CA2728053A1 - Sole unit for footwear - Google Patents

Abstract

A water-vapour-permeable and water-permeable sole unit (15) for footwear (11), having at least one sole layer (25) with at least one large aperture (27) extending through the thickness thereof and at least two sheet-like formations arranged one on top of the other, which seal the at least one aperture and of which a first sheet-like formation has a textile water-vapour-permeable barrier layer (39) and a second sheet-like formation has a water-vapour-permeable decorative layer (45), which is arranged under the first sheet-like formation, at least in the region of the at least one aperture, and is visible from the underside of the sole layer (25) in the at least one aperture. A decorative layer (45) according to the invention allows the achievement of aesthetic and visual design possibilities for the appearance of the underside of the sole unit (15) that would either be prevented by the material of the fibrous layer (39) or could only be accomplished with the fibrous layer (39) with some difficulty.

Description

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 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 WO 2009/153054 Al Page 3 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 WO 2009/153054 Al Page 4 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 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 WO 2009/153054 Al Page 6 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 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, WO 2009/153054 Al Page 8 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 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 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 WO 2009/153054 A I Page I I

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 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 WO 2009/153054 Al Page 13 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.

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 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.

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 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:
WO 2009/153054 Al Page 18 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 WO 2009/153054 Al Page 19 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 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 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, WO 2009/153054 Al Page 22 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).

WO 2009/153054 Al Page 23 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 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 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 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 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, 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 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 WO 2009/153054 Al Page 30 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 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 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 WO 2009/153054 Al Page 33 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.

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 WO 2009/153054 Al Page 35 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.

WO 2009/153054 Al Page 36

Claims (30)

1. Claims Water vapor permeable and water permeable sole unit (15) for footwear (11) having:
   at least one sole layer (25) with at least one large through hole (27) extending through the sole layer thickness;
   at least two one- or multi-piece sheet structures arranged one above the other which close the at least one through hole (27), wherein a first sheet structure has a textile water vapor permeable barrier layer (39) and a second sheet structure has a water vapor permeable decor layer (45), which is arranged beneath the first sheet structure at least in the area of at least one through hole (27) and is visible from the bottom of the sole layer (25) in the at least one through hole (27).
2. 2. Sole unit (15) according to Claim 1, wherein the decor layer (45) comprises a material that is dyed or has at least one dye.
3. 3. Sole unit (15) according to Claim 1 or 2, wherein the decor layer (45) comprises a substrate and a coating covering the surface of the substrate, wherein the coating is made of a material which is dyed or has at least one dye.
4. 4. Sole unit according to at least one of the preceding claims, wherein the decor layer (45) is bonded to the barrier layer (39) only in the edge areas in such a way that especially during walking movement a movement of the decor layer (45) relative to barrier layer (39) is made possible.
5. 5. Sole unit according to at least one of the preceding claims, wherein the decor layer (45) is constructed with dirt-repellant material.
6. 6. Sole unit according to at least one of the preceding claims, wherein the material of the decor layer (45) is chosen from the material group of grid-like, net-like, porous or perforated sheet material.
7. 7. Sole unit according to at least one of the preceding claims, wherein the material of the decor layer (45) is chosen from the material group metal, plastic, textile, leather or a combination thereof.
8. 8. Sole unit according to Claim 7, wherein the decor layer (45) is constructed with monofilament fibers.
9. 9. Sole unit according to Claim 7, wherein the decor layer (45) is constructed with yarn, which is encased with silicone or with essentially colorless silicone-like material in such a way that net- or grid-like openings in this decor layer remain open and water vapor permeability is therefore retained.
10. 10. Sole unit according to Claim 7, wherein the decor layer (45) is constructed with yarn, which is impregnated with silicone or essentially colorless silicon-like material in such a way that capillary areas occurring in the yarn in which soiling substances might otherwise penetrate are closed.
11. 11. Sole unit according to Claim 7, wherein the decor layer (45) is made entirely of metal.
12. 12. Sole unit according to at least one of the preceding claims, wherein the decor layer (45) is constructed with a metalized plastic grid.
13. 13. Sole unit according to at least one of the preceding claims, wherein the large area through hole (27) is at least partially spanned by a stabilization connector.
14. 14. Sole unit according to Claim 13, wherein the decor layer (45) is bonded to the barrier layer (39) only in peripheral edge areas and/or in edge areas formed with the at least one stabilization connector.
15. 15. Sole unit according to at least one of the preceding claims, wherein the barrier layer (39) is formed as protection against penetration of foreign objects penetrating through the large area through hole (27) to above the first sheet structure of the components of the sole unit.
16. 16. Sole unit according to Claim 16, wherein the barrier layer (39) is embodied as puncture-proof for protection from puncturing foreign objects, like nails.
17. 17. Sole unit according to at least one of the preceding claims, wherein the barrier layer (39) is constructed with the material that stabilizes the shoe sole composite.
18. 18. Sole unit according to at least one of the preceding claims, wherein:
    the barrier layer (39) comprises at least two fibrous components which differ with regard to their melting temperatures;
    
    at least one portion of a first fibrous component has a first melting temperature and a lower first softening temperature range and at least one portion of a second fibrous component has a second melting temperature and a lower second softening temperature range and the first melting temperature and the first softening temperature range are higher than the second melting temperature and the second softening temperature range;
    
    and the barrier layer (39) is thermally mechanically consolidated, as a consequence of thermal activation of the second fibrous component with a tackifying temperature in the second softening temperature range while maintaining water vapor permeability in the thermally consolidated range.
19. 19. Sole unit according to Claim 18, wherein the second softening temperature range of the second fibrous component lies below the temperature necessary for the dyeing of the second fibrous component.
20. 20. Sole unit according to at least one of the preceding claims, wherein the barrier layer (39) has a water vapor permeability in the range from 3,000 g/m2.24 h to 20,000 g/m2.24 h, especially in the range from 8,000 g/m2.24 h to 15,000 g/m2.24 h, and especially 12,588 g/m2.24 h.
21. 21. Sole unit according to at least one of the preceding claims, wherein the decor layer (45) has a water vapor permeability in the range from 10,000 g/m2.24 h to 50,000 g/m2.24 h, especially in the range from 20,000 g/m2.24 h to 30,000 g/m2.24 h, and especially 26,000 g/m2.24 h.
22. 22. Sole unit according to at least one of the preceding claims, which has a water vapor permeability in the range from 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, and especially 9,337 g/m2.24 h.
23. 23. Sole unit (15) according to at least one of the preceding claims, wherein the sole layer (25) is made up of an injectable material.
24. 24. Sole unit (15) according to Claim 23, wherein the sole layer (25) is injected onto the barrier layer (39) and the decor layer (45) in such a way that the barrier layer (39) and the decor layer (45) are connected via the sole layer material with the sole layer (25).
25. 25. Sole unit (15) according to Claim 23 or 24, wherein the barrier layer (39) and the decor layer (45) are connected to each other by means of sole layer material.
26. 26. Sole unit (15) according to at least one of Claims 23 to 25, wherein the barrier layer (39) and the decor layer (45) are penetrated by sole layer material.
27. 27. Sole unit (15) according to at least one of the preceding claims, wherein the sole layer (25) is an outsole (29) of the sole unit (15).
28. 28. Sole unit (15) according to at least one of Claims 1 to 27, wherein the sole layer (25) is a midsole of the sole unit (15).
29. 29. Sole unit (15) according to at least one of the preceding claims, wherein the barrier layer (39) and the decor layer (45) are connected to a unit that is usable as an insert.
30. 30. Footwear (11) with a sole unit (15) according to at least one of the preceding claims and comprising a shaft (13) provided on a sole sided shaft end region (55) with a waterproof and water vapor permeable shaft bottom functional layer (37), wherein the sole unit (15) is bonded to the shaft end region (55) such that the shaft bottom functional layer (37) is unbonded to the barrier layer (39) at least in the region of the at least one through hole (27).