Note: Descriptions are shown in the official language in which they were submitted.
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Sole Unit for Footwear
For quite some time, footwear has been available with a waterproof and water
vapor
permeable shaft, which allows such footwear to release sweat moisture in the
shaft area
despite its waterproofness. In order for sweat moisture to also escape into
the sole area, a
switch was made to a sole structure having an outsole with through holes
extending through
its thickness and also a waterproof and water vapor permeable sole functional
layer, for
example, in the form of a membrane. One example is shown in EP 0 382 904 A2,
whose
outsole has through holes in the form of microperforations with a
corresponding limitation of
water vapor permeability.
In order to provide greater water vapor permeability with respect to the
strong sweating
tendency of the human foot, a switch has been made to providing the outsole
with large
through holes in comparison with microperforations. One example is shown in
EP 0 275 644 A2 from whose teaching it is known to make the through holes as
large as
possible in order to achieve particularly high water vapor permeability.
The larger the through holes of the outsole, the greater the hazard that a
waterproof
membrane situated above the through holes of the outsole will be damaged by
foreign
objects, such as pebbles, that penetrate the through holes, and therefore that
its
waterproofness will be compromised. EP 0 275 644 A2 therefore proposes that a
protective
layer, for example, made of a latticed or felt material, be arranged between
the outsole with
its through holes and the membrane situated above it, which protective layer
keeps foreign
objects that penetrate the through holes of the outsole from reaching the
membrane.
Additional examples having large through holes of the outsole, in which the
through holes are
closed by means of a membrane against the penetration of water to the shoe
interior
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and in which a protective layer is situated beneath the membrane and is
intended to prevent
the penetration of foreign objects to the membrane are known from WO
2004/028284 Al,
WO 2006/010578 Al, WO 2007/147421 Al and WO 2008/003375 Al. In all these
cases, a
textile backing in the form of a fine mesh is laminated onto one side of the
membrane,
usually a film. A mesh-like protective layer arranged between the membrane and
through
holes of the outsole offers a certain degree of protection against the
penetration of foreign
objects to the membrane. To improve protection for the membrane an additional
protective
layer, which is a felt layer, for example, is arranged between the membrane
and the mesh-like
protective layer. Double protection for the membrane is therefore created in
which two
superimposed layers participate, each of which has its own technical
protective function.
The material choice for these layers and their thickness and perforation
strength values must
be adapted to the requirements of the corresponding practical variant. This
applies to the
known solutions and to the solutions presented with the present invention.
Another example of very large sole openings is shown in WO 2007/101624 Al,
according to
which the large through holes of the outsole are stabilized by stabilization
connectors and/or
stabilization lattices. These carry water vapor permeable textile material,
for example, a felt-
like material, fit into the through holes. The shoe sole composite constructed
in this way is
connected to a shaft whose shaft bottom is closed with a waterproof and water
vapor
permeable shaft bottom functional layer so that the entire shoe is waterproof
and water
vapor permeable.
A fibrous layer having at least two fibrous components that differ in terms of
their melting
temperatures is particularly well suited for the textile material, wherein at
least a portion of a
first fibrous component has a first melting temperature and a lower first
softening
temperature range, and at least a portion of a second fibrous component has a
second melting
temperature and a
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lower second softening temperature range, and the first melting temperature
and first
softening temperature range are higher than the second melting temperature and
the second
softening temperature range, and wherein the fibrous layer is mechanically
consolidated as a
result of thermal activation of the second fibrous component with a tackifying
temperature in
the second softening temperature range, while maintaining water vapor
permeability in the
thermally consolidated area. In this case either the through hole or
optionally several through
holes of the outsole can be closed with individual pieces of the textile
material or all through
holes of the outsole are closed with a single piece of textile material.
The textile material in this known footwear has two functions. In the first
place it serves for
stabilization of the sole structure, especially with respect to the fact that
an outsole with large
openings cannot adequately contribute itself to stabilization of the sole
structure. The textile
material is formed with a relatively high intrinsic stability, which favors
the overall stability
of the sole structure. In the second place, in the finished footwear according
to
WO 2007/101624 Al, for example, a waterproof, water vapor permeable membrane
is
situated above the sole structure, and is protected by the textile material
from damage by
foreign objects, such as pebbles, that could damage the membrane.
Polymers chosen, for example, from PES (polyester), polypropylene, PA
(polyamide) and
mixtures of polymers are especially well suited for the textile material.
In one variant according to the already mentioned WO 2007/101624 Al the
textile material
consists of a fibrous composite in the form of a nonwoven fabric mechanically
consolidated
thermally and additionally surface-consolidated by thermal surface treatment,
with two
fibrous components, each of which is constructed with polyester fibers. The
first fibrous
component with
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the higher melting temperature then forms a support component of the fibrous
composite, and
the second fibrous component with the lower melting temperature forms a
consolidating
component. In order to guarantee temperature stability of the entire fibrous
composite of at
least 180 C, especially in view of the fact that footwear can be exposed to
relatively high
temperatures during production, for example, during molding-on of an outsole,
in the
considered variant, polyester fibers having a melting temperature above 180 C
are used for
both fibrous components. There are different variations of polyester polymers
that have
different melting temperatures and softening temperatures lying
correspondingly below them.
In the considered variant of the felt-like material, a polyester polymer
having a melting
temperature of about 230 C is chosen for the first component, whereas for the
second fibrous
component a polyester polymer having a melting temperature of about 200 C is
chosen. The
second fibrous component can be a core-shell fiber, the core of this fiber
consisting of a
polyester with a softening temperature of about 230 C and the shell of this
fiber consisting of
a polyester with a tackifying temperature of about 200 C. Such a fibrous
component with two
fibrous fractions of different melting temperatures is also referred to as
"Bico". Additional
information concerning such textile materials in which a felt-like material
can be involved
can be found in the already mentioned WO 2007/101624 Al.
The thermally mechanically consolidated textile material which is particularly
well suited for
the two aforementioned purposes, namely stabilization and membrane protection,
has the
disadvantage that its fibrous component with the lower melting temperature,
which serves as
the consolidating component, cannot be satisfactorily dyed, or can be only
insufficiently
dyed, and therefore remains white in the fibrous composite, which gives the
textile material
overall an unsatisfactory appearance. This becomes noticeable as a drawback
because the
textile material is visible through the large through holes of the outsole.
The increasing
demand to configure the entire footwear and therefore also its sole bottom
fashionably by
also giving the bottom of
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the sole structure a fashionable appearance, especially by appropriate and
varied dyeing, can
therefore not be satisfied with this textile material.
It is also known to close large openings in a sole with other materials, for
example, with felt-
like material consisting at least partially of aramid fibers like KEVLAR.
However, aramid
fibers also are not able to be dyed, or can be dyed only very poorly, so that
the already
mentioned problems occur in this case too.
For example, it is known from the already mentioned WO 2006/010578 Al to close
large
sole openings with a mesh made of nylon, for example. A membrane, which can be
connected on the mesh side with a protective layer of felt material, is
situated above this
mesh. A mesh consists of a mesh structure, in which from external contact,
especially during
walking with the correspondingly designed shoe, meshes can be released from
the structure
which then hang down within the sole opening. Loose meshes and/or hanging
fibers are not
visually desirable and under some circumstances can reduce the safety of the
shoe.
It is also conceivable for a textile fabric or knit to be used instead of a
felt-like material,
which also has the problem of non-dyeability because of the fibers that are
used, and here
again individual fibers can become separated from the fabric composite.
In the cited cases, either the non-dyeability of the fibers that are used, or
smaller damage to
the fibrous structure can lead to an unsatisfactory appearance of the material
that is used and
therefore the shoe that is equipped with it.
A sole unit for footwear is created with the present invention, which permits
a satisfactory
and largely arbitrary fashionable configuration of the bottom of the sole
structure with
respect to
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dyeing and patterning, as well as material choice, without seriously
compromising the water
vapor permeability of the sole unit or its barrier or protective function.
This is achieved with a sole unit according to the invention as specified in
Claim 1, with
which footwear according to invention can be produced according to Claim 25.
Variants of
the invention are specified in the dependent claims.
A sole unit for footwear according to the invention is water vapor permeable
and water-
permeable, and has at least one sole layer with at least one large-surface
through hole
extending through its thickness. It also has at least two superimposed sheet
structures that
close the at least one through hole, a first sheet structure of which has a
textile water vapor
permeable barrier layer and a second sheet structure of which has a water
vapor permeable
decor layer, which is arranged beneath the first sheet structure at least in
the area of the at
least one through hole and is visible from the bottom of the sole layer in the
at least one
through hole.
In one variant of the invention the barrier layer is constructed with a
fibrous layer, which has
at least two fibrous components which differ with regard to their melting
temperatures,
wherein at least one portion of a first fibrous component has a first melting
temperature and a
lower first softening temperature range and at least one portion of a second
fibrous
component has a second melting temperature and a lower second softening
temperature range
and the first melting temperature and the first softening temperature range
are higher than the
second melting temperature and the second softening temperature range. The
fibrous layer is
mechanically consolidated thermally as a consequence of thermal activation of
the second
fibrous component with a tackifying temperature in the second softening
temperature range
while maintaining water
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vapor permeability in the area mechanically thermally consolidated range.
There can be different reasons in footwear with a sole unit, especially of the
type just
mentioned, for covering the material of the sole unit visible from the bottom
of the outsole
through its large area through holes, also called openings, at least partially
by means a decor
layer according to the invention.
The use according to the invention of such a decor layer in a sole unit having
an
aforementioned fibrous layer is based on the finding that dyeing of the
fibrous component
with the lower melting temperature, which serves as the consolidating
component, requires
that this fibrous component be heated to a temperature above the softening
temperature of
this fibrous component so that this fibrous component cannot be dyed. This is
different with
the other fibrous component that has the higher melting temperature. Its
melting temperature
is higher than the temperature required for dyeing. Dyeing is therefore
possible only with
respect to the fibrous component having the higher melting temperature, but
not with respect
to the fibrous component having the lower melting temperature, so that white
spots within the
fibrous composite of the textile material cannot be avoided, which leads to an
aesthetically
unappealing appearance.
This problem is countered in a sole structure with such a fibrous layer
according to the
invention in that the unsatisfactory coloring of the textile material is
tolerated and a decor
layer is positioned in front of this textile material, which is made of
material with appropriate
color or dyeing, this material, for example, being grid-like or net-like or
consisting of a
perforated sheet or a textile material with high water vapor permeability,
which therefore
scarcely compromises the water vapor permeability of the sole unit by the
decor layer.
Therefore, with the solution according to the invention, with essentially no
adverse effect on
water vapor permeability, the less attractive appearance of the textile
fibrous layer can be
concealed behind the decor layer,
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which is not subject to the limitation with respect to color or dyeing
described above in
conjunction with the textile material. The decor layer can therefore be dyed
and configured
independently and according to almost any fashion ideas, which is not possible
for the textile
material of the aforementioned fibrous layer. One can deliberately use
materials for the decor
layer that are readily dyed and/or can be patterned or naturally have
attractive colors
and/or patterns.
With the solution according to the invention a technical requirement, namely a
protective
function, and an aesthetic requirement, namely a visually attractive
appearance, can be more
easily implemented and also made commercially more attractive in that meeting
these two
requirements is no longer attempted with a single layer, and the requirements
are instead
divided between two different layers, each of which can be deliberately
configured with
respect to its special requirement and function. On the one hand, in the layer
with the
technical function, compromises no longer need be made in order to achieve at
least a half-
way attractive aesthetic impression. On the other hand, the layer with the
aesthetic function
can be configured almost exclusively according to this function, because it
does not need to
provide the technical function of the other layer.
There are various commercial advantages of decoupling according to the
invention of the
technical function, for example, stabilization function, and the aesthetic
function. The layer
with the technical function, for example, the stabilization layer, can be
produced in a standard
color so that it can be used for all shoes that are to be equipped with such a
technically
effective layer, which is very cost effective. The layer with the aesthetic
function, namely the
decor layer, can be chosen from a standard assortment, which is also very cost
effective.
Using a decor layer according to the invention can also be advantageous for a
case in which
materials for both components of the thermally consolidated fibrous layer are
or should be
available that are not subject to the aforementioned limitation with respect
to color or
dyeing. For
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example, the thermally mechanically consolidated textile material of the
fibrous layer is
higher in price than materials suitable for the decor layer. There is a strong
trend especially in
the high fashion market sector of leisure shoes to provide the same or
different shoe models
with different colors and different patterns, for example, in order to respond
to different age
groups with different fashion configurations. If this requirement had to be
met with
differently colored and patterned fibrous layers, each shoe manufacturer would
have to
acquire and stock correspondingly colored and/or patterned different fibrous
layers. This
would be a drawback not only from a logistical standpoint both for the
manufacturer of the
fibrous layers and for the shoe manufacturer, but also with respect to higher
purchasing costs
for the shoe manufacturer as a result of the relatively limited number of
pieces per color
and/or pattern. Owing to the fact that, when the decor layer is used, the
appearance of the
bottom of the sole unit is no longer determined by the fibrous layer material
but by the
appearance of the decor layer, the shoe manufacturer can order uniform fibrous
layer material
and can concentrate on the decor layer with respect to the visual and fashion
appearance of
the bottom of the sole unit. The shoe manufacturer or, if the shoe
manufacturer itself does not
produce the soles for his shoes, the sole manufacturer can order material for
this purpose in
targeted amounts and colors, as well as structures and material types, or can
himself
configure the material with respect to dyeing and color pattern, in which case
he can order
materials for the decor layers desired by him from a larger number of
suppliers, so that he can
turn to different material manufacturers both with respect to pricing and also
with respect to
availability of different materials. Regardless of whether or not the material
of the fibrous
layer can be dyed according to the desired ideas, it can be worth considering
to visually
configure the bottom of the sole unit with respect to color and pattern with
an additional
decor layer, especially for the aforementioned reasons of logistics,
versatility, and pricing.
If the material for the decor layer is to be dyed after its production, for
example, by spraying,
screen printing or the like, it need only be kept in mind that dyeing or
patterning must be
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performed in such a way that the meshes or other openings or pores of the
material of the
decor layer remain open far enough that the desired water vapor permeability
is retained.
Such color configuration with such means and methods would not be possible in
a textile
layer, especially a felt layer, which in known cases is visible through the
through holes of the
outsole. On the one hand, color patterns, especially of a finely structured
type, cannot be
produced with sufficient resolution on the surfaces of textile materials like
felt. On the other
hand, it can be avoided only with difficulty that during the application of
color by spraying or
screen printing the surfaces of such materials are significantly clogged so
that the desired
water vapor permeability can no longer be achieved. In addition, such
techniques are
relatively expensive. Embossing of textile materials results in a non-uniform
surface height,
which is again a drawback during molding on of the sole material, since the
flow of sole
material into the textile layer cannot be calculated.
A decor layer according to the invention is particularly advantageous in a
variant in which the
fibrous layer has two fibrous components and a material is used for the second
fibrous
component in which the softening temperature range of the second fibrous
component is
lower than the temperature required for dyeing the second fibrous component.
In this case the
aesthetically less attractive appearance of the fibrous layer with its white
spots can only be
laminated with a decor layer according to the invention so that the bottom of
the sole unit can
be configured as visually attractive.
Especially for the case in which shoes with a sole unit provided with a decor
layer according
to the invention are directed toward younger consumers, a "metal look"
achieved with the
decor layer can be attractive. Consequently, in one variant of the invention
the decor layer
consists of material that offers the appearance of metal. In a first variant
of the invention
prescribed for this purpose the material of the decor layer consists
exclusively of metal, for
example, a metal grid or
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metal net. In a second variant of the invention proposed for this purpose the
material of the
decor layer consists of a metalized plastic grid or is constructed with
metalized fibers that are
brought to a yam structure or in the form of a yarn net.
Material examples for a purely metallic decor layer are iron, aluminum and
steel. Material
examples for a decor layer of metalized plastic are woven, knit and warp knit
fabrics with a
sheathing of tin, silver, copper, nickel or other alloys, for example, POLYMET
from
Platingtech Beschichtung GmbH & Co. KG, Niklasdorf, Austria. The material
becomes tear
resistant, wear resistant and corrosion resistant. Material examples for a
decor layer of non-
metalized plastic include polyester, polypropylene, polyurethane, polymers,
polyamide, for
example, polyamide mesh silver from Panatex, 25030 Zocco d'Erbusco, Italy.
However, materials made water vapor permeable by machining, for example,
perforation, or
also perforated sheet material, for example, made of polyamide, polyurethane,
etc. or
naturally water vapor permeable sheet material, for example, plastic, textile,
leather, metal,
glass fibers or a combination thereof, are also suitable as material for the
decor layer.
One can also combine the aforementioned material examples for the decor layer
with each
other or with additional materials in order to achieve desired color and
pattern effects.
In one variant of the invention the decor layer has a substrate and a coating
covering the
surface of the substrate, the coating being constructed with a material that
is dyed or has at
least one dye. In this way different material requirements for a decor layer
can be combined,
for example, a substrate with desired mechanical properties and desired water
vapor
permeability can be combined with a coating that can be dyed and patterned
exclusively
according to aesthetic
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viewpoints, because it need not contribute to the desired or required
mechanical properties
and the desired water vapor permeability of the decor layer.
In one variant of the invention the decor layer is constructed with dirt
repellant material.
For the case in which the decor layer is constructed with net-like, grid-like
or mesh-like
material, for example, textile material, the decor layer can be constructed
either with
monofilament fibers or with multifilament yams.
Multifilament yams are composed of several fibers, between which capillary
areas exist.
Soiling substances, such as dirt, contaminated liquids, such as dirty water,
or contaminating
liquids, such as oils, can penetrate into said yarns, and can scarcely be
removed again from
the yarn so that the yarn and the decor layer constructed with it appear
permanently and
irreversibly soiled or can at least be visually compromised.
In one variant of the invention this is prevented by the fact that the decor
layer is constructed
with monofilament fibers that naturally have no capillary channels. In a
particularly preferred
variant of this type a fibrous material that is nonabsorbent, for example, a
plastic material, is
used for the monofilament fibers.
In one variant of the invention in which the decor layer is constructed with
yarn, i.e., with a
multifilament structure, the incorporation of soiling substances is prevented
by encasing the
yarn in plastic, such as silicone or essentially colorless silicone-like
material, so that net or
grid-like openings in this decor layer remain open and water vapor
permeability is therefore
retained. By this sheathing of the yarn such soiling substances cannot
penetrate between the
fibers forming the yarn. A soiling of the decor layer that can hardly be
eliminated and
therefore is permanent is
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thereby prevented. On the other hand, the color of the yarn and therefore of
the decor layer
remains visible by sheathing with such essentially colorless materials.
In another variant the capillary areas of the multifilament yarn are at least
partially filled or
impregnated with a plastic. The penetration of dirt into the capillary areas
is thereby
suppressed and a permanent soiling of the decor layer is prevented.
In one variant of the invention the decor layer is connected to the barrier
layer only in edge
areas such that, especially during walking movements, a relative movement of
the decor layer
is made possible relative to the barrier layer. This means that everywhere the
decor layer is
situated above a large area through hole in the underlying sole layer,
especially the outsole
(and is visible through this large-surface through hole), the decor layer is
not joined to the
barrier layer, which makes relative movement of the decor layer possible
relative to the
barrier layer at least in the areas of this large area through hole. Soiling
substances, like
especially dry sludge or the like, which has become fixed in the grid or net
openings, can be
loosened or released by this relative movement of the decor layer so that it
can fall off and a
clean decor layer remains. This dirt-loosening relative movement can also be
produced by the
sole structure of the footwear, which has been removed from the foot, being
bent by hand, for
example, when the dirt is so firmly attached that it is not adequately
loosened from the decor
layer by walking movements.
In one variant of the invention the decor layer is connected to the barrier
layer only in
peripheral edge areas. For a case in which the barrier layer is assigned one
or more
stabilization connectors, the decor layer can also or additionally be
connected to the barrier
layer in the area of the stabilization connector or connectors. It is
important only that the
decor layer remain unconnected from the barrier layer where the at least one
through hole of
the sole layer, for example, the outsole, is situated, so that the dirt
loosening relative
movement of the decor layer relative to the barrier layer is possible there.
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In one variant of the invention the two expedients just disclosed for keeping
the decor layer
clean are combined. In this variant, on the one hand, the decor layer is
connected to the
barrier layer only in the edge areas so that the mentioned relative movement
is made possible,
which promotes the loosening and falling off of dirt that has adhered in the
openings of the
decor layer. On the other hand, in this variant the decor layer is constructed
either with
monofilament material or with yarn encased by or impregnated with silicone or
silicone-like
material, so that soiling substances cannot penetrate the yarn and the yarn
remains clean and
in its original color appearance. In this variant dirt can penetrate into the
openings of the net-
like or grid-like decor layer, where it is loosened again and can fall out as
a result of the
outlined relative movement between the decor layer and barrier layer, so that
the decor layer
becomes clean again and has its original visual appearance.
The loosening of dirt from the openings of the decor layer is particularly
effective and
thorough in a variant in which, in addition to the expedients just explained,
a barrier layer is
used that is relatively smooth at least on its side facing the decor layer and
has a closed
surface, for example, because it consists of a fibrous material that can be
smoothed and
superficially closed by means of a thermal surface treatment. When such a
barrier layer is
used, dirt settles only in the openings of the decor layer because it does not
adhere to the
smooth, closed surface of the barrier layer. In this variant, which is
constructed by a
combination of a barrier layer with a smooth surface and a decor layer, which
is connected,
on the one hand, only in edge to the barrier layer and, on the other hand, is
constructed with
monofilament material or yarn impregnated with or encased by silicone or
similar material, a
particularly effective and thorough keeping clean of the decor layer are
achieved, and
therefore a maintenance of an unimpaired visual appearance of the decor layer
and therefore
the bottom of the shoe structure of the footwear, are achieved.
In one variant of the invention the decor layer is constructed with leather,
which is finished so
as to be water-, oil- and dirt-repellant in order to counteract a penetration
of soiling
substances into the leather structure and therefore an impairment of the
visual appearance of
this decor layer. Fluorocarbons, especially in the form of fluorocarbon
resins, silicone-
containing agents, and the
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like, for example, are suitable as finishing material for this purpose. In
this variant the leather
serving as the decor layer is also preferably joined to the barrier layer only
in its edge areas in
order to permit the relative movement between the decor layer and barrier
layer just
explained and therefore to promote the falling out of dried dirt from the
decor layer.
In variants of the invention, the decor layer can have a water vapor
permeability in the range
of 10,000 g/m2'24 h to 50,000 g/m2'24 h, especially in the range of 20,000
g/m2-24 h to
30,000 g/m2'24 h. In one variant of the invention, the decor layer has a water
vapor
permeability of 26,000 g/m2'24 h. In variants of the invention, the
stabilization layer, here
also called the barrier layer or fibrous layer (textile material), has a water
vapor permeability
in the range of 3,000 g/m2'24 h to 20,000 g/m2'24 h, especially in the range
of 8,000 g/m2'24 h
to 15,000 g/m2'24 h. In one variant of the invention, the stabilization layer
has a water vapor
permeability of 12,588 g/m2'24 h. With such values for water vapor
permeability for the
decor layer and the stabilization layer, a water vapor permeability desired
for the entire sole
unit can be achieved.
In variants of the invention, the entire sole unit can have a water vapor
permeability in the
range of 1,000 g/m2'24 h to 20,000 g/m2'24 h, especially in the range from
6,000 g/m2'24 h to
12,000 g/m2'24 h. In one variant of the invention the water vapor permeability
in the entire
sole unit is 9,337 g/m2'24 h.
In one variant of the invention the sole layer of the sole unit to which the
decor layer is
assigned consists of an injectable material, especially a plastic material.
This permits another
variant of the invention, in which the sole layer is molded onto the fibrous
layer and the decor
layer in such a way that the fibrous layer and decor layer are joined to the
sole layer via sole
layer material. In one variant the fibrous layer and decor layer can be joined
to each other by
means of sole layer material.
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In one variant the fibrous layer and decor layer can be penetrated by sole
layer material.
These variants permit a particularly advantageous connection of the sole
layer, fibrous layer
and decor layer because it is inexpensive and technically less demanding.
In one variant of the invention the sole layer forms an outsole. In another
variant of the
invention the sole layer forms a midsole of the sole unit.
In one variant of the invention the fibrous layer and decor layer form an
insert. This leads to
the possibility that sole structures of the same type, which have the same
outsole or midsole
and/or other identical components, for example, can make available a
relatively large number
of sole units according to the invention in a rational and therefore cost-
effective fashion from
a logistically advantageous standpoint by their combination with differently
configured
inserts, which differ from each other especially with respect to their decor
layer.
The invention also creates footwear with a sole unit provided with a decor
layer according to
the invention and having a shaft which is provided on a sole sided shaft end
region with a
waterproof and water vapor permeable shaft bottom functional layer, wherein
the sole unit
provided with the shaft bottom functional layer is bonded to the shaft end
region such that the
shaft bottom functional layer is unbonded to the fibrous layer at least in the
region of the at
least one through hole. The latter provides particularly high water vapor
permeability,
because no glue is present between the fibrous layer and shaft bottom
functional layer in the
area of the through hole(s), which would lead to a reduction in water vapor
permeability.
In one variant of the invention the footwear, in addition to the shaft bottom
functional layer,
has a shaft functional layer extending over a significant area of the shaft
outer material,
which is
WO 2009/153054 Al Page 17
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bonded waterproof to the shaft bottom functional layer or is bonded to it to
form a sock-like
insert (also called a bootie).
Such footwear (except for the foot insertion opening), on the one hand, is
waterproof all the
way around but is still water vapor permeable, and on the other hand can be
configured in
largely any way with respect to the appearance of the sole bottom of the
footwear, which is
particularly important in fashion shoes for aesthetic reasons or because the
shoe manufacturer
desires a special visual configuration of the sole bottom pointing toward him.
Definitions and test methods
Footwear:
Foot covering with a closed upper part (shaft arrangement) which has a foot
insertion opening
and at least one sole or one sole unit.
Shaft outer material:
A material which forms the outside of the shaft and therefore the shaft
arrangement and
consists, for example, of leather, textile, plastic, or other known materials
and combinations
thereof, or is constructed with them and generally consists of a water vapor
permeable
material. The lower end of the shaft outer material on the sole side forms an
area adjacent to
the upper edge of the sole or sole unit and above a boundary plane between the
shaft and sole
or sole unit.
Inlay sole (insole):
An inlay sole is part of the shaft bottom. A lower shaft end area on the sole
side is fastened to
the inlay sole.
Sole:
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A shoe has at least one outsole, but can also have several types of sole
layers arranged one
above the other and forming a sole unit.
Outsole:
Outsole is understood to mean that part of the sole area that touches the
floor/ground or
produces the main contact with the floor/ground. The outsole has at least one
tread surface
that touches the floor.
Midsole:
In a case in which the outsole is not directly applied to the shaft
arrangement, a midsole can
be inserted between the outsole and the shaft arrangement. The midsole can
serve, for
example, for cushioning, damping or as filler material.
Bootie:
A sock-like inner lining of a shaft arrangement is referred to as a bootie. A
bootie forms a
sack-like lining of the shaft arrangement which essentially completely covers
the interior of
the footwear.
Functional layer:
Waterproof and/or water vapor permeable layer, for example, in the form of a
membrane or a
correspondingly treated or finished material, for example, a textile with
plasma treatment.
The functional layer can form at least one layer of a shaft bottom of the
shaft arrangement in
the form of a shaft bottom functional layer, but can also be provided as a
shaft functional
layer that at least partially lines the shaft. Both the shaft functional layer
and the shaft bottom
functional layer can be part of a multilayer, generally two-, three- or four-
layer membrane
laminate. The shaft functional layer and the shaft bottom functional layer can
each be part of
a functional layer bootie. If, instead of a functional layer bootie, a shaft
functional layer and a
separate shaft bottom
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functional layer are used, these are sealed, for example, in the sole sided
lower region of the
shaft arrangement relative to each other in a waterproof seal. Shaft bottom
functional layer
and shaft functional layer can be formed from different materials or the same
material.
Appropriate materials for the waterproof, water vapor permeable functional
layer include
especially polyurethane, polypropylene and polyester, including polyether
esters and their
laminates, as described in documents US-A-4,725,418 and US-A-4,493,870. In one
variant
the functional layer is constructed with microporous expanded
polytetrafluoroethylene
(ePTFE), as described, for example, in documents US-A-3,953,566 and US-A-
4,187,390. In
one variant the functional layer is constructed with expanded
polytetrafluoroethylene
provided with hydrophilic impregnation agents and/or hydrophilic layers; see,
for example,
document US-A-4,194,041. A microporous functional layer is understood to mean
a
functional layer whose average pore size is between about 0.2 gm and about 0.3
gm.
Laminate:
Laminate is a composite consisting of several layers that are permanently
bonded to each
other, generally by mutual gluing. In a functional layer laminate, a
waterproof, water vapor
permeable functional layer is provided with at least one textile layer. The at
least one textile
layer, also called backing, primarily serves for protection of the functional
layer during its
processing. One speaks here of a two-layer laminate. A three-layer laminate
consists of a
waterproof, water vapor permeable functional layer embedded in two textile
layers. The
functional layer and the at least one textile layer are bonded to one another
by means of a
continuous water vapor permeable glue layer or by means of a discontinuous
glue layer of
non-water vapor permeable glue. In one variant, glue in the form of a spot-
like pattern can be
applied between the functional layer and the one or two textile layers. The
spot-like or
discontinuous application of glue occurs because a
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full surface layer of a glue that is not water vapor permeable itself would
block the water
vapor permeability of the functional layer.
Barrier layer:
A barrier layer serves as a barrier against penetration of substances,
especially in the form of
particles or foreign objects, for example, pebbles, to a material layer to be
protected,
especially to a mechanically sensitive functional layer or functional layer
membrane.
Decor layer:
A decor layer is a material layer provided for aesthetic reasons whose
function includes
covering the appearance of a material layer that is visible without the decor
layer but is
covered by the decor layer and is provided especially for its technical
function, especially if
the material layer has an unsatisfactory or undesired aesthetic appearance.
Porous:
Within the context of a decor layer according to the invention, porous means
that the material
of the decor layer is naturally water permeable and water vapor permeable or
permeable as a
result of processing.
Puncture resistant:
The puncture resistance of a textile fabric can be measured with a measurement
method used
by the EMPA (Federal Material Testing and Research Institute) using a test
instrument of the
Instron tensile testing machine (model 4465). By means of a punch, a round
textile piece
13 cm in diameter is punched out and fastened to a support plate in which 17
holes are
situated. A punch to which 17 pin-like needles (sewing needle type 110/18) are
fastened is
brought down with a speed of 1,000 mm/min far enough that the needles pass
through the
textile piece into the holes of the support plate. The force for puncturing
the textile piece is
measured by means of a
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measurement probe (a force sensor). The result is determined from a sample
number of
three samples.
The puncture resistance of a material layer like the barrier layer or
stabilization layer is tested
by means of the test method TM 37 SATRA of SATRA Technology Centre, Wyndham
Way,
Kettering, Northamptonshire, NN 16 8SD, United Kingdom.
Reference document:
European Standard EN 344-1, especially section 4.3.3 (penetration resistance).
Test description:
The force required to drive a hardened steel nail with a sharp tip through a
boot or shoe
bottom is determined.
Test device-parameters:
Tear testing device from Instron Deutschland GmbH, Werner-von-Siemens-Strasse
2,
64319 Pfungstadt;
A steel nail provided with a sharp tip with a diameter of 4.5 mm and a tip
angle of 30 serves
as anvil;
the advance speed is 10 3 mm/min;
Test locations: The test TM 37 SATRA prescribes for the puncture resistance
test of a sole
four test sites distributed over the sole having a spacing at least 20 mm from
each other (ball
of the foot inside, ball of the foot outside, instep area, heel). Since the
puncture resistance of
the barrier layer is at issue in conjunction with the present invention,
which, however, is
directly threatened with penetration by pointed objects only in the area of
the large-surface
through hole provided for high water vapor permeability of the sole layer
equipped with it,
for those variants of the invention in which no such through holes are
prescribed in the heel
area, the test location in the heel area is left out during use of the test TM
37 SATRA.
Definition of puncture resistance:
Within the context of the present invention, puncture resistant means that the
tested material,
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especially the shoe stabilization material or barrier material according to
the invention,
withstands a force of at least 40 Newton in the puncture test TM 37 SATRA.
Thickness:
The thickness of the shoe stabilization material according to the invention is
tested according
to DIN ISO 5084 (10/1996).
Waterproof-
A functional layer/functional layer laminate/membrane is considered
waterproof, optionally
including seams provided on the functional layer/functional layer
laminate/membrane, if it
guarantees a water entry pressure of at least I X 104 Pa. The functional layer
material
preferably guarantees a water entry pressure of more than I X 105 Pa. The
water entry
pressure is to be measured according to a test method in which distilled water
at 20 2 C is
applied to a sample of 100 cm2 of the functional layer with increasing
pressure. The pressure
increase of the water is 60 3 cm H2O per minute. The water entry pressure then
corresponds
to the pressure at which water first appears on the other side of the sample.
Details of the
procedure are stipulated in ISO Standard 0811 from 1981.
Whether a shoe is waterproof can be tested, for example, with a centrifuge
arrangement of the
type described in US-A-5 329 807.
Water vapor permeable:
A functional layer/functional layer laminate is considered water vapor
permeable if it has a
water vapor permeability number Ret of less than 150 m2 X Pa X W-'. Water
vapor
permeability is tested according to the Hohenstein skin model. This test
method is described
in DIN EN 31092 (02/94) or ISO 11092 (1993).
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The water vapor permeability values of the barrier layer/fibrous
layer/stabilization
layer/decor layer according to the invention are tested by means of the so-
called cup method
according to DIN EN ISO 15496 (09/2004) [A3].
The gauge of water vapor permeability of the sole unit [A4] can be determined
with the
measurement method specified in document EP 0 396 716 B 1, which was conceived
for
measurement of the water vapor permeability of an entire shoe. For measuring
the water
vapor permeability of only the sole unit of a shoe, the measurement method
according to
EP 0 396 716 B 1 can also be used by measuring with the measurement layout
depicted in
Figure 1 of EP 0 396 716 B 1 in two consecutive measurement scenarios, namely
once of the
shoe with a water vapor permeable sole unit and another time of the otherwise
identical shoe
with a water vapor impermeable sole unit. The percentage of water vapor
permeability that is
attributed to the water vapor permeability of the water vapor permeable sole
unit can then be
determined from the difference between the two measured values.
In each measurement scenario, using the measurement method according to EP 0
396 716 B 1,
the following sequence is used:
1. Conditioning the shoe by leaving it in a climatized room (23 C, 50%
relative
humidity) for at least 12 hours.
2. Removal of the insert sole (foot bed).
3. Lining the shoe with a waterproof, water vapor permeable lining material
adapted to the shoe interior, which material is waterproof and can be closed,
water vapor tight, in the area of the foot insertion opening of the shoe with
a
waterproof, water vapor permeable sealing plug (for example, made of
Plexiglas and with an inflatable sleeve).
4. Filling water into the lining material and closure of the foot insertion
opening
of the shoe with the sealing plug.
5. Preconditioning of the shoe filled with water by leaving it at rest for a
predetermined period of time (3 hours) in which the temperature of the
water is
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kept constant at 35 C. The climate of the surrounding room is also kept
constant at 23 C and 50% relative humidity. The shoe is blown against
frontally during the test by a fan with an average of at least 2 m/s to 3 m/s
wind velocity (to destroy a resting air layer forming around the standing
shoe,
which would cause significant resistance to water vapor passage).
6. Reweighing the shoe filled with water and sealed with a sealing plug after
preconditioning (gives the weight m2 (g)).
7. Allowing it to stand again and an actual test phase of 3 hours under the
same
conditions as in step e).
8. Reweighing the sealed shoe filled with water (gives the weight m3 (g))
after
the test phase of 3 hours.
9. Determination of the water vapor permeability of the shoe from the water
vapor amount that has escaped during the test time of 3 hours through the shoe
(m2 - m3) (g) according to the relation M = (m2 - m3) (g)/3 (h).
After both measurement scenarios have been conducted in which the water vapor
permeability values have been measured on the one hand for the entire shoe
with water vapor
permeable sole unit (value A) and on the other hand for the entire shoe with
water vapor
impermeable shaft bottom structure (value B), the water vapor permeability
value for the
water vapor permeable sole unit alone can be determined from the difference A -
B.
It is important during measurement of the water vapor permeability of the shoe
with the water
vapor permeable sole unit to avoid a situation in which the shoe or its sole
stands directly on
a closed substrate. This can be achieved by raising the shoe or by placing the
shoe on a grate
structure so that it is ensured that the ventilation air flow can flow
additionally or completely
beneath the outsole.
It is useful in each test layout for a certain shoe to conduct repeat
measurements and to
consider average values from them so as to better be able to estimate the
measurement
scatter. At least two measurements should be conducted for each shoe with the
measurement
layout. In all measurements a natural fluctuation of the measurement results
off 0.2 g/h
around the actual
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value (for example, 1 g/h) should be assumed. For this example, measured
values between
0.8 g/h and 1.2 g/h could therefore be obtained for the identical shoe.
Influencing factors for
these fluctuations could be the person performing the test, for example, or
the quality of
sealing on the upper shaft edge. By averaging several individual measured
values for the
same shoe a more exact picture of the actual value can be obtained.
All values for water vapor permeability of the sole unit are based on a
normally tied man's
shoe of size 43 (French size) in which this size statement is not standardized
and shoes of
different manufacturers can come out differently.
The invention will now be further explained by means of variants that
represent merely
nonrestrictive examples for implementation of the invention. In the
accompanying drawings:
Figure 1 shows a perspective view of the variant of a shoe with a shaft and a
shoe sole
composite with a sole unit designed according to the invention;
Figure 2 shows a perspective view of the shoe according to Figure l in which
the shoe
sole composite is still not bonded to the shoe shaft;
Figure 3 shows the shoe sole composite according to Figures 1 and 2 in a
perspective
plan view;
Figure 4 shows a schematic cross-sectional view of the shoe depicted in Figure
1 in a
variant with a glued on shoe sole composite in the assembly stage according to
Figure 2, in which the shaft is not completely shown; and
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Figure 5 shows a schematic cross-sectional view according to Figure 4, but for
a variant
of a shoe with a shoe sole composite injected onto the shaft, in which the
shaft
is also not fully shown.
When terms like top, bottom, right, left, etc. are used here, this invariably
refers only to the
specific depiction in the corresponding figure and does not apply absolutely.
Figures 1 and 2 show a perspective oblique view from the bottom of an
embodiment example
of a shoe 11 according to the invention with a shaft 13 and a sole unit 15
according to the
invention. The shoe 11 in Figure 1 is shown in a state in which the shaft 13
and the sole
unit 15 are bonded to each other. Figure 2 shows the shoe according to Figure
1 in an
assembly stage, before the sole unit 15 is bonded to shaft 13.
The shoe 11 has a forefoot area 17, a midfoot area 19, a heel area 21 and a
foot insertion
opening 23. The sole unit 15 has a sole layer in the form of a support layer
25, which
contributes critically to the stabilization of the finished sole unit 15 and
which has large area
through holes 27 in the forefoot area 17 and midfoot area 19 (Figure 2). As a
result of its
stabilization effect, the support layer 25 here is also called the
stabilization layer. Large area
in this context means that the individual through holes 27 have an area in the
range of a few
to several cm2, for example, in the range from about 2 cm2 to about 30 cm2,
within this range,
for example, from 10 cm2 to 20 cm2. The through holes 27 are chosen as large
as possible in
order to provide a sole unit 15 having the largest possible water vapor
permeability.
An outsole 29 assembled from several individual outsole parts is situated
beneath the support
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layer 25, namely an outsole part 29a in the heel area, an outsole part 29b in
the ball of the
foot area and an outsole part 29c in the toe area. These outsoles parts are
fastened to the
bottom of the support layer 25. In the ball of the foot area and in the toe
area the outsole
parts 29b and 29c have large area through holes 27 which are dimensioned such
that the
through holes 27 of the support layer 25 remain completely or essentially free
of outsole
material, so that the water vapor permeability of the sole unit achieved by
the through
holes 27 of the support layer 25 is not adversely affected.
In the depicted variant, a damping sole layer 31 is situated above the support
layer 25 and
causes tread damping, thereby improving the walking comfort of the shoe. The
damping sole
layer 31 has a damping sole part 4131 a in the heel area and a damping sole
part 4131 b in the
forefoot area. The damping sole parts 4131 a and 4131 b also have large area
through holes
which fully or at least essentially leave open the through holes 27 of support
layer 25 in order
to avoid compromising or significantly compromising the water vapor
permeability achieved
with the through holes 27 of the support layer 25.
In one variant of the invention, the sole can also be made in one part. This
means that the
damping layer and the outsole layer are then combined to form a single sole
layer, in which,
with respect to tread damping properties and walking properties, a material
selection that best
allows for the two properties is made.
Not only the damping sole layer 31 but also the parts of the outsole 29
consist of an elastic
material having a certain softness, in order to achieve good walking comfort
and to produce
an outsole with good tread properties. Because of this relatively soft elastic
material and
because of its composition from individual parts with large through holes, the
outsole 29
cannot sufficiently contribute to the stability of the entire sole unit 15.
Even in variants with a
one-part outsole,
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because of the soft elastic material and the large through holes a
sufficiently satisfactory
stability of the entire sole unit is not achieved.
Because of its relatively soft material and its large area through holes, on
the one hand, and
its composition of individual parts, on the other, neither the parts of the
outsole 29 nor the
parts of the damping sole layer 31 offer the stability desired for a sole
unit. For this reason the
support layer 25 acting as a stabilization layer is provided, which can be
made from a
relatively stiff material because it need not allow for either tread damping
properties or
outsole properties. In order to improve the stabilization properties of the
stabilization
layer 25, which can be adversely affected to a certain extent despite its
relatively stiff
material because of the large area through holes 27, the individual through
holes 27 of the
support layer 25 are spanned by stabilization connectors 33. The support layer
25 therefore
acquires a degree of bending and warping rigidity, which imparts the desired
stabilization to
the entire sole unit 15.
As shown in Figure 2, the lower end of shaft 13 is closed with a shaft bottom
35 before the
sole unit 15 is bonded to shaft 13. The shaft bottom 35 is provided with a
shaft bottom
functional layer 37, as explained below in conjunction with Figures 4 and 5.
Said shaft
bottom functional layer 37 has a membrane, for example, which is at least
waterproof and
preferably also water vapor permeable.
Whereas Figure 2 shows the sole unit 15 in a perspective oblique view from the
bottom, the
sole unit 15 is shown in Figure 3 in a perspective oblique view from the top.
As shown in
Figure 3, several pieces 39a, 39b, 39c and 39d of a barrier layer formed as a
fibrous layer 39
are situated on the top of the support layer 25 that faces away from outsole
29 in its middle
area 25b and its forefoot area 25c. Through holes 27 and support layer 25 not
visible in
Figure 3 are covered with these fibrous layer pieces 39a, 39b and 39c. The
tread damping
layer parts 4131 a and 4131 b
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arranged in the heel area and in the forefoot area of the sole unit 15 on the
top of support
layer 25 are also visible in Figure 3. The tread damping layer part 413 la in
the heel area is
essentially full-surface in the depicted variant, whereas the tread damping
layer part 413 lb in
the forefoot area is provided with recesses in places where the fibrous layer
pieces 39b, 39c
and 39d are situated. The fibrous layer pieces 39a to 39d lie above the
stabilization
connectors 33 that are not visible in Figure 3. In the variant depicted in
Figure 3 the support
layer 25 has limitation edges 43a, 43b and 43c, which enclose the
corresponding through
holes 27 of support layer 25 and serve as receptacles for the corresponding
fibrous
layer peaks.
Since the outsole parts of outsole 29, the support layer 25 and the tread
damping layer
parts 4131 a and 4131b have different functions within the shoe sole composite
that forms the
sole unit 15, they are expediently also constructed with different materials.
The outsole parts
that have good abrasion resistance and are supposed to offer tread safety,
consist of
thermoplastic polyurethane (TPU) or rubber suitable as outsole material. The
tread damping
layer parts 4131 a and 4131 b, which are supposed to cause impact damping
during walking
movements for the user of the shoe, consist of correspondingly elastically
compliant material,
for example, ethylene-vinyl-acetate (EVA) or polyurethane (PU). The
stabilization layer 25,
which serves as support for the unconnected outsole parts 29a, 29b, 29c and
for the also
unconnected tread damping layer parts 4131 a and 4131b and as a stabilization
element for the
entire sole unit 15 and which is supposed to have a corresponding elastic
rigidity, consists of
at least one thermoplastic, for example.
The fibrous layer pieces 39a, 39b and 39c and 39d, on the one hand, serve as
mechanical
protection for the shaft bottom functional layer 37 with which the shaft
bottom 35 is
provided. Small particles like pebbles, for example, which penetrate the
through holes 27 of
support layer 25 and reach the shaft bottom functional layer 37 and could
damage it are kept
away from the fibrous layer pieces to protect the shaft bottom functional
layer 37. In one
variant of the footwear
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according to the invention the fibrous layer pieces 39a, 39b and 39c, 39c and
39d additionally
have a stabilizing function. For this purpose, the fibrous layer pieces 39a,
39b and 39c, 39c
and 39d consist of a mechanically thermally consolidated fibrous material of
the already
mentioned type with at least two fibrous components of different melting
temperatures and
correspondingly different softening temperatures. By choosing the ratio of
fractions of the
fibrous components having two different melting temperatures and by the degree
of heating
and therefore softening of the second fibrous component, the thermal
consolidation, on the
one hand, and water vapor permeability of the fibrous layer, on the other
hand, can be
influenced as desired. Owing to its thermal consolidation, the fibrous layer
39 or the fibrous
layer pieces 39a, 39b, 39c and 39d can act as stabilization elements for the
sole unit 15.
The fibrous layer 39 as such is already known from WO 2007/101624 Al.
Additional details
with respect to fibrous layer 39, of which the fibrous layer pieces 39a, 39b
and 39c, 39c and
39d consist, specifically with respect to the material choice and material
composition and
with respect to production and thermal activation, are therefore not specified
in greater detail
here, but can be taken from WO 2007/101624 Al. The same applies to details
with respect to
the outsole 29, the tread damping layer 31 and the support layer 25, for
example, with respect
to structure, shape and employed materials, which can also be taken from
WO 2007/101624 Al.
As was already mentioned previously, the fibrous layer material used in
practical variants has
the drawback that the material used for the second fibrous component with the
lower melting
temperature cannot be dyed, because temperatures are required for dyeing that
lie above the
melting temperature of this fibrous component. The fibrous component with the
higher
melting temperature in this fibrous layer material can therefore be dyed while
the second
fibrous component with the lower melting temperature remains white. As already
mentioned,
the visual
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and aesthetic configuration possibilities of the fibrous layer therefore have
very
narrow limits.
This problem is remedied with a decor layer 45 according to the invention,
which is shown in
Figures 1 and 2 as the grid visible in the through holes 27 and in the
following explained
Figures 4 and 5 by a series of square points. In the variant of a sole unit 15
depicted in
Figures 1 and 2 several decor layer pieces 45 are provided, each of which is
assigned to one
of the through holes 27 of the stabilization layer 25, and each of which has
the dimensions of
the corresponding through hole 27 according to the fibrous layer pieces 39a,
39b, 39c and
39d depicted in Figure 3. In this way the bottom of each of these fibrous
layer pieces 39a,
39b, 39c and 39d that are visible through the corresponding through holes 27
is covered by a
corresponding decor layer piece and therefore made invisible. Since almost any
materials can
be used for the decor layer 45, as long as they are dyed or are able to be
dyed, on the one
hand, and are water vapor permeable, on the other, the desired coloring and
patterning of the
decor layer 45 has virtually no limits.
Two variants of footwear according to the invention in the production stage
according to
Figure 2 are shown in a cross-sectional view in Figures 4 and 5, in the case
of Figure 4 with
respect to footwear with the sole unit 15 glued onto the shaft 13 and in the
case of Figure 5
with respect to footwear with the sole unit 15 molded onto the shaft 13. Each
of the figures
shows a cross section through a forefoot area of a shaft 13 and a shoe 11,
very schematically
and not absolutely realistic in terms of dimension and scale. Only the shaft
bottom 35 and a
left shaft part of shaft 13 are shown, in which the right shaft part not shown
is mirror
symmetrical to the depicted shaft part.
In the two variants depicted in Figures 4 and 5 the shaft 13 has an outer
material layer 47, a
shaft functional layer 49 and a liner layer 51. In both variants the lower
shaft end 55 on the
sole side is closed by means of a multilayer shaft bottom 35, which has a
shaft bottom
functional layer 37. In
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both variants the shaft functional layer 49 and the shaft bottom functional
layer 37 are bonded
to each other essentially waterproof, which leads to a waterproof shoe all the
way around and,
when a not only waterproof but also water vapor permeable functional layer is
used, a water
vapor permeable shoe all the way around. And in both variants the sole unit 15
has the
components already mentioned in conjunction with Figures 1 to 3, namely an
outsole 29 and
a support layer 25. In both cases the large area through hole 27, which
extends through the
mentioned sole layers, is covered by a fibrous layer 39, beneath which a decor
layer 45
is situated.
The two variants in Figures 4 and 5 differ with respect to the layers of their
sole unit 15, the
structure of their shaft bottom 35 and the type of fastening of the sole unit
15 to the shaft 13,
and the type of sealing between the shaft functional layer 49 and the shaft
bottom functional
layer 37.
In the variant depicted in Figure 4, the sole unit 15 has, in addition to
outsole 29 and support
layer 25, a tread damping layer 31, and the shaft bottom 35 has an inlay sole
53, often also
called an insole, which is connected to the lower shaft end 55 on the sole
side by means of a
Strobel seam 57. A shaft bottom functional layer laminate 59 is situated
beneath the inlay
sole 53, a three-layer laminate in the depicted variant, which has the shaft
bottom functional
layer 37 embedded between a lower functional layer support layer 61 and an
upper functional
layer support layer 63. The two functional layer support layers 61 and 63 each
consist of a
textile layer, for example. The upper textile layer 63 is designed such that
it can be penetrated
by liquid sealing material 65, which is located between the bottom of the sole
sided lower end
of the shaft functional layer 49 and the top of the peripheral edge of the
shaft bottom
functional layer 37, in-order to produce a waterproof seal between the shaft
functional
layer 49 and the shaft bottom functional layer 37. As shown in Figure 4, the
sole sided lower
end of the shaft outer material 47 is raised from the sole sided lower end of
the shaft
functional layer 49 and glued to the bottom of the shaft bottom functional
layer laminate 59
by means of sole adhesive 67. The sole unit 15 is
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prefabricated and is fastened by means of the one sole adhesive 67, which was
applied at
least to the top of the peripheral edge zone of the sole unit 15, to the sole
sided lower shaft
end 55.
In the variant depicted in Figure 5 with the sole unit 15 molded onto shaft
13, the sole unit 15
has no tread damping layer 31. The shaft bottom 35 is formed by an inlay sole
laminate 69
which is also a three layer laminate whose one outer layer, the upper outer
layer 63 in the
depicted variant, consists of a stable and rigid material such that this inlay
sole laminate 69
can assume the function of an inlay sole or insole for closure of the lower
shaft end 55. In this
variant the shaft functional layer 49 and the shaft liner 51 have an overhang
on the sole sided
end beyond the shaft outer material 47. This overhang is spanned by means of a
mesh
band 71, which is permeable to the liquid outsole material during molding. The
mesh band 71
is bonded on one side only to the shaft outer material 47 but not to the shaft
functional
layer 49 and on the other side is connected via a Strobel seam 57 to both the
shaft functional
layer 49 and the shaft liner 51 and to the inlay sole laminate 69. The sole
unit 15 of this
variant has, in addition to the support layer 25 provided with the fibrous
layer 39 and the
decor layer 45, only one outsole layer 29 in which the support layer 25
equipped with the
fibrous layer 39 and the decor layer 45 is embedded during molding of the
outsole layer 29 in
the manner depicted in Figure 5. During molding of the outsole layer 29 onto
shaft 13, liquid
outsole material penetrates through the mesh band 71, on the one hand, to the
overhang of the
sole sided lower end of the shaft functional layer 49 and to the Strobel seam
57 and, on the
other hand, to the bottom of the peripheral edge area of the inlay sole
laminate 69, where it
can penetrate its lower textile layer and reach the shaft bottom functional
layer 37 there. In
this way, by means of outsole material, the transition between the shaft
functional layer 49
and the shaft bottom functional layer 37 is sealed.
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CA 02728053 2010-12-14
In both variants depicted in Figures 4 and 5 the support layer 25 is
preferably produced by
injection molding. The decor layer 45 and the fibrous layer 39 can be inserted
into the
injection mold before the injection process. During the injection process,
material of the
support layer 25 penetrates through the outer peripheral area of decor layer
45 and into the
outer peripheral area of fibrous layer 39 so that the support layer 25, the
decor layer 45 and
the fibrous layer 39 are fastened to each other by the molding process.
In a modification of the variant depicted in Figures 4 and 5 the fibrous layer
39 and the decor
layer 45 are combined with each other into a unit before they are joined to
the sole unit 15.
This unit can form an insert that is produced separately from the remaining
components of
the sole unit 15 and is inserted during production of the sole unit 15. This
insertion occurs
into the sole layer with which the unit of decor layer 45 and fibrous layer 39
is to
be provided.
In the variants depicted in the figures, this insert is inserted into support
layer 25. In other
variants not shown, in which the sole layer provided with decor layer 45 and
fibrous layer 39
is not formed by a support layer but by an outsole or a midsole of a different
type from the
support layer, for example, the insert can be inserted into the corresponding
sole layer. This
means the insert is produced separately and is then inserted into an
appropriate sole layer
according to the design and/or desired appearance of the specific sole unit
15. Inserts with
visually different decor layers 45 can be kept in stock and a correspondingly
selected insert
inserted into the sole unit 15 depending on the shoe type for which it is
intended.
In the variant depicted in Figure 5, at least one of the stabilization
connectors is formed as a
support connector 73 within the through hole 27 of the support layer 25. For
this purpose the
support connector 73 is designed such that it extends to the contact surface
75 of the outsole
layer 29 and is therefore supported during walking with the shoe on floor 77,
just like
the outsole
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layer 29. A particularly good stabilization of the sole unit 15 even during
walking is therefore
achieved with the support connector 73 depicted in Figure 5.
Such a support connector is not present in the variant depicted in Figure 4 at
least in the
cross-sectional plane in the through hole 27 of the support layer 25 depicted
there.
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