FR3133978A1 - Sole, article of footwear comprising such a sole, and methods of manufacturing said sole and said article of footwear - Google Patents

Abstract

The present invention relates to a sole (250) comprising a molded sole shell (200) comprising an external face, an interior bottom and first (216) and second side walls between which said interior bottom extends. Said sole (250) comprises a sole element (300) comprising an edge, said edge comprising a first main male interlocking portion having a determined shape, and said sole shell (200) comprises an interior volume for receiving said element of sole (300) and a second main female interlocking portion, having a determined shape configured to cooperate by interlocking with said first main interlocking portion so as to hold said sole element (300) in position relative to the shell sole (200), said second main interlocking portion being formed in the first side wall (216), and possibly by at least one portion of said interior bottom. The present invention also relates to an article of footwear comprising said sole (250). Figure 11

Description

Sole, article of footwear comprising such a sole, and methods of manufacturing said sole and said article of footwear

The present invention relates to the field of soles, and footwear, in particular sports shoes, comprising such soles.

The present invention also relates to the field of methods for manufacturing such soles, and to articles of footwear comprising such soles.

Conventional footwear generally includes an upper and a sole structure. The upper is secured to the sole structure and forms a void inside the footwear to comfortably receive and secure a foot. The sole structure is secured to a lower region of the upper, and operatively disposed between the ground, and the upper.

In footwear for playing sports, the sole structure may include an outsole and a midsole. The midsole often includes a polymer foam material that absorbs impact with the ground during impact to lessen the effects on the foot and leg during walking, running or other ambulatory activities. The sole structure may also include a liner positioned proximate the lower surface of the foot to improve the comfort of the article of footwear.

The soles are traditionally joined to the uppers using an assembly called Strobel during which the different sole elements (insole, midsole and outsole in particular) are assembled. The manufacturing processes for a classic shoe require dozens of steps, and produce numerous scraps resulting from cutting materials.

The aim is to simplify the manufacturing processes for footwear, in particular by reducing the number of steps and/or energy and material consumption. This issue is also part of the search for a manufacturing process that can be implemented as close as possible to the place of use of the footwear item in order to reduce its carbon impact, facilitate stock management, and allow the personalization of the footwear item.

One solution is to eliminate the sewing steps necessary to shape the initially flat rod in three dimensions. The upper is obtained from the assembly of one or a few pieces, and no longer from multiple pieces sewn together by sewing.

WO 2019/234374 A1 thus proposes a first textile liner formed in three dimensions directly at the outlet of a textile loom (for example a knitting loom), partially hot-melt, entering into the construction of the upper, then to secure this first liner to an outsole. The first textile liner is reinforced by placing a second, three-dimensional, partially hot-melt textile liner around the first liner by wrapping the junction between the first liner and the outsole in order to improve resistance to delamination. The assembly comprising the first and second textile liners and the outsole undergoes a heat treatment to melt the hot-melt threads and freeze the shape of an upper. The manufacturing process is simplified by significantly reducing the number of manufacturing steps.

However, it is sought to further improve these footwear items, in order to lighten them, improve their resistance to abrasion and tearing, and their breathability.

Limiting the number of steps in the manufacturing of an article of footwear restricts the range of technical functions and aesthetic renderings available.

Footwear manufactured by a thermocompression process has fairly rigid outsoles due to the compaction of the thermofused material. It is not possible to reliably process foam that is crushed during the thermocompression process. The outsoles of such items therefore lack flexibility and cushioning.

It is possible to partially overcome this problem by selecting very flexible hot-melt materials. However, it is difficult to find flexible hot-melt materials whose melting or softening temperature is suitable for use by thermocompression, and which also have good abrasion resistance if they are to form outsoles.

Indeed, the melting temperature(s) used must be lower than the melting or degradation temperature of the textile elements of the footwear which are not intended to be at least partially thermofused.

Furthermore, if we seek to use recycled materials, hot melt at least in part, for the manufacture of the outsole by thermocompression, it is difficult to control the resulting hardness and therefore flexibility because the precise composition of said materials recycled is not always precisely known.

There is thus a need for an article of footwear comprising one or more thermofused textile portion(s), or partially thermofused textile portion(s), which is light, flexible, and breathable, while offering resistance to abrasion. and satisfactory tear, and comfortably conforms to the shape of the foot.

There is a need for a comfortable sole and footwear item comprising said sole which can be manufactured by thermocompression and whose sole is adapted to the use of the footwear article, and which can use recycled and at least partly hot-melt waste. .

There is also a need for a process for manufacturing such a sole and an article of footwear comprising said sole which are simplified while offering numerous possibilities as to the technical and aesthetic functions which can be assigned to the sole and to the article. footwear comprising said sole.

The present invention relates, according to a first aspect, to a sole, in particular for a sports shoe, comprising a molded sole shell, in particular a molded outsole shell. Said sole shell comprises an external face, an interior bottom and first and second side walls between which said interior bottom extends.

Said sole comprises a sole element comprising an edge, said edge comprising a first male or female main interlocking portion, respectively, having a specific shape.

Said sole shell comprises an interior volume for receiving said sole element and a second main female, respectively male, interlocking portion, having a determined shape configured to cooperate by interlocking with said first main interlocking portion so as to maintain in place position said sole element relative to the sole shell, said second main interlocking portion being formed in the first side wall, and possibly by at least one portion of said interior bottom.

Advantageously, the sole shell is hollow and is adapted to accommodate the sole element in its interior volume, in particular in a removable manner.

In an exemplary embodiment, the sole shell is an outsole shell.

In particular, the outsole shell comprises an external face:
- of which at least one portion is an engagement portion with the ground; and or
- of which at least one portion is directly facing the ground, in particular said portion is not a portion of engagement with the ground; and or
- comprises one or more abrasion-resistant sole element(s) arranged on said external face of said sole shell, for example one or more elements in an elastomeric material (in particular not covering the entire surface of the external face).

Advantageously, the sole shell comprises first and second side walls, and possibly front and rear side walls, the average thickness of which is thin, that is to say a few millimeters, in particular ranging from 0.5 mm. to 8 mm, more particularly ranging from 0.5 mm to 5 mm.

Advantageously, the sole shell is not full. This arrangement makes it possible to give flexibility to the sole shell, and makes it possible to manufacture the latter, totally or in part, with hot-melt material(s), the hardness of which would not be suitable for obtaining a sole, in particular wear, full and flexible enough to allow the foot to roll comfortably.

Furthermore, the sole shell being hollow, is lighter, compared for example to outsoles of the state of the art.

In the state of the art, an adult-sized outsole has an average mass of around 300g.

Advantageously, the sole shell, for example for a shoe size 43FR or 9.5US, has a mass less than or equal to 300g, in particular of the order of 225g.

Advantageously, said sole shell has a mass greater than or equal to 180 g.

Advantageously, when the sole element is arranged inside the sole shell, the sole element is configured to fill a part, in particular substantially the entirety, of the internal receiving volume of the sole shell.

Advantageously, this arrangement makes it possible to form a sole assembly comprising the sole shell and the sole element occupying the volume occupied by an outsole of the state of the art while offering the function of an outsole. wear and the function of an additional sole element distinct from the sole shell, said sole element thus being able to be a cushioning midsole and/or an insole.

Preferably, the first main interlocking portion and the second main interlocking portion are adapted to cooperate together in a removable manner in order to hold the sole element in position relative to the sole shell, and in order to disengage at the requests the sole element in relation to the sole shell, thus making it possible to separate the sole shell and the sole element.

In one embodiment, the sole shell, in particular the wear shell, comprises one or more material(s) chosen from: thermoplastic polyurethanes, thermoplastic polyolefins (PP, PE), polyurethane elastomers, elastomers of polyolefin, preferably chosen from thermoplastic polyurethanes and polyurethane elastomers.

Preferably, the sole shell includes a forefoot region, a midfoot region, and a rearfoot region.

Preferably, the sole shell comprises a front side and a rear side between which said sole shell extends, and a lateral side and a medial side between which the sole shell extends.

Preferably, the sole shell comprises an internal face and an external face, possibly substantially opposite the internal face, in particular the internal face is the surface of the interior bottom of the sole shell.

Preferably, the external face of the outsole shell is an external face of which at least part engages with the ground.

Preferably, the first side wall of the sole shell extends from the lateral or medial side of the sole shell, preferably from the medial side.

Preferably, the second side wall extends from the lateral or medial side of the sole shell, preferably from the lateral side.

Preferably, the first side wall and the second side wall of the sole shell extend vertically on either side of the interior bottom of the sole shell and above said interior bottom.

Preferably, the sole shell comprises a rear side wall extending from the rear side of the sole shell and a front side wall extending from the front side of the sole shell.

Preferably, the rear side wall and/or the front side wall of the sole shell extend(s) (each) vertically from the inner bottom of the sole shell and above said inner bottom.

Preferably, the first side wall and/or the second side wall of the sole shell is/are (each) curved towards the interior volume of the sole shell.

Preferably, the rear side wall and/or the front side wall is/are (each) curved towards the interior volume of the sole shell.

Preferably, the sole element comprises a forefoot region, a midfoot region, a rearfoot region.

Preferably, the sole element comprises a front side and a rear side between which said sole element extends, and a lateral side and a medial side between which said sole element extends.

In the present text, the lateral side of the article of footwear/the sole/the upper and in general of any element relating to an article of footwear according to the invention is understood to mean any element or part of the article of footwear/the sole. / of the upper placed between the central longitudinal axis of the article of footwear / of the sole / of the upper and the natural external side of the foot.

In this text, the medial side of the article of footwear/the sole/the upper and, in general, any element relating to an article of footwear, means any element or part of the article of footwear/the sole/the upper. arranged between the central longitudinal axis of the article of footwear/sole/upper and the natural external side of the foot.

Preferably, the sole element comprises an internal face and an external face, more preferably the internal face is substantially opposite the external face.

Preferably, said edge of the sole element comprising the first male or female main interlocking portion, respectively, is an edge extending from the lateral side or the medial side of the sole element, preferably from the medial side.
When the border extends on the medial side, said border is referred to herein as medial border, and when the border extends on the lateral side, said border is designated as lateral border.

Preferably, the sole element comprises a lateral border extending between the internal and external faces of the sole element, on the lateral side of the sole element.

Preferably, the sole element comprises a medial edge extending between the internal and external faces of the sole element, on the medial side of the sole element.

Preferably, the sole element comprises a front edge and a rear edge each extending between the internal and external faces of the sole element.

Preferably, said interior volume of the sole shell is delimited, at least in part, between the interior bottom, and the first and second side walls, as well as the front and rear side walls of the sole shell.

Advantageously, the front and rear side walls, and the first and second side walls, form a substantially continuous rim, projecting vertically above the interior bottom, and all around the interior bottom.

In one embodiment,
- said edge of the sole element comprising said first main male, respectively female, interlocking portion, having a determined shape, is a medial edge, and
- the sole element further comprises a lateral edge comprising a first male or female auxiliary interlocking portion, respectively, having a specific shape, and
- said second female main interlocking portion, respectively male, is formed in the first side wall of the sole shell, and optionally in at least one portion, in particular in at least one medial portion, of the interior bottom of the sole shell , And
- the sole shell comprises a second auxiliary female, respectively male, interlocking portion, formed in the second side wall of the sole shell, and optionally in at least one portion, in particular at least one lateral portion, of the interior bottom of the sole shell,
said second female auxiliary interlocking portion, respectively male, being configured to cooperate by interlocking with said first male auxiliary interlocking portion, respectively female, so as to hold said sole element in position relative to the sole shell.

This arrangement makes it possible to maintain the sole element laterally and medially in position in the sole shell.

The first main and/or auxiliary male or female interlocking portion(s), respectively female(s), of the sole element may be (each) substantially continuous, or can also be (each) discontinuous, that is to say in several distinct parts, each part of which individually takes up the characteristics of the first main or auxiliary interlocking portion.

In one example, the first main or auxiliary male, respectively female, interlocking portion, in particular formed in the lateral or medial border:
- extends respectively partly in the forefoot region and partly in the midfoot region; and or
- is lying down.

The second main and/or auxiliary female, respectively male, interlocking portion(s) of the sole shell may be substantially continuous, or may be discontinuous, c that is to say in several distinct parts of which each part individually takes up the characteristics of the second main or auxiliary nesting portion.

In one example, the second main or auxiliary female, respectively male, interlocking portion, in particular formed in the first side wall or the second side wall, and possibly by at least one lateral or medial portion of the interior bottom of the sole shell:
- extends respectively partly in the forefoot region and partly in the midfoot region; and or
- is lying down.

In one embodiment, the sole shell, in particular wear, in particular corresponding to a size of the article of footwear 43 FR (in particular to a size US 9.5), has a mass less than or equal to 300g, preferably less than or equal to 280g or 260g or 240g or 225g.

In particular, the sole shell, in particular wear, has a mass greater than or equal to 150g or 180g or 190g or 200g or 205g.

In the range indicated above, the mass of the sole shell varies depending on the size of the article of footwear (in particular for an adult shoe size).

In one example, the sole shell comprises non-thermally melted particles at least in part.

In one example, said non-thermally melted particles at least in part have an average size ranging from 0.5 mm to 10 mm, in particular from 1 mm to 5 mm.

In one example, the sole shell comprises, in particular consists essentially, of one or more polymer material(s) having a Shore A hardness ranging from 40 to 90.

Shore A hardness can be measured as an example using ISO 48-4:2018 entitled “Vulcanized or thermoplastic rubber – Determination of hardness – Part 4: Penetration hardness by the durometer method (hardness Shore)”.

In a variant embodiment, the sole element is a flexible sole element and deformable compared to the sole shell so that it can be deformed during its positioning in the interior receiving volume of the sole shell.

Advantageously, the sole element can be folded in two, and deformed, without significant degradation of its properties, which facilitates its insertion by deformation into the interior receiving volume of the sole shell.

In a variant, the density of the sole element is greater than or equal to 40 g/L and less than or equal to 120 g/L, preferably greater than or equal to 50 g/L and less than or equal to 110 g/L. L, more preferably greater than or equal to 60g/L and less than or equal to 80 g/L.

In a variant, the energy absorption on impact of the material of the sole element ranges from 2 Joules to 7 joules, in particular ranges from 2.2 joules to 5.7 joules.

This energy absorption value is preferably measured according to standard ASTM F 1976-13 entitled “Standardized test method for measuring the impact attenuation of sports shoe cushioning systems”.

In a variant, the sole shell comprises one or more recess(s) arranged in one or more walls of the shell, in particular arranged in the first side wall and/or the second side wall and/or the front side wall and/or the rear side wall.

This arrangement makes it possible to lighten the sole shell and refine the wall comprising one or more recesses in order to give it more flexibility to receive by deformation the sole element in its interior volume and to make the male interlocking portions cooperate. ) and female(s) among themselves.

In a variant, the internal face of the sole element, housed in the internal receiving volume of the sole shell, forms a foot support zone configured to be placed facing the foot when the footwear is worn , and the support zone is set back vertically from the upper edge of the first or second side wall of the sole shell along all or part of the first or second side wall, and optionally the support zone of the element of sole is vertically recessed from the upper edge along all or part of the front side wall and/or along all or part of the rear side wall of the sole shell.

The vertical setback is in one example at least 5 mm or at least 10 mm or even at least 15 mm, in particular less than or equal to 25 mm.

This arrangement advantageously makes it possible to reduce the weight of the sole shell and the sole element, and facilitates the maintenance of the sole element relative to the sole shell.

In a variant, the sole shell (in particular its interior bottom) comprises, in cross section, an external layer comprising a polymer material A forming at least part of the external face of the sole shell, at least one intermediate layer comprising a polymer material B optionally mixed with a polymer material C, an external layer comprising a polymer material D forming at least part of the internal face of the sole shell, said at least one intermediate layer being arranged between the external layer and the internal stratum.

In particular, the materials A, B, C and D are different from each other by at least one property, more particularly said distinctive property is chosen from: a difference in Shore A hardness, the nature of the polymer material, the mode of 'Young of the polymer material (E in Pa).

In one example, polymer material D has a Shore A hardness greater than the Shore A hardness of polymer material B and optionally greater than the Shore A hardness of polymer material C.

In one example, the polymer materials A, B, optionally C, and D are chosen from polyurethanes (optionally thermoplastic polyurethane elastomers), and/or polyolefins (optionally thermoplastic polyolefin elastomers).

In a variant, the sole element is a midsole and/or a sockliner.

Preferably, the midsole is a cushioning midsole mitigating the forces of impact with the ground.

In an exemplary embodiment, an insole is secured to the internal face of the midsole.

In a variant, the sole element is a sole comprising one or more foamed polymer(s), for example chosen from polyurethanes, polyamides, such as (polyether amide block), for example PEBAX® , and polyolefins.

In a variant embodiment, the sole element is intended to be secured to the sole shell, in particular wear, in a removable manner.

This arrangement allows a user to personalize the sole by choosing the sole element adapted to a specific use, for example according to the morphology of the user or the sport practiced.

In a variant embodiment, said first main nesting portion is a first main male nesting portion, and said second main nesting portion is a second main female nesting portion consisting essentially of a cavity, in particular a main one, comprising an upper wall and a lower wall together forming an open clamp, in particular the upper wall forms an upper stop for the sole element.

This advantageous shape of the second main interlocking portion of the sole shell makes it possible to pinch the first main interlocking portion arranged along the edge of the sole element.

The sole element being advantageously flexible and deformable, the first main interlocking portion deforms to fit the second main interlocking portion.

Preferably, the upper wall is formed in the first side wall, in particular arranged on the medial or lateral side.

Preferably, the lower wall is formed by a portion, in particular medial or lateral, of the interior bottom of the sole shell.

In particular, the lower and upper walls are inclined towards each other and meet on the medial, or lateral, side of the sole shell.

In particular, the cavity is open to the interior volume of the sole shell.

In one embodiment, said first auxiliary nesting portion is a first male auxiliary nesting portion, and said second auxiliary nesting portion is a second female auxiliary nesting portion consisting essentially of a cavity, in particular auxiliary, comprising an upper wall and a lower wall together forming an open clamp, in particular the upper wall forms an upper stop for the sole element.

In a variant embodiment, the sole shell comprises a main cavity formed in the first side wall, in particular the side wall, and a portion of the interior bottom of the sole shell; said sole shell further comprises an auxiliary cavity formed in the second side wall, in particular the medial wall, and a portion of the interior bottom of the sole shell.

Alternatively, the edge of the sole element extends between an upper edge and a lower edge, and the lower edge projects outwardly from the edge relative to the upper edge so that the upper edge is set back from the bottom edge.

In an exemplary embodiment, the edge of the sole element is a medial edge and extends between an upper medial edge and a lower medial edge, and the lower medial edge advances towards the outside of the medial edge by relative to the upper medial edge so that the upper medial edge is recessed relative to the lower medial edge.

In an exemplary embodiment, the sole element further comprises a side edge extending between an upper side edge and a lower side edge, and the lower side edge advances outwardly from the side edge relative to the upper side edge so that the upper side edge is recessed relative to the lower side edge.

In a variant embodiment, the first main male interlocking portion of the sole element has a substantially beveled shape from the lower edge, in particular lateral, of the edge, in particular lateral.

Preferably, the first male auxiliary interlocking portion of the sole element has a substantially beveled shape from the edge, in particular medial, lower of the edge, in particular medial.

In a variant embodiment, the sole shell, in particular wear shell, comprises a rearfoot region, a midfoot region and a forefoot region, and said a second main interlocking portion, and optionally said second auxiliary interlocking portion, is/are arranged in the forefoot region, and optionally partly in the midfoot region of the sole shell.

The connection between the sole shell and the sole element is carried out at least in the forefoot region where the strongest mechanical stresses are exerted on the sole, particularly in flexion. This arrangement thus improves support, in particular in a removable manner, and improves support for the deformation of the sole element relative to the sole shell.

In a variant embodiment, the sole element comprises a rearfoot region, a midfoot region and a forefoot region, and said a first main interlocking portion, and optionally said a first auxiliary interlocking portion, is/are arranged in the forefoot region, and possibly partly in the midfoot region, of the sole element.

In a variant embodiment, the sole element comprises a rear edge projecting vertically above an interior support face of the foot of said sole element, and the sole shell comprises a rear side wall comprising an upper edge inclined towards the inside of the sole shell and forming an upper stop for said rear edge of the sole element.

This arrangement advantageously makes it possible to further improve the positioning of the sole element in the interior receiving volume of the sole shell.

This configuration of the rear side wall of the sole shell can be obtained using the thermocompression process described below using an inflatable bladder. During demolding, despite the undercut shape of the rear side wall of the sole shell, the bladder is in a deflated state, which facilitates demolding and thus allows complex shapes (undercut) to be obtained.

In an exemplary embodiment, the upper edge of the rear edge of the sole element is substantially flush with the inclined upper edge of the rear side wall of the sole shell.

In a variant embodiment, the first side wall comprises an upper edge of which at least part is inclined towards the inside of the sole shell.

Preferably, the second side wall of the sole shell comprises an upper edge of which at least part is inclined towards the inside of the sole shell.

In a variant embodiment, the sole element comprises, in particular consists essentially, of particles agglomerated in at least one expanded polymer.

The inventors have determined that the sole element thus has good deformability facilitating its placement in the sole shell, and the cooperation by interlocking of the first main interlocking portion, respectively auxiliary, with the second main interlocking portion, respectively auxiliary.

In addition, this type of sole element has good cushioning properties to act as a midsole, and is lightweight.

Preferably said expanded polymer is chosen from: thermoplastic polyurethanes, polyurethane elastomers, polyamides for example (polyether amide block), such as PEBAX®, polyolefins (such as polypropylenes and polyethylenes), and elastomers polyolefin.

We understand by “the particles are agglomerated” that said particles form a monolithic block in which the particles are joined together, in particular the particles are stuck together via thermo-fused portions of said at least one expanded polymer.

The particles can have any shape but are preferably beads.

In a variant embodiment, the sole element comprises an internal foot support face, and said internal foot support face is set back vertically from the inclined upper edge of the rear side wall of the sole shell, in particular of a withdrawal R _AR greater than or equal to 10 mm, more particularly less than or equal to 30 mm, in particular greater than or equal to 20 mm.

This arrangement makes it possible to improve the rear support of the sole element in the sole shell.

In a variant embodiment, the sole element comprises an internal foot support face, and said internal foot support face is set back vertically from the upper edge, possibly inclined, of the first or second side wall of the sole shell, in particular with a shrinkage R _M greater than or equal to 10 mm, more particularly less than or equal to 25 mm, in particular greater than or equal to 15 mm.

This arrangement makes it possible to improve the lateral support and/or medial support of the sole element in the sole shell.

In a variant embodiment, the sole element comprises an internal foot support face, and said internal foot support face is set back vertically from the upper edge of the front side wall of the sole shell, in particular an R _AV withdrawal greater than or equal to 3 mm, more particularly less than or equal to 30 mm, in particular less than or equal to 20 mm or 10 mm.

Advantageously, the support of the foot is not ensured only by the upper but also by the sole shell via the indentations R _AV, R _M and R _AR.

In a variant embodiment, the sole shell is hollow, in particular comprises an empty interior receiving volume.

In a variant embodiment, the sole shell comprises first and second side walls, and front and rear side walls, in particular in connection with each other and forming a vertical rim all around the interior bottom.

Preferably, each of said side walls having a thickness greater than or equal to 1 mm and less than or equal to 10 mm, in particular less than or equal to 6 mm, more particularly less than or equal to 4 mm.

Preferably, the interior bottom has a thickness ranging from 3 mm to 15 mm, in particular ranging from 3 mm to 6 mm.

Preferably, the height of the side walls is greater than or equal to 10 mm, in particular greater than or equal to 20 mm, more particularly greater than or equal to 30 mm, particularly in the rearfoot region of the sole shell.

In a variant embodiment, the thickness of the sole shell is substantially decreasing from the interior bottom towards the first side wall and/or towards the second side wall.

The present invention relates, according to a second aspect, to an article of footwear, in particular a sports shoe, comprising a sole according to any one of the alternative embodiments with reference to the first aspect of the invention.

Advantageously, the sole can be secured to an upper in a conventional manner, for example using a ströbel assembly, or by thermocompression as described in particular below with one or more textile tubular element(s). (s) comprising one or more thermofusible textile portion(s) and therefore thermofused after thermocompression.

In a variant embodiment, the footwear item comprises at least one tubular textile element, optionally comprising at least one textile portion at least partially thermofused, the sole shell and said at least one tubular textile element are bonded by at least one thermofused portion , in particular by at least one thermofused portion of the sole shell and/or at least one thermofused textile portion of said textile tubular element.

In one embodiment, the textile tubular element is a woven or knitted tubular element, preferably knitted.

The tubular textile element is preferably a knitted sock.

Advantageously, a textile tubular element, for example internal or external, comprises a textile part, in particular internal or external, covering at least partly the foot and a sole part, in particular internal or external, in textile connection, in particular knitted, with said textile part covering at least part of the foot.

Advantageously, the tubular textile element, in particular whether internal or external, is of unitary knitted construction.

By unitary knitted construction we understand that the tubular element is in a single knitted piece and does not include one or more knitted yoke(s) secured by sewing or welding to the single knitted piece after knitting of the latter. The knitted tubular element may include seams for finishing, for example closing the toe.

In a first embodiment, the textile tubular element is an internal textile tubular element comprising one or more thermofused textile portion(s), and the sole part of the internal textile tubular element is arranged between the sole shell and the sole element. In particular, the textile part of the internal sole of the internal textile tubular element is partially or entirely heat-fused and covers all or part of the internal face of the internal bottom and all or part of the internal faces of the side walls, in particular of the first and second side walls and possibly front and rear side walls, of the sole shell.

In a second embodiment, the footwear item comprises an internal textile tubular element and an external textile tubular element, and the sole shell according to the first aspect is arranged between the internal sole part of the internal textile tubular element and the external sole part of the external textile tubular element. In particular, the internal textile tubular element is arranged entirely or partially in the volume accommodating the foot of the external textile tubular element, the sole shell being disposed between said internal and external textile tubular elements.

In particular, the textile part of the internal sole of the internal textile tubular element is partially or entirely heat-fused and covers all or part of the internal face of the internal bottom and all or part of the internal faces of the side walls, in particular of the first and second side walls and possibly front and rear side walls, of the sole shell.

In one example, the outer sole part of the external textile tubular element, partly or entirely thermofused, covers at least part, or entirely, the external face, in particular the external face of engagement with the ground, of the shell of the sole of the footwear item.

In a third embodiment, the footwear item comprises an internal textile tubular element and an external textile tubular element, and the sole shell according to the first aspect, the external sole part of the external textile tubular element being arranged between the sole shell according to a first aspect of the invention, and the internal sole part of the internal textile tubular element. In particular, the internal textile tubular element is arranged entirely or partly in the volume for receiving the foot of the external textile tubular element, the external textile tubular element being arranged at least in part between the sole shell and the internal textile tubular element.

In particular, the textile part of the inner sole and the textile part of the outer sole are partially or entirely heat-fused and cover all or part of the internal face of the inner bottom and all or part of the internal faces of the side walls, in particular of the first and second side walls and possibly front and rear side walls, of the sole shell.

In one example, the external face of the sole shell forms at least part, or entirely, the external face of engagement with the ground of the article of footwear.

Advantageously, in particular in the embodiments below, the textile part of the internal sole of the internal textile tubular element is partially or entirely heat-fused (in particular is heat-compressed), against the interior surface of the interior volume for receiving the sole shell so that the internal face of the interior bottom, the internal faces of the first and second side walls and the internal faces of the front and rear side walls of the sole shell are covered, in whole or in part, with the sole part internal of the internal textile tubular element, said part of the internal sole being partially or completely heat-fused.

The sole textile part of the internal textile tubular element, and optionally the sole part of the external textile tubular element, is/are thin so that the sole shell of the footwear article includes all of the characteristics/ variants/embodiments defined with reference to the sole shell of the sole according to the first aspect of the invention.

Advantageously, the sole shell, covered with one or more thermofused internal and/or external textile tubular element(s) partially or entirely, therefore comprises a first main male interlocking part, respectively female, configured to cooperate by interlocking with the second female main interlocking part, respectively male, of the sole element for maintaining the sole element in position relative to the sole shell, and in particular comprises any one of the alternative embodiments defined with reference to the first aspect of the invention (first male or female auxiliary interlocking part, respectively, beveled lower medial or lateral edge, etc.).

Advantageously, in the first, second and third preceding embodiments, the sole element is placed against the internal sole part of the internal textile tubular element in whole or in part thermofused.

In one embodiment, the upper comprises the textile covering part, in particular internal, of at least part of the foot of the tubular textile element, in particular internal, and the sole comprises the textile part of the sole, in particular internal, of said tubular textile element, in particular internal, and possibly a part of the textile part covering at least part of the foot.

In embodiments, the article of footwear comprises internal and external tubular textile elements superimposed at least in part, the internal tubular textile element being arranged at least in part in the accommodating volume of the foot of the tubular textile element external.

Textile tubular element (in particular internal or external)

A textile tubular element, in particular whether it is an internal or external textile tubular element, comprises (in particular is essentially made up of) one or more multifilamentary thread(s), in particular partially or completely thermofused, and/or one or more yarn(s) spun from fibers, in particular partially or totally thermomelted, and/or one or more monofilament yarn(s), in particular partly or totally thermomelted .

The textile part covering at least partly the foot of a textile tubular element, in particular whether it is internal or external, may comprise one or more non-heat-fused thread(s) entirely or in part with one or more thermofused wire(s) in whole or in part.

The textile tubular element is preferably a knitted tube, in particular a tube knitted on a circular knitting machine of small diameter (that is to say whose diameter is between 5 cm and 20 cm, in particular between 5 cm and 15 cm).

The tubular textile element is preferably a tube comprising a bent part, in particular intended to receive the heel.

The textile tubular element preferably comprises an open front end, in particular which is closed, more particularly closed by sewing. Preferably, the open front end is a toe receiving area.

Advantageously, the tubular textile element comprises a volume for receiving or accommodating the foot and an opening for introducing the foot for accommodating the foot in said accommodating volume.

The textile part covering at least part of the foot of a textile tubular element can cover the whole or one or more region(s) of the top of the foot.

The textile sole part of a tubular textile element can cover all or one or more region(s) of the bottom of the foot.

The covering textile part and/or the sole textile part is/are arranged according to the configuration of the desired footwear item.

Preferably, the textile covering part, in particular of the internal or external textile tubular element, covers one or more region(s) of the top of the foot chosen from: the forefoot region arranged on the side lateral and/or the forefoot region located on the medial side; and/or the forefoot region extending between the lateral side and the medial side; and/or the instep area; and/or the midfoot region disposed on the lateral side and/or the midfoot region disposed on the medial side; and/or the rearfoot region disposed on the lateral side and/or the rearfoot region disposed on the medial side; and/or the rearfoot region extending between the lateral side and the medial side; and possibly at least partly the leg region.

The region(s) of the bottom of the foot in which a part of the sole extends, in particular of the internal or external tubular textile element, is/are chosen from: the front region foot extending between the lateral and medial sides of the article of footwear; and/or the midfoot region extending between the lateral and medial sides of the article of footwear; and/or the rearfoot region extending between the lateral and medial sides of the article of footwear.

Preferably, a tubular textile element comprises an external face and an internal face, in particular substantially opposite.

Preferably, the internal face of the external textile tubular element is oriented opposite the external face of the internal textile tubular element.

Preferably, the external face of the external textile tubular element is oriented facing the exterior of the article of footwear.

Advantageously, a tubular textile element comprises one or more non-thermo-fused yarn(s), and/or one or more thermo-fused yarn(s) at least in part, in particular entirely or in part.

In one embodiment, the internal textile tubular element and the external textile tubular element are two distinct and separate knitted pieces.

In this case, when the internal and external textile tubular elements are superimposed at least in part, the internal textile tubular element being arranged in a volume for receiving the foot of the external textile tubular element, the internal mounting face of the The external textile tubular element is oriented facing the external mounting face of the internal textile tubular element.

The internal mounting face of the internal tubular textile element is then oriented facing the accommodating volume of the foot of the article of footwear.

In one embodiment, the internal textile tubular element and the external textile tubular element are in the same textile part (in particular knitted), in particular are in textile connection (in particular knitted) at the level of their openings for introducing the foot in their respective foot receiving volumes or at the level of their respective open toes.

In this case, the internal textile tubular element being arranged in the accommodating volume of the foot of the external textile tubular element by inversion, said internal and external textile tubular elements being superposed at least in part, the internal mounting face of the external textile tubular element is oriented facing the internal mounting face of the internal textile tubular element.

The external mounting face of the internal tubular textile element is then oriented facing the accommodating volume of the foot of the article of footwear.

Advantageously, on the article of footwear corresponding to the finished article, in practice, the external face of the internal textile tubular element is oriented directly opposite the internal face of the external textile tubular element.

In one embodiment, the external face of the sole shell, in particular of the outsole shell, possibly covered in all or part of the sole part (in particular external) with a textile tubular element (in particular external) , forms all or part of the external face of engagement with the ground of the article of footwear.

In particular, the textile sole part of the textile tubular element (in particular external) matches, in particular forms a covering conforming to, the contour of one or more slot(s) opening out and open(es) on the external face of said shell sole.

Thermofused textile portion at least in part

Advantageously, a textile portion at least partly thermofused is:
- a part of one or more thread(s) which is partially thermofused so that said portion retains a recognizable textile structure, the thread(s) being glued to each other and/or to another or other wire(s), and/or is/are stiffened (in particular without being glued together); Or
- a part of one or more wire(s) which is heat-melted so that said portion forms a film or a coating or a polymeric melt such as a binder (in particular the textile structure is no longer recognizable).

Advantageously, in all cases, a change of state of the hot-melt textile portion is observed, in particular making it possible to bond the threads together and/or to form a film or a coating or a binder or a matrix, and/or to stiffen the wire(s), in order to maintain the shape given during thermocompression and to form differentiated technical zones.

The textile tubular element, in particular the internal textile tubular element (ETTI) and/or the external textile tubular element (ETTE), may (each) comprise one or more thermofused textile portion(s) s) or partially thermomelted (also referred to in this text as textile portion(s) at least partly thermomelted).

A textile portion at least partly thermofused can be a portion:
- a single-component monofilament yarn that is at least partially heat-melted (and therefore in particular hot-melt before its transformation) or two-component comprising at least a first component that is at least partially heat-melted (and therefore in particular hot-melt before its transformation) and at least one second component not hot melt (and therefore in particular not hot melt before its transformation) as defined in this text,
- a multifilament yarn comprising one or more single-component filament(s) thermofused at least partially (and therefore in particular hot-melt(s) before transformation) or two-component filament(s), each filament comprising at least a first at least partially hot-melt component (and therefore in particular hot-melt) and at least one second non-heat-melt component (and therefore in particular not hot-melt before transformation) as defined in the present text, possibly mixed with one or more single-component filament(s) (s) non-hot melt(s) (and therefore in particular non-hot melt(s)) as defined(s) in this text.

For example, a single-component yarn is a polyurethane monofilament yarn, for example having a melting temperature ranging from approximately 80°C-120°C.

For example, a two-component yarn comprises filaments each of which is of the core-coat type, that is to say comprising a coat comprising said first component having a melting temperature ranging from approximately 80°C-120°C and a core comprising said second component, in particular said second component having a melting or softening temperature higher than that of the first component, for example ranging from 150°C to 190°C.

Said thermofused wire(s) (or hotmelt(s)) at least partially one-component or two-component has/have (each) preferably a linear mass ranging from 300 dtex to 1200 dtex, in particular ranging from 400 dtex to 800 dtex, notably ranging from 600 dtex to 700 dtex.

We understand by one or more thermofused wire(s) at least partially: one or more thermofused wire(s) in their entirety, and one or more partially thermofused wire(s).

Preferably, said thermofused wire(s) at least partially is/are one-component multifilament wire(s).

Preferably, said single-component or two-component hot-melt multifilament wire(s) each have an elongation at break greater than or equal to 80% or 100%, more preferably greater than or equal to 115%, preferably less than or equal to 200%.

Son)

The monofilament yarn(s) and/or the fiber spun yarn(s) and/or the multifilament yarn(s) defined in this text may /may be in one or more material(s) chosen from:
- a list I comprising: polyesters, in particular chosen from polyethylene terephthalate (PET) and polybutylene terephthalate (PBT) or a combination of the latter; polyamides, in particular chosen from PA 6, PA 6-6, and a combination of the latter; polyolefins, in particular polyethylene, polypropylene, and a combination thereof; elastanes; and a combination of these; and or
- a list II comprising: cotton, regenerated cellulose, for example viscose, linen, sisal, wool, jute, silk, hemp, and a combination of these;
- a list III including: para-aramids, meta-aramids and carbon; and or
- a list IV including: recycled textiles, in particular recycled clothing, for example thermal protective clothing such as clothing for firefighters.

The material(s) listed in List I, and/or List II, and/or List III and/or List IV, may be recycled and/or biosourced ) at least in part. The monofilament wire(s) preferably has/have a diameter greater than or equal to 0.01 mm and less than or equal to 5 mm, more preferably greater than or equal to 0.1 mm and less than or equal at 2mm.

The multifilament yarn(s) and/or yarn(s) spun from fibers preferably have a linear mass greater than or equal to 10 dtex and less than or equal to 1000 dtex, more preferably greater than or equal to 30 dtex and less than or equal to 500 dtex.

Advantageously, the non-heat-fused wire(s) comprises/includes, in particular is/are essentially made up of one or more polymer material(s) whose melting or degradation temperature is higher than the maximum temperature used in the manufacturing process of the footwear.

The wire(s), in particular not thermofused, may also be one or more elastic wire(s).

By elastic thread we understand any thread whose elongation at break is greater than or equal to 100% or 200%, in particular greater than or equal to 300%, in particular greater than or equal to 400%. The elastic thread preferably comprises an elastic core, in particular made of elastane, and possibly one or more covering threads. Elongation can be measured using ASTM D 1578-93 (2016). By definition, elastic thread is not heat-fused.

Definitions

In the present text, hot melt or first hot melt component means any material or first component which is hot melted or partially hot melted during the manufacture of the article of footwear according to the invention.

In this text, non-hot melt means any material/component which is not hot melted during the manufacture of the article of footwear according to the invention. This material or component may be a thermoplastic material or not, but which has a melting or softening temperature or a degradation temperature which is higher than the highest heating temperature used in the manufacturing process of the article of footwear according to the invention.

It is understood in the present text by hot-melt wire(s) at least partially that said wire(s) is/are completely hot-melt(s) or comprises/includes only a portion of their structure which is hot-melt.

The present invention relates, according to a third aspect, to a method of manufacturing a sole, in particular according to any alternative embodiment with reference to the first aspect of the invention, said method comprising:
- a thermocompression step a) of one or more at least partially hot-melt sole material(s) with a molding assembly comprising a mold and an inflatable bladder, and said mold comprises a molding cavity of a sole shell, in particular an outsole shell, said molding impression comprising an interior bottom and first and second side walls between which said interior bottom extends, and said molding impression of the sole shell, in particular the outsole shell, comprises a second main female, respectively male, interlocking portion, having a determined shape formed, in particular undercut, in the first side wall of the molding cavity, and optionally by at least one portion of said interior bottom;
- a step of demoulding b) of the sole shell, in particular after deflation of said inflatable bladder;
- a step of providing c) a sole element comprising an edge, said edge comprising a first male or female main interlocking portion, respectively, having a determined shape configured to cooperate by interlocking with said second main interlocking portion female, respectively male, of the molded sole shell so as to maintain said sole element in position relative to the sole shell, in particular wear, said sole shell comprising an interior volume for receiving said sole element.

The at least partly hot-melt sole material(s) may be as described above with reference to the first aspect of the invention.

For example, the sole material(s) comprise particles originating from at least partly hot-melt waste, for example said particles have been crushed.

Said waste may be shoe soles and/or shoes and/or textiles.

In a variant embodiment, the molding imprint of the sole shell, in particular wear, comprises a rear side wall comprising an undercut upper edge.

It is understood in the present text by undercut element that said element (for example the upper edge of the rear side wall of the molding cavity) is slightly oblique relative to the wall of the molding cavity and thus tends to prevent extracting the molded object.

An undercut inclination is an inclination opposite to that of the undercut.

The present invention relates, according to a fourth aspect, to a method of manufacturing an article of footwear comprising the method of manufacturing a sole according to any one of the alternative embodiments with reference to the third aspect of the invention, and comprising the thermocompression of at least one textile tubular element comprising at least one hot-melt textile portion, said thermocompression step is carried out:
- during the thermocompression step a), the mold also comprising an upper imprint, and the inflatable bladder being configured to compress the sole material(s) and at least said textile tubular element against the sole imprints and of stem; Or
- in a thermocompression step additional to the thermocompression step a) with a molding assembly comprising a mold comprising an upper imprint, a sole imprint, and an inflatable bladder for thermocompressing and bonding said textile tubular element to the shell of sole, especially wear.

Preferably, the sole shell is secured to the textile tubular element by at least one thermofused portion, in particular at least one thermofused portion of the sole shell and/or at least one thermofused textile portion of said textile tubular element.

In an exemplary embodiment, said method comprises the thermocompression of an ETTE and an ETTI, the sole shell being arranged between the ETTE and the ETTI, in particular between the sole part of the ETTE, and the sole part of the ETTI.

In an exemplary embodiment, the sole part of the ETTE and/or the sole part of the ETTI comprises (each) one or more hot-melt wire(s) in part or in full.

In an exemplary embodiment, said method comprises the thermocompression of an ETTE and an ETTI, the sole part of the ETTE is arranged between the sole shell and the sole part of the ETTI.

Advantageously, the sole shell is secured to the ETTI and/or the ETTE via a thermofused portion of the sole shell and/or via at least one thermofused textile portion of the sole shell. 'ETTI and/or at least one thermofused textile portion of the ETTE.

In a variant, the sole part of the textile tubular element comprises at least 80% by mass of hot-melt thread(s) at least in part.

In a variant, at least 80% by mass of the internal sole part of the ETTI and/or at least 80% by mass of the external sole part of the ETTE comprises each of the wire(s). ) hot melt(s) at least in part.

The alternative embodiments according to a first aspect, a second aspect, a third aspect, and a fourth aspect can be combined with each other and independently of each other.

Description of the designs

The invention will be better understood on reading the following description of the embodiments of the invention given by way of non-limiting examples, with reference to the appended drawings, in which:

there represents schematically in perspective, seen from the medial side, a first example of a sole shell, in particular wear, according to the invention;

there schematically represents in perspective the first example of a sole shell, in particular wear, of the seen from its lateral side;

there schematically represents the sole shell shown in according to section plane III-III;

there schematically represents the sole shell of the according to section plane IV-IV;

there schematically represents the sole shell of the according to the section plane VV;

there schematically represents, seen from the medial side, a first example of a sole element according to the invention;

there schematically represents the sole element of the view according to section plane VII-VII;

there schematically represents the sole element of the view according to section plane VIII-VIII;

there schematically represents, seen from above, the first example of a sole element;

there schematically represents, seen from below, the first example of a sole element;

there schematically represents a second example of sole shell seen along its lateral side, receiving in its interior receiving volume the first example of sole element;

there schematically represents, seen from the medial side, a first example of an article of footwear according to the invention;

there schematically represents the external face of engagement with the ground of the article of footwear shown in Figures 12 and 13.

A first example of a sole shell 10 is shown in Figures 1 to 5, in this particular example it is an outsole shell.

This sole shell 10 is molded, in particular by thermocompression of one or more thermoplastic material(s) at least in part, and therefore hot-melt(s) at least in part, using a set of mold and an inflatable bladder, in particular as described above. Advantageously, the sole shell 10 is full because the molten material is pressed against the walls of the molding assembly.

Advantageously, the sole shell 10 comprises an external face 11, and an internal face 12. The sole shell 10 also comprises an interior bottom 14, a first side wall 16 disposed on the medial side of the sole shell 10, also designated by medial wall 16, a second side wall 18 disposed on the lateral side of the sole shell 10, also designated by side wall 18, a front side wall 20 disposed on the front side of the sole shell 10, and a rear side wall 22 disposed on the rear side of the sole shell 10. Advantageously, the walls 16,18,20 and 22 form a rim extending substantially continuously from and along the periphery of the interior bottom 14, and project vertically above said inner bottom 14.

Advantageously, the interior bottom 14 extends between the first and second side walls 16,18 and between the front 20 and rear side walls 22.

Preferably, the sole shell 10 comprises a forefoot region 30, a midfoot region 32 and a rearfoot region 34.

Advantageously, the sole shell 10 comprises a second main female interlocking portion 40 formed in the first side wall 16 and by at least one medial portion 42 of said interior bottom 14 as well as a second female auxiliary interlocking portion 50 formed in the second side wall 18 and by at least one side portion 52 of said interior bottom 14.

For example, the second main female nesting portion 40 consists essentially of a cavity 44 comprising an upper wall 44a and a lower wall 44b forming an open clamp 46, in particular the upper wall 44a forms an upper stop for the element of sole 100 described below.

Preferably, the lower wall 44b corresponds to the medial portion 42 of the interior bottom 14.

For example, the second female auxiliary interlocking portion 50 consists essentially of a cavity 54 comprising an upper wall 54a and a lower wall 54b forming an open clamp 56, in particular the upper wall 54a forms an upper stop for the element of sole 100 described below.

Preferably, the lower wall 54b corresponds to the side portion 52 of the interior bottom 14.

For example, the open clamps 56 and 46 are arranged respectively on the lateral side and on the medial side of the sole shell 10, and are open on the interior volume 13 of the sole shell 10.

The second female auxiliary interlocking portion 50 is here formed in the side wall 18 but could be formed indifferently in the medial wall 16.

The second main female interlocking portion 40 and/or the second female auxiliary interlocking portion 50 is/are (each) here substantially continuous, in particular the clamp 46 and/or the clamp 56 is/are substantially continuous(s) , and extends partly in the forefoot region 30 and partly in the midfoot region 32. The clamp 46 and/or the clamp 56 could also be discontinuous, that is to say say a clamp 46 or 56 can essentially consist of several sub-clamps substantially aligned so as to form a general clamp.

The sole shell 10 may include a recess 60 hollowed out in the medial wall 16 or first side wall 16, from its internal face. The sole shell 10 may include a recess 70 hollowed out in the side wall 18 or second side wall 18, from its internal face. These recesses 60,70 make it possible to lighten the sole shell 10. Preferably, the second main interlocking portions 40 and auxiliary 50 are arranged in the forefoot region 30 and partly in the midfoot region , in this example the second main 40 and auxiliary 50 interlocking portions extend substantially continuously.

Preferably, the cavities 44,54 or the clips 46,56 are elongated and extend horizontally from the midfoot region towards the forefoot region of the sole shell 10. However, these cavities 44,54 could not be substantially continuous but be discontinuous, that is to say arranged in several parts arranged horizontally and extending towards the front side of the sole shell 10 as discussed above. Preferably, the cavities 44,54 or clamps 46,56 substantially follow the general shape of the first or second side wall 16,18 in which they are formed.

Preferably, the main cavities 44,54 or clamps 46,56 substantially follow the general shape of the first or second side wall 16,18 in which they are formed.

Advantageously, the rear side wall 22 of the sole shell 10 comprises an upper edge 24 inclined towards the inside of the outsole shell 10. The rear side wall 22 is in particular curved towards the interior volume 13 of the shell of sole 10.

Advantageously, the first side wall 16 comprises an upper edge 17 of which at least part is inclined towards the inside of the sole shell 10, and the second side wall 18 comprises an upper edge 19 of which at least part is inclined towards the inside the sole shell 10.

Advantageously, the volume 13 of the sole shell 10 is configured to receive a first example of sole element 100 described with reference to Figures 6 to 10.

The sole element 100 comprises an edge, in particular a medial edge 110 because it is placed on the medial side of the sole element 100, a lateral edge 120 placed on the lateral side of the sole element 100, a front edge 130 placed on the front side of the sole element 100, and a rear edge 140 arranged on the rear side of the sole element 100.

The sole element 100 comprises an internal face 102 and an external face 104, in particular substantially opposite the internal face 102.

The medial border 110 extends between an upper edge 112 and a lower edge 114, and in particular between the internal 102 and external 104 faces.

The side edge 120 extends between an upper edge 122 and a lower edge 124, and in particular between the internal 102 and external faces 104. Advantageously, the sole element 100 comprises a forefoot region, a region of midfoot and a rearfoot region.

Advantageously, the lower edge 114 advances outwards from the medial edge 110 relative to the upper edge 112 so that the upper edge 112 is set back relative to the lower edge 114. For example, the medial edge 110 comprises a first main male interlocking portion 150 formed in the lower edge 114, in particular the first main male interlocking portion has a general shape substantially beveled from the lower edge 114 of the medial border 110.

Advantageously, the lower edge 124 advances outwards from the side edge 120 relative to the upper edge 122 so that the upper edge 122 is set back relative to the lower edge 114. For example, the side edge 120 comprises a first male auxiliary interlocking portion 170 formed in the lower edge 124, in particular the first male auxiliary interlocking portion 170 has a general shape substantially beveled from the lower edge 124 of the side edge 120. The first interlocking portions main and auxiliary male interlocking portions 150 and 170 each have a determined shape, and the second main and auxiliary female interlocking portions 40 and 50 also each have a determined shape and are configured to cooperate by interlocking respectively with the first main and auxiliary interlocking portions. auxiliary males 150 and 170, so as to hold the sole element 100 in position relative to the sole shell 10 when the sole element 100 is housed in the interior receiving volume 13.

Thus, the first main male portion 150 is pinched by the clamp 46, and the first auxiliary male portion 170 is pinched by the clamp 56.

Advantageously, the sole element 100 can thus be arranged in the interior receiving volume 13 of the sole shell 10, and is held in position relative to the sole shell 10 on the medial side and on the lateral side of the sole shell 10. sole shell 10, and this in a removable manner.

Advantageously, the sole element 100 is a flexible and deformable sole element which facilitates its insertion and cooperation between the male 150,170 and female 40,50 interlocking portions.

For example, the sole element 100 is made of polyurethane or polyamide foam or is essentially made up of beads in at least one expanded polymer which are agglomerated together, in particular glued together. Said expanded polymer can be for example polyurethane or polyamide or even polyolefin, for example polypropylene or polyethylene, or preferably in an elastomer of the latter.

Advantageously, the sole element 100 comprises a rear edge 144 projecting vertically above the internal face 102 of said sole element 100. The internal face 102 forms a support face for the foot.

Advantageously, the inclined upper edge 24 of the sole shell 10 forms an upper stop for the inclined upper edge 145 of the rear edge of the sole element 100 when the sole element 100 is housed in the interior receiving volume 13 of the sole shell 10. This arrangement favors the maintenance in position of the sole element 100 in the sole shell 10 by ensuring an anchoring point complementary to those provided on the medial side and the lateral side of the sole shell 10 .

For example, the sole shell 10 can be attached directly to a conventional upper of an article of footwear (for example a flat knitted or woven upper without a sole part), for example by sewing, or even by gluing. Then, the sole element 100 is placed in the interior receiving volume 13 of the sole shell 10 and held in position via the first and second interlocking portions 40,50,150,170 and forms with the latter a sole 90.

For example, the sole shell 10 can be secured to a tubular textile element, in particular called internal, such as a knitted sock, during a thermocompression step. The tubular textile element thus comprises a textile sole part comprising one or more hot-melt thread(s) at least in part, in particular consisting essentially of hot-melt thread(s), and its textile sole part is housed in the interior receiving volume 13 of the sole shell 10. During the thermocompression step, an inflatable bladder configured so as to present second main and auxiliary molding nesting portions is implemented under appropriate conditions ( for example the inflation pressure is 4 bars, and the heating temperature ranges from 110°C to 160°C) so that the sole part of the textile tubular element matches the interior volume of the sole shell 10 while by maintaining the determined functional shapes of the second main 40 and auxiliary 50 interlocking portions of the sole shell 10 as described above. Furthermore, this thermocompression step makes it possible to secure a tubular textile element to the sole shell 10.

Advantageously, the tubular textile element comprises a textile part covering at least part of the foot, optionally comprising one or more hot-melt wire(s) in part or totally, said covering part forms all or part of the rod of the final article of footwear.

Preferably, in the previous variants, the sole shell 10 is an outsole shell whose external face 14 forms the external face of engagement with the ground of the article of footwear.

It is also possible to secure one or more distinct and separate element(s), resistant to abrasion, on the external face of the sole shell 10 so that the external face of the sole shell 10 does not come into direct contact with the ground.

It is possible in the previous variant to add a so-called external textile tubular element.

In one example, the sole shell 10 is arranged between the sole part in whole or in part hot-melt of an external textile tubular element and the sole part in all or part hot-melt of an internal textile tubular element of which the sole part is housed in the interior receiving volume 13 of the sole shell 10.

There represents a second example of sole 250 comprising a sole shell 200 and a sole element 300. The sole shell 200 may be similar to the sole shell 10, and the sole element 300 may be similar to the sole element 300. sole 100.

The sole element 300 comprises a rear edge 310 projecting vertically above an interior support face of the foot 320 of said sole element 300, and the sole shell 200 comprises a rear side wall 220 comprising an upper edge 240 inclined towards the inside of the sole shell 200 and forming an upper stop for said rear edge 310 of the sole element 300.

In one example, the support face of the foot 320 of the sole element 300 is set back vertically from the upper edge 240 of the rear side wall 220 by a height R _AR , for example of the order of 28 mm, and the inclined upper edge 315 of the rear edge 310 of the sole element 300 is flush with the upper edge 240.

In one example, the medial wall 216 or first side wall 216 has an upper edge 216a projecting vertically above the support face of the foot 320. Thus, the support face of the foot 320 is set back vertically from the edge upper 216a of the medial wall 216 of R _M , the recess R _M being for example of the order of 20 mm.

In one example, the support face of the foot 320 is set back vertically from the upper edge 230a of the front side wall 230 of R _AV , the setback R _AV being for example of the order of 5-6 mm.

In one example, the sole element 300 housed in the internal receiving volume of the sole shell 200, does not project vertically above one of the side walls (first and second side walls, front side walls and rear) of the sole shell 200. The sole shell 200 is therefore hollow, and includes a sufficiently large volume to receive and house the sole element 300, while arranging one or more side wall(s) projecting vertically above the bearing face of the foot 320 of the sole element 300.

Figures 12 to 14 represent a first example of an article of footwear 400, in particular a sports shoe, comprising for example the sole shell 10 and the sole element 100 or else the sole shell 200 and the sole element 300 .

The footwear item 400 comprises an upper 500 and a sole 600 connected to the upper 500 via at least one thermofused portion.

In one example, the upper 500 comprises an external textile part covering the foot 510 and an internal textile part covering the foot 520 partly superimposed with the external textile part covering the foot 510.

In particular, the external textile covering part of the foot 510 extends between the medial and lateral sides of the upper 500 and between the front and rear sides of the upper 500. In this example, the external textile covering part 510 is extends into the forefoot 430, midfoot 432 and rearfoot 433 regions but does not include an instep area.

In this example, the outer textile covering part 510 combines transparent monofilament yarns, for example made of polyethylene terephthalate, with thermofused yarns so as to form thermofused textile portions, in particular transparent or translucent.

In this example, the internal textile part covering the foot 520 also extends between the medial and lateral sides and between the front and rear sides of the upper 500. In this example, the internal textile part covering the foot 520 comprises a instep zone, and in particular a region surrounding all or part of the opening for introducing the foot covering more of the lower part of the leg than the region surrounding all or part of the opening for introducing the foot the external textile part covering the foot 510.

The sole 600 comprises a sole shell 650 similar to the sole shell 10 or 200, as well as a sole element (not visible in Figures 12 to 14), similar to the sole element 100 or 300, arranged in the interior receiving volume of the sole shell 650 and removably held in position with the latter.

The sole 600 also comprises a part of an external textile sole in whole or in part thermofused, in textile connection with the external textile part covering the foot 510, as well as a part of internal textile sole in all or part thermofused, in textile connection with the internal textile part covering the foot 520.

Advantageously, the external and internal textile covering parts of the foot 510 and 520 are glued together via thermofused textile portions, in particular which comprise the external textile covering part 510 and possibly the internal textile covering part 520.

For example, the region surrounding all or part of the opening for introducing the foot of the internal textile part covering the foot 520 comprises one or more elastic thread(s), in particular based on elastane.

The footwear article 400 is preferably manufactured by a thermocompression process comprising a preliminary step of manufacturing the outsole shell 650 by thermocompression, and a step of assembling the sole shell 650 with internal textile tubular elements and external superimposed at least in part.

In one example, the internal textile tubular element preferably comprises an internal textile part covering the foot, and an internal textile sole part in textile connection with said internal textile part covering the foot and consisting essentially of hot-melt thread(s). (s) possibly mixed with one or more non-hot melt thread(s). Preferably, the internal textile tubular element is a sock.

Similarly, the external textile tubular element preferably comprises an external textile part covering the foot, and an external textile sole part in textile connection with said internal textile part covering the foot and consisting essentially of hot-melt thread(s). (s) possibly mixed with one or more non-hot melt thread(s). Preferably, the external textile tubular element is a sock.

In this example, the external textile tubular element and the internal textile tubular element are separate knitted pieces.

During the preliminary thermocompression step a) of the sole shell 650, an assembly comprising one or more at least partly hot-melt sole material(s), for example hot-melt particles (for example comprising polyurethane) mixed with non-hot melt particles (e.g. crushed waste), is thermocompressed with a molding assembly comprising a mold and an inflatable bladder. The mold comprises a molding cavity of the outsole shell 650, said molding cavity comprising an interior bottom and first and second side walls between which said interior bottom extends, and said molding cavity of the outsole shell 650. outsole comprises a second main female, respectively male, interlocking portion, having a determined shape formed undercut, in the first side wall of the molding cavity, and by at least one portion of said interior bottom. In particular, the molding impression comprises molding impressions of the first and second main and auxiliary nesting portions as described above. During the thermocompression step, the assembly comprising the particles is heated to a temperature allowing the fusion of the hot-melt particles, and an inflation pressure of the order of 3 bars to 5 bars is applied to the inflatable bladder under conditions suitable so that the hot-melt mixture comprising non-hot-melt particles is compressed against the molding cavity.

The heating temperature is determined to melt the targeted hot melt particles.

The method then comprises a step of demolding the outsole shell after deflation of the bladder, in particular before the sole shell 650 is cooled, that is to say before it reaches room temperature so as to facilitate unmolding given the numerous undercut shapes.

In an additional thermocompression step with a molding assembly comprising a mold comprising an upper impression, a sole impression, similar to the molding impression implemented in the preliminary thermocompression step a), and an inflatable bladder, the partially superimposed internal and external textile tubular elements associated with the sole shell are thermocompressed under appropriate conditions to obtain the connection of the sole shell with the internal and external tubular elements, melting in all or part the sole parts of the elements tubular textiles, and melt at least partially any textile portions that comprise the external textile covering part of the foot and/or that comprise the internal textile covering part of the foot.

During the additional thermocompression step, the sole shell can be placed between the internal and external textile sole parts, or the external sole part can be placed between the internal sole part and the sole shell.

In any thermocompression step, preliminary or additional, an inflatable bladder configured so as to present first main and auxiliary molding nesting portions is implemented.

Finally, the method of manufacturing the article of footwear 400 comprises a step of providing c) a sole element similar to the sole element 100 or 300. The sole element is arranged in the interior volume for receiving the the sole shell 650 and removably secured to the sole shell 650 by making the first male interlocking portions cooperate with the second female interlocking portions.

The internal textile part of the sole and/or the external textile part of the sole in whole or in part thermofused is/are very thin so that the second female, respectively male, interlocking portions perfectly fit the first portions. of female, respectively male, sockets, so that their constructions are preserved.

The sole shell according to the invention is hollow and comprises an empty internal receiving volume filled in part by the sole element providing cushioning and/or recovery functions and forming a recycled sole at least in part, and light . The footwear has an original construction, the sole shell being held in connection with the upper via heat-fused textile portions. It is thus advantageously possible to manufacture an article of footwear, in particular a lightweight sports shoe, whose sole is also manufactured by thermocompression while associating it with a flexible and deformable sole element.

Claims (16)

Sole (90,600), in particular for a sports shoe (400) characterized in that it comprises a molded sole shell (10,200,650) comprising an external face (11), an interior bottom (14) and first (16,216) and second (18) side walls between which said interior bottom (14) extends, in that said sole (90,600) comprises a sole element (100,300) comprising an edge (110,120), said edge (110,120) comprising a first portion main male interlocking (150), respectively female, having a determined shape, and in that said sole shell (10,200,650) comprises an interior volume for receiving (13) said sole element (100,300) and a second portion of main female interlocking (40), respectively male, having a determined shape configured to cooperate by interlocking with said a first main interlocking portion (150) so as to hold said sole element (100,300) in position relative to the shell of sole (100,200,650), said second main interlocking portion (40) being formed in the first side wall (16,216), and possibly by at least one portion (42,52) of said interior bottom (14). Sole (90,600) according to claim 1, characterized in that the sole element (100,300) is a sole element (100,300) flexible and deformable compared to the sole shell (10,200,650) so as to be able to be deformed during its positioning in an interior receiving volume (13) of the sole shell (10,200,650). Sole (90,600) according to either of Claims 1 and 2, characterized in that the sole element (100,300) is designed to be secured to the sole shell (10,200,650) in a removable manner. Sole (90,600) according to any one of claims 1 to 3, characterized in that said first main interlocking portion (150) is a first main male interlocking portion, and said second main interlocking portion (40) is a second main female nesting portion consisting essentially of a cavity (44) comprising an upper wall (44a) and a lower wall (44b) together forming an open clamp (46), in particular the upper wall (44a) forms a upper stop for the sole element (100,300). Sole (90,600) according to any one of claims 1 to 4, characterized in that the edge (110,120) of the sole element (100,300) extends between an upper edge (112,122) and a lower edge (114,124) , and in that the lower edge (114,124) advances towards the outside of the border (110,120) relative to the upper edge (112,122) so that the upper edge (112,122) is recessed relative to the lower edge ( 114,124). Sole (90,600) according to any one of claims 1 to 5, characterized in that the first main male interlocking portion (150) of the sole element (100,300) has a general shape substantially beveled from the lower edge (114,124) of the border (110,120). Sole (90,600) according to any one of claims 1 to 6, characterized in that the sole shell (10,200,650) comprises a rearfoot region, a midfoot region and a forefoot region, and in that said second main interlocking portion (40) is arranged in the forefoot region, and optionally partly in the midfoot region. Sole (90,600) according to any one of claims 1 to 7, characterized in that the sole element (100,300) comprises a rear edge (144,310) projecting vertically above an interior support face (102,320). ) of the foot of said sole element (100,300), and in that the sole shell (10,200,650) comprises a rear side wall (22,220) comprising an upper edge inclined (24,240) towards the inside of the sole shell (10,200,650) and forming an upper stop for said rear edge (144,310) of the sole element (100,300). Sole (90,600) according to claim 8, characterized in that the sole element (90,600) comprises an internal foot support face (102,320), and said internal foot support face (102,320) is recessed vertically of the inclined upper edge (24,240) of the rear side wall (22,220) of the sole shell (10,200,650), in particular of a recess R _AR greater than or equal to 10 mm. Sole (90,600) according to any one of claims 1 to 9, characterized in that the first side wall (16,216) comprises an upper edge (216a) of which at least part is inclined towards the inside of the sole shell ( 10,200,650). Sole (90,600) according to any one of claims 1 to 10, characterized in that the sole element (100,300) comprises agglomerated particles which are each in at least one expanded polymer. Article of footwear (400), in particular a sports shoe (400), characterized in that it comprises a sole (90,600) according to any one of claims 1 to 11. Article of footwear (400) according to claim 12, characterized in that it comprises at least one tubular textile element, optionally comprising at least one textile portion at least partially thermofused, and in that the sole shell (10,200,650) and said at at least one textile tubular element are bonded by at least one thermofused portion, in particular at least one thermofused portion of the sole shell (10,200,650) and/or at least one thermofused textile portion of said textile tubular element. Method of manufacturing a sole (90,600), in particular according to any one of claims 1 to 11, characterized in that it comprises:
- a thermocompression step a) of one or more at least partly hot-melt sole material(s) with a molding assembly comprising a mold and an inflatable bladder, and in that said mold comprises a molding cavity of a sole shell, said molding cavity comprising an interior bottom and first and second side molding walls between which said interior bottom extends, and in that said molding cavity of the sole shell comprises a second portion main socket of female, respectively male molding having a determined shape formed, in particular undercut, in the first side wall of the molding cavity, and possibly by at least one molding portion of said interior bottom;
- a step of demolding b) the sole shell (10,200,650), in particular the outsole shell, in particular after deflation of said inflatable bladder;
- a step of supplying c) a sole element (100,300) comprising an edge (110,120), said edge (110,120) comprising a first main male interlocking portion (150), respectively female, having a specific shape configured to cooperate by interlocking with a second female molded main interlocking portion (40), respectively male, of the sole shell (10,200,650) so as to hold said sole element (100,300) in position relative to the sole shell (10,200,650 ), said sole shell (10,200,650) comprising an interior receiving volume (13) of said sole element (100,300). Manufacturing method according to claim 14, characterized in that the molding impression of the sole shell, in particular wear, comprises a rear side wall comprising an undercut upper edge. Method of manufacturing an article of footwear (400), in particular according to any one of claims 12 and 13, characterized in that it comprises the method of manufacturing a sole (90,600) according to one or the other of claims 14 and 15, and in that it comprises the thermocompression of at least one textile tubular element comprising at least one hot-melt textile portion, said thermocompression step is carried out:
- during the thermocompression step a), the mold also comprising an upper imprint, and the inflatable bladder being configured to compress the sole material(s) and at least said textile tubular element against the shell imprints of sole and upper in an inflated state; Or
- in a thermocompression step, additional to the thermocompression step a), with a molding assembly comprising a mold comprising an upper imprint, a sole shell imprint, and an inflatable bladder for thermocompressing and bonding said textile tubular element to the sole shell (10,200,650).