

Non depicted outsole and shoe last

T toe

H heel

B lining

E cut

Claims

1. Partly multi-layered upper, comprising a base upper (2) with top opening (21), lacing means (23) and a closed lasting margin (24), with fixed insole (25) and a partly additional upper (3) with cut-outs for lacing means (30), wherein the partly additional upper (3) surrounds at least a hindfoot region (12) of the base upper (2) forming part of a sports shoe (1), characterized in that the partly additional upper (3) comprises a midsole margin (31) and is suitable to be wrapped around a midsole edge (40) of a midsole (4), fastened in a taut manner and glued with its midsole margin (31) at least partly to an undersurface of the midsole (4) in a taut manner.

2. Partly multi-layered upper (2, 3) according to claim 1, wherein the partly additional upper (3) is additionally partially folded over or wrapped around in the midfoot region (11) around the midsole (4) and a midsole edge (40).

3. Partly multi-layered upper (2, 3) according to one of the preceding claims, wherein the base upper (2) and/or the partly additional upper (3) are made of knitted fabric.

4. Partly multi-layered upper (2, 3) according to one of the preceding claims, wherein the base upper (2) and/or the partly additional upper (3) are equipped with paddings.

5. Partly multi-layered upper (2, 3) according to one of the preceding claims, wherein the base upper (2) is glued after turning over the lasting margin (24) to the insole (25) underneath the base upper (2).

6. Sports shoe (1) with a closed upper with a lasting margin (24) and an insole (25) inserted in the closed upper, a midsole (4) and an outsole, wherein the upper is attached to the midsole (4) and the outsole is attached to the midsole (4), characterized in that, the upper is a partly multi-layered upper, comprising a closed base upper (2) and a partly additional upper (3), wherein a midsole margin (31) of the partly additional upper (3) is partially folded over at least in the hindfoot region (12) around the base upper (2) and the midsole (4) with a midsole edge (40), folded over to an undersurface of the midsole (4), wherein the partly additional upper (3) is fastened in a taut manner and secured by bonding before an outsole is bonded to the undersurface of the midsole (3) with folded over midsole margin (31).

7. Sports shoe (1) according to claim 6, wherein the partly additional upper (3) is additionally partially folded over or wrapped around in the midfoot region (11) around the midsole (4) and a midsole edge (40).

8. Sports shoe (1) according to one of the claims 6 or 7, wherein (3) auch an (2) im Heel Bereich verklebt.

9. Sports shoe (1) according to one of the claims 6 to 8, wherein the base upper (2) and/or the partly additional upper (3) are made of knitted fabric.

10. Sports shoe (1) according to one of the claims 6 to 9, wherein the base upper (2) and/or the partly additional upper (3) are equipped with paddings.

11. Manufacturing method of a sports shoe (1), comprising the steps: - pulling a base upper (2) with a top opening (21), a bottom region (22), lacing means (23) and a lasting margin (24) over a shoe last,

- closing the base upper (2) on the side opposite the top opening (21) at the lasting margin (24) with an insole (25) using Strobel technique,

- glueing a midsole (4) with a midsole inner surface (41), below the shoe last with the surrounding base upper (2), closed with the insole (25)

- pulling a partly additional upper (3) with cut-outs for lacing means (30) and a midsole margin (31) over the closed base upper (2) on the shoe last, enclosing at least the hindfoot region (12),

- pulling the partly additional upper (3) tight in direction of the midsole (4), folding over underneath the midsole (4) under tension, before beeing attached underneath the midsole (4) by gluing.

12. Manufacturing method according to claim 11, wherein the partly additional upper (3) is pulled with its midsole margin (31) over the closed base upper (2) on the shoe last also in at least a part of the midfoot region (11), wrapped around the midsole edge (40) and attached there.