CN107252150B - Shoes suitable for foot shape - Google Patents

Abstract

The invention relates to an upper (51) for a shoe, in particular for a sports shoe. The upper comprises a plurality of first portions (91) for receiving at least one toe of the foot, wherein the first portions (91) are movable substantially independently of each other, and wherein the first portions (91) comprise a knit.

Description

Shoes suitable for foot shape

The present application is a divisional application of an application entitled "footwear adapted to a foot shape", having an application number of "201410160424.4", having an application date of "2014, 04, and 21".

1. Field of the invention

The invention relates to a shoe, in particular to a sports shoe.

2. Description of the Prior Art

Typically, a shoe includes a sole and an upper secured to the sole. The sole and the upper are made of leather in conventional shoes and of synthetic material in sports shoes.

Shoes differ from socks in that the upper of the shoe provides the foot with greater stability than the sock. The shoe is more tightly secured to the foot than the sock. In addition, the sole of the shoe protects the foot from injury and provides cushioning, i.e., the sole absorbs the impact of forces, for example, during running. By using suitable materials, such as rubber and/or profiling, the sole of the shoe further provides the necessary stiction with the ground. The sock does not fulfill the above-mentioned functions of the shoe.

In a typical shoe, the foot of the wearer of the shoe is completely surrounded by the upper and sole, i.e., the toes of the foot are adjacent to one another. In addition, the toes are placed on the sole such that each toe contacts the sole as a whole. Individual contact of the individual toes with the ground through the sole is not possible. At the same time, the toes can move into the interior of the shoe, which apply a force on the sole only as a whole.

This situation is considered disadvantageous and anomalous. Barefoot walking is considered ideal from a foot medical standpoint, where the toes are free to move to the maximum extent, and each toe is in direct contact with and can feel the ground.

However, comfortable barefoot walking is only possible on soft, non-hazardous floors. Even small stones are considered uncomfortable and pose the risk of injury to the foot, like glass fragments. Furthermore, especially in winter, the outdoor ground is often too cold for comfortable barefoot walking.

On the one hand, in order to give the wearer of the shoe a more natural feeling when walking, similar to barefoot walking, and on the other hand, to protect the foot from injuries and cold, shoes are known which comprise special parts to accommodate the toes. Each toe can move that portion where the toe is placed independently of the other portions. This allows each toe to contact the ground individually and feel the ground. Thus, the comfort of walking resembles the sensation of barefoot walking, but at the same time the sole of the shoe protects the foot from injury and cold.

For example, US2007/0144039a1 relates to a piece of footwear that allows for individual movement of the toes of a wearer of the piece of footwear while providing comfort, protection and improved tactile feedback.

However, a drawback of this shoe has proved to be that the connection between the different parts is considered uncomfortable for the toes. The parts are usually sewn together or glued together so that there is a thick and easily felt seam between the toes. This is considered uncomfortable and may even result in the space between the toes being worn.

DE 102011055154 a1 relates to a sock for covering the foot and to the use of strong and cut resistant yarn for the sock. A piece of sock is provided in a sock-like manner, surrounding each toe and consisting at least in part of a material resistant to cutting.

DE 202007011165U 1 relates to a piece of footwear, in particular designed as a sock or a lap, substantially consisting of a lap element formed at least partially covering the foot and a sole element, the latter being connected to each other in one piece.

DE 102011055154 a1 and DE 202007011165U 1 provide solutions that are completely different from shoes or shoe uppers. As already explained above, the sock does not provide the necessary stability to the foot, particularly in the field of sports. Furthermore, the solution provided lacks any kind of cushioning, which is particularly indispensable during running, to protect the joint from the force cramps.

It is therefore an object of the present invention to provide a shoe, in particular a sports shoe, which imparts a walking sensation similar to barefoot walking, while not causing an uncomfortable sensation in the space between the toes.

3. Summary of the invention

According to a first aspect of the invention, this problem is solved by an upper for a shoe, in particular an athletic shoe, by the shoe comprising a plurality of first portions for receiving at least one toe of the foot, wherein the first portions can be moved substantially independently of each other, and wherein the first portions comprise a knitted fabric.

An upper according to the present invention includes a first portion for receiving at least one toe of each foot. The first portions may be moved substantially independently of each other to allow the toes to move freely to a particular range, i.e., without limitation of movement of the toes as in the case of a conventional shoe. Thus, in the event that the portion moves, its adjacent portions can move slightly due to the transmission of friction or forces on the upper and/or the sole.

Since the first portions are able to move substantially independently, the toes may also move substantially independently of one another. This creates a natural walking sensation similar to barefoot walking. The toes can move freely and contact the ground alone, and the ground can be felt. Furthermore, a gripping movement of the toes is also possible, which is indispensable in some types of movements, such as climbing.

Since the first part forms a braid, thick seams at the joints of the part can be avoided. For example, the portion may be manufactured as a single piece of braid on a corresponding machine. Thus, the parts have been joined together seamlessly during the manufacturing process. Another possibility is to connect the first parts by means of a coupling. In this respect, the edges of the parts can be joined together in a course-oriented manner, i.e. stitch-joining stitches, for example on a corresponding joining machine without creating a thick annoying seam.

It has to be noted that the above mentioned techniques to avoid thick annoying seams can be achieved only by using a woven fabric.

In a preferred embodiment of the invention, the first part is formed in one piece. Thereby, thick annoying seams are avoided. Can be produced as a single-piece knit in a simple, cost-effective and rapid manner on a corresponding weft or warp knitting machine. Since the first parts are already joined together during the manufacturing process, no corresponding subsequent work step is required.

In an alternative embodiment of the invention, the first parts are connected together by a joint. The binding allows the stitch run to join the edges of the fabric without creating a thick annoying seam. Bonding can be used for both weft and warp knit fabrics.

Preferably, the first portion is substantially seamlessly joined, i.e., the connection of the portion between the toes is made without seams. Further, the knit includes seams in other areas that are not disposed between the toes (i.e., decorative seams). The seamless joining of the first part, the space between the toes being free from any seam, is considered to be very annoying.

Preferably, there is a separate first portion for each toe. So that each toe can move freely to the maximum extent possible, and adjacent toes can be moved individually. Thus, the walking sensation is very similar to barefoot walking.

Preferably, the fabric comprises at least one weft knitted area. Can be manufactured, for example, by a weft knitting machine, allowing simple, cost-effective and rapid manufacture of the knitted fabric.

Particularly preferably, the weft fabric is flat woven. Further preferably, the braid is weft knitted in two layers. Further preferably, the two layers are joined to create the first portion at the side edges.

In a preferred embodiment of the invention, at least one weft-knitted zone is three-dimensional weft-knitted. Three-dimensional (3D) weft knitting allows the weft knit fabric to be directly adjusted to the shape of the foot during weft knitting. No separate cutting is required. The shape of the toes, instep or heel may also be weft knitted directly into a knit.

In a preferred embodiment of the invention, the upper, including the first portion, is formed as a single piece of knitting. This allows for a simple, cost-effective and quick manufacture of the entire upper. The subsequent work step of joining for joining the first portions to each other and to the rest of the upper is not necessary. Furthermore, the waste generated is minimized.

In an alternative embodiment of the invention, the knit of the upper is made by a circular weft knitting machine. A circular weft knitting machine enables simple manufacture of the first part, should follow as much as possible the circular shape of the toes and is therefore well suited for manufacture on a circular knitting machine, since it is formed as tubular as possible.

In an alternative, preferred embodiment of the invention, the knitted fabric comprises at least one warp knitted region. Warp knit fabrics can be manufactured economically and efficiently, first quickly.

Preferably, the at least one warp knitted area is three dimensional warp knitted. Three-dimensional (3D) warp knitting allows warp knit fabrics to be provided with shapes that adjust directly to the foot during warp knitting. No separate cutting is required. The shape of the toes, instep, or heel may be warp knitted directly into a braid.

Preferably, the fabric of the upper is weft knitted on a flat weft knitting machine. Weft-knitted fabrics can be produced simply, economically and efficiently on flat weft knitting machines.

Preferably, the at least one first portion comprises a first region comprising an elastic yarn. Further preferably, the first portion comprises a second region, wherein the first region comprises yarns having a greater elasticity than the second region. In this way, at least one first portion is produced with elastic zones, so that it can optimally fit the toes. Elastic regions, for example elastic regions arranged in a direction transverse to the toes, allow the first portion associated with the toes to be adapted to the length of the toes.

Preferably, the first portions at least partially overlap. In this way, an even more comfortable feeling is created between the toes, since they are less spread out, which is more similar to barefoot walking.

Preferably, the at least one first portion comprises a second yarn in addition to the first yarn of the braid. Preferably, the second yarn is a stability yarn. This stabilizes the toes longitudinally and laterally and the toes remain in position relative to the sole. Sliding of the toes beyond the sole is reduced or prevented altogether.

Preferably, the second yarn is disposed at the tip of the toe and further preferably extends along the side of the toe onto the toenail. In this manner, the second yarn acts like a toe cap, which reduces or completely prevents the sliding of the toes and protects the toes.

Preferably, the second yarn is a melt yarn or a rubber yarn. The melted yarn or rubber yarn may be made into a braid during the manufacturing process, for example, as an additional yarn. The melted yarn may then be heated to melt, which when cooled forms a strengthened region. The rubber yarns ensure increased adhesion to the floor surface and increased wear resistance.

Additionally or alternatively, the second yarn may achieve the necessary stability to reduce or prevent the toes from sliding relative to the sole by printing or coating the first portion. The printing or coating may be, for example, by Polyurethane (PU), polymer or rubber.

The upper preferably further includes an elastic yarn. The incorporation of elastic yarns into the upper allows for simple sizing to the size of each foot and a better fit overall. In addition, sliding into the upper is easier and may be done without laces. However, laces, hooks, and loops or straps may additionally be secured to the upper.

According to a further aspect of the invention, a shoe, in particular a sports shoe, comprises an upper as described above and a sole having a second portion, corresponding to and joined to the first portion of the upper. In this regard, the second portion corresponds in number to the first portion. However, this is not mandatory. Thus, there may be more first portions than second portions, and vice versa. Additionally or alternatively, the second portion may correspond in size to the first portion, the sizes not being identical. Thus, for example, a first portion may be smaller than a corresponding second portion, and vice versa. Due to the fact that the first and second portions correspond to each other, the obtained shoe allows the toes to move freely and a natural walking feel to the maximum possible, avoiding thick annoying seams between the toes.

Preferably, at least a section of the sole and the upper form a single piece of knitting. This allows for easy, cost effective and fast manufacturing. At the same time, material waste is reduced to a minimum.

Preferably, the shoe comprises a midsole. Preferably, the midsole is provided in a single piece of braid. The single-piece braid may then form an outsole in the sole region, while the midsole may have, for example, a cushioning function.

The midsole is preferably removably disposed. In this way, the shoe may be adjusted, for example, according to the various areas of application, or alternatively or additionally according to the weight of the wearer. In addition, the shoe should be easily configured, with the midsole and braid configured separately.

Preferably, the sole is weft or warp knitted. Weft or warp knitted soles can be manufactured cost effectively with minimal material waste on the respective machines. By using the techniques described below, weft-knitted or warp-knitted soles can be precisely conformed to the requirements and to the field of application of the shoe.

In a preferred embodiment, the sole is reinforced by a coating. This additionally or alternatively provides stability to the sole in a simple manner. Depending on the coating, the sole may alternatively or additionally be made waterproof, wear resistant and strong.

Preferably, the coating is a coated polymer. This may be, for example, polyurethane. The polymer may be applied by heat and pressure. Alternatively, the polymer may be sprayed. Optionally, the coating is a rubber coating. This has a high static friction, i.e. a good "grip". Furthermore, the rubber coating is very abrasion resistant.

In a preferred embodiment, the sole is additionally or alternatively reinforced by additional yarns, i.e. in addition to the yarns of the braid. Preferably, it is a rubber yarn. Alternatively or additionally, a monofilament. The yarns may be simply weft or warp knitted into a knit of the sole, for example during weft or warp knitting.

In a further preferred embodiment, the sole comprises a spacer weft knit or a spacer warp knit. In this way, additional cushioning can be achieved or the sole of the shoe can resist cold. The spacer weft or warp knit fabric is preferably provided with a filler. May be foamed particles, foam, or other suitable filler material.

It is further preferred that the sole is made of a spacer weft knit or a spacer warp knit. In this way, a sole with cushioning can be obtained in one working step.

Preferably, the sole is reinforced according to the wearer of the shoe. Further preferably, the wearer may additionally or alternatively reinforce the sole depending on the use of the shoe, depending on the posture of the wearer running. For example, for runners whose heel first contacts the ground, the heel section of the sole may be specially reinforced to allow for additional shock absorption.

Preferably, the thickness of the sole is determined according to the weight of the wearer of the shoe. Preferably, the thickness of the sole may additionally or alternatively be determined depending on the use of the shoe by the wearer. This allows the characteristics of the sole to be optimally adjusted according to the needs of the wearer of the shoe.

A further aspect of the invention relates to a method for manufacturing an upper as described above, having the steps of providing a plurality of first portions for receiving at least one toe of a foot, whereby the upper is formed to allow the first portions to move substantially independently of each other and the first portions are formed as a knit.

4. Description of the drawings

Aspects of the present invention will be described in detail with reference to the following drawings. These figures show:

FIG. 1 a: schematic representation of a textile structure that can be used in the present invention;

FIG. 1 b: a schematic representation of a weft knit fabric with stuffer yarns that can be used in the present invention;

FIG. 2: three different weaves of warp knit fabric that can be used in the present invention;

FIG. 3: courses and wales that can be used in the weft knitted fabric of the invention;

FIG. 4: stitches formed by latch needles in the weft knitting stage;

FIG. 5 a: an embodiment of an upper that can be used with the present invention has two textile areas joined together;

FIG. 5 b: an alternative embodiment of an upper that can be used with the present invention has two textile areas joined together;

FIG. 6: three cross-sections of an embodiment of an upper that can be used in the invention, connected to the sole by means of adhesive tapes (figures 6a, 6b and 6 c);

FIG. 7: cross-sectional views of fibers of yarns that can be used in the braid of the present invention;

FIG. 8: front and back views of a fabric that can be used in the present invention;

FIG. 9: a schematic top view of an upper according to the present invention;

FIG. 10: a schematic partial view of an upper according to the present invention;

FIG. 11: a schematic side view of a shoe according to the invention comprising an upper;

FIG. 12: a partial schematic view of a shoe including an upper according to the present invention;

FIG. 13: a side view of an embodiment of a shoe including an upper according to the present invention;

FIG. 14: a bottom side view of a shoe including an upper according to the present invention.

5. Detailed description of the preferred embodiments

In the following, embodiments and variants of the invention are described in more detail by means of an upper for a shoe, in particular a sports shoe.

The use of braids is applicable to products such as: such as an upper or a sole, such as an insole, a stitched sole, a midsole and/or an outsole, is provided with areas having different properties providing different functions with low production work. These properties include, for example, flexibility, stretchability (expressed, for example, as young's modulus), air and water permeability, thermal conductivity, heat capacity, hygroscopicity, static friction, abrasion resistance, hardness, and thickness.

Various techniques are employed to achieve this property or functionality, as will be explained below. This includes appropriate techniques in the manufacture of the braid, such as braiding techniques, selection of fibers and yarns, coating of the fibers, yarns or braid with a polymer or other material, use of monofilaments, application of monofilament and polymer combination coatings, melting/fusing of yarns and multi-layer braided materials. In general, the yarns used to make the braid may be configured (i.e., covered accordingly). Additionally or alternatively, the finished braid may be configured accordingly.

Another aspect of the functionality that can be provided relates to the specific use of the fabric of a specific area of the product, for example the upper or the sole, and the joining of the different components by means of suitable joining techniques. The described aspects and techniques, as well as other aspects and techniques, are described below.

The described techniques may be used alone or in any combination.

Braided fabric

The knitted fabric used in the present invention is classified into a weft knitted fabric and a single thread warp knitted fabric on the one hand, and a multi-thread warp knitted fabric on the other hand. A distinguishing feature of the fabric is that it is formed of yarns or loops that are looped around. These loops, also known as stitches, can be made from one or more yarns or threads.

Yarn or thread is the term for one or more fibrous structures, being elongated with respect to their diameter. The fibers are elastic structures that are thin relative to their length. Very long fibers are known as filaments, the length of which is hardly limited for their use. Monofilament yarns consist of one single filament, i.e. of one single fiber.

In weft and single thread warp knits, the formation of stitches requires at least one thread or yarn which extends in the longitudinal direction of the product, i.e. substantially at right angles to the direction of manufacture of the product during manufacture. In a multi-warp knit fabric, the formation of a stitch requires at least one warp sheet, i.e. a plurality of so-called warp yarns. These stitches forming threads extend in the longitudinal direction, i.e. substantially in the direction of manufacture during manufacture of the product.

Fig. 1a shows the basic differences between the woven fabric 10, the weft fabrics 11 and 12 and the warp knit fabric 13. The woven fabric 10 has at least two thread pieces, generally disposed at right angles to each other. In this aspect, the lines are located above or below each other without forming stitches. The weft-knitted fabrics 11 and 12 are formed by knitting a thread from left to right through stitches that are looped. View 11 shows a front view (also called front loop side) and a back view 12 (also called back loop side) of the weft knitted fabric. The front and back loop product sides are routed differently at the leg portions 14. The back loop fabric side 12 is covered with a leg portion 14 opposite the front loop fabric side.

Figure 1b shows an alternative way of a weft knitted fabric with so-called stuffer yarns 15 that can be used in the present invention. The stuffer yarns 15 are lengths of thread placed between two wales in the longitudinal direction, held by the transverse threads of other textile elements. The combination of the filling yarn 15 with other textile elements influences the properties of the weft-knitted fabric and achieves a variety of pattern effects. The stretchability of the weft knitted fabric in the wale direction may be reduced, for example, by the packing yarn 15.

As shown in fig. 1a, the multi-filament warp knit fabric 13 is produced by warp knitting with multi-filaments from top to bottom. Thus, the stitch loops of the thread are interlocked with the stitches of the adjacent thread. Depending on the pattern, the stitches of adjacent threads are looped to produce one of seven basic connections (also known as "weaving" in multi-thread warp knitting), such as cylindrical, twill, 2x1 plain, satin, velour, atlas (atlas) and twill.

By way of example, woven twill weave 21, 2x1 plain weave 22 and weave 23 are shown in fig. 2. The result of the different loops being buckled depends on how the stitches of the thread 24, as exemplified by the emphasis, are buckled in the stitches of the adjacent thread. In the twill weave 21, the threads forming the stitches are zigzag passed through the braid in the longitudinal direction and bound/tied (binding) between two adjacent wales. The 2x1 plain weave 22 is tied up/bound in a manner similar to the twill weave 21, but with each warp yarn forming a stitch skipping over a wale. In the weaving pattern 23, each warp yarn forming a stitch runs to a turning point to form a trapezoid and then changes direction.

Stitches with binding sites (binding sites) attached on top of each other are called wales. Fig. 3 shows wales as an example of the weft knitted fabric 31. The term wale is similarly used for warp knit fabrics. Thus, wales run vertically through the mesh fabric. The rows of stitches are arranged adjacent to each other, and in figure 3 a weft knitted fabric 32 is shown as an example, called a course. The term course is similarly used for warp knit fabrics. Accordingly, the courses pass through the mesh fabric in the lateral direction.

Three basic weft constructions are known in weft-knitted fabrics, which can be identified by the running of stitches along a wale. For plain, single plain jersey (jersey), only the back loops are identifiable along the wales on one side of the fabric and only the back loops are identifiable along the other side of the product. This structure is produced on one row of needles of the knitting machine, i.e. the arrangement of adjacent knitting needles, also referred to as single plain single jersey knit fabric. For rib fabrics, the front and back loops alternate in the course, i.e., only the front or only the back loops are visible along the wales, depending on the side of the product that is considered to be a wale. This structure is produced on two rows of needles, which are offset in pairs. For reversible knitted fabrics, the front and back loops are alternately present in a wale. Both sides of the product look the same. This structure is made by stitch conversion with a latch needle as shown in fig. 4. Stitch switching can be avoided if a double latch needle is used, which contains a hook and a tongue (latch) at each end.

An important advantage of woven fabrics over textiles is their versatile structure, and the surface that can be created with the structure. Substantially the same manufacturing techniques can be used to make very heavy and/or stiff braids, and very soft, transparent and/or stretchable braids. Parameters that can be substantially influenced by the properties of the material are the weft or warp pattern, the yarns used, the size of the needles or the distance of the needles, and the tensile tension under the influence of the yarns on the needles.

An advantage of weft knitting is that some yarns may be weft-knitted at freely chosen positions. In this way, the selected area may provide certain performance. For example, an upper for a soccer shoe may be provided with areas made of rubber yarns to achieve higher stiction, thus enabling the player to better control the ball. For weft knitting certain yarns at selected places, no additional elements need to be added.

In a factory environment, the braid is manufactured by machinery. These machines typically include a plurality of needles. In weft knitting, latch needles 41 are usually used, each comprising a movable tongue 42, e.g.FIG. 4As shown. The tongue 42 closes the hook 43 of the needle 41 so that the thread 44 can be pulled through the stitch 45 without the needle 41 becoming caught by the stitch 45. In weft knitting, the latch needles are usually individually movable, so that each individual needle can be controlled individually in order to catch the thread forming the stitch.

A difference is made between flat knitting and circular knitting machines. In flat knitting machines, a thread feeder feeds thread back and forth along a row of needles to the needles. In circular knitting machines, the needles are arranged in a circular manner and the thread is fed in a circular motion along one or more circular needle rows.

It is also possible for the knitting machine to comprise two parallel rows of needles instead of a single row of needles. The needles of the two rows of needles may for example be opposite each other at right angles when viewed from the side. This enables a finer structure or weave to be made. The use of two rows of needles allows the manufacture of single layer weft knitted fabrics or double layer weft knitted fabrics. When the stitches produced on the first row of needles are intertwined with the stitches produced on the second row of needles, a single layer weft knit fabric is produced. Thus, a double layer weft knitted fabric is produced when the stitches produced on the first row of needles are not selectively entangled with or are only entangled with the stitches produced on the second row of needles and/or are only entangled with the ends of the weft knitted fabric. If the stitches produced on the first row of needles are selectively loosely intertwined with the stitches produced on the second row of needles by means of additional yarns, this is called a spacer weft. Additional yarns, such as monofilaments, are thus guided back and forth between the two layers, thus creating a space between the two layers. The two layers may be joined together, for example, by a so-called process.

In general, the following weft-knitted fabrics can therefore be produced on a weft knitting machine: if only one row of needles is required, a single layer weft knit fabric is produced. When two rows of needles are used, the stitches of the two rows of needles may be consistently attached to each other so that the resulting braid comprises a single layer. When two rows of needles are used, two layers are created if the stitches of the two rows of needles are not joined or are joined only at the edges. If the stitches of the two rows of needles are alternatively connected by additional threads, a spacer weft fabric is produced. The additional thread, also called spacer thread, can be fed by a separate yarn feeder.

Single-thread warp knits are made by co-moving needles. Optionally, the needles are fixed and the fabric is moved. In contrast to weft knitting, it is not possible for the needles to move individually. Similar to weft knitting, there are flat single thread warp knitting and round warp knitting machines.

In multi-thread warp knitting, one or more coiled wires are used, i.e. the wires are coiled adjacent to each other. In stitch formation, individual warp threads are located around the needles and the needles move together.

The techniques described herein and other aspects of braid manufacture can be found in "clothing knowledge", 6 th edition, author h. eberle et al (published under the english heading "clothing technology"), "textiles and clothing vocabulary", 6 th edition, author Alfons Hofer and "textile dictionary", 11 th edition, author Walter Holthaus.

Three-dimensional braided fabric

Three-dimensional (3D) knits can also be produced in weft and warp knitting machines, in particular in flat knitting machines. Although it is weft or warp knitted in a single pass, it still belongs to a woven fabric comprising a spatial structure. Three-dimensional weft or warp knitting techniques allow the production of a spatial knit in a single pass without the need for stitching, cutting or one-piece manufacturing.

A three-dimensional knit can be produced, for example, by forming partial courses to vary the number of stitches in the wale direction. The corresponding mechanical process is called "needle park". This may be combined with a change in the structure in the course direction and/or a change in the number of stitches, as desired. When forming partial courses, the formation of stitches occurs only temporarily along the partial width of the weft or warp knit fabric. The needle does not participate in the formation of the stitch and holds the half stitch ("needle stop") until the weft knitting again occurs in this position. This enables, for example, a projection.

For example, by three-dimensional weft or warp knitting, the upper may ultimately be adjusted to a shoemaker's last or foot, and a sole may be formed. The tongue may be weft knitted into a suitable shape, for example. The contours, structures, handles, bends, slots, openings, fasteners, loops, and pockets can all be integrated with the braid in a single process.

A three-dimensional braid can be used in the present invention in an advantageous manner.

Functional braided fabric

Knits, in particular weft knits, can have a range of functional properties and can be used in an advantageous manner in the present invention.

The knitted fabric can be produced by weft knitting technology, which has different functional areas while maintaining its profile. Depending on the stitch pattern, the yarn, the size of the needles, the gauge or the tensile tension, the yarn is positioned on the respective selected needle, so that the structure of the fabric can be adjusted to achieve functional requirements in certain areas.

For example, a structure with large stitches or openings may be included in the area of the braid where ventilation is desired. Instead, fine mesh stitch patterns, stiffer yarns or even multi-layer weft constructions may be used in areas where support and stability are desired, as will be described below. In the same way, the thickness of the braid is variable.

Having more than one layer of braid provides a large number of possible constructions for the braid, which offer many advantages. A knit having more than one layer (e.g., two layers) can be weft or warp knitted in a single stage on a weft knitting machine having multiple rows of needles (e.g., two rows) or a warp knitting machine, as described in the previous paragraph "knit". Alternatively, multiple layers (e.g., two) may also be weft or warp knitted at different stages, then placed over each other, and attached to each other, e.g., by sewing, welding, or bonding.

The multiple layers radically improve the stiffness and stability of the braid. In this respect, the hardness obtained depends on to what extent the layers are connected to each other by what technique. The same yarn or different yarns are used for the various layers. For example, weft knitted fabrics for single layers are weft knitted from multifilament yarns and single layers are weft knitted from monofilaments with the stitches being intertwined. In particular the stretchability of the weft layer is reduced due to the combination of different yarns. An advantageous alternative to this structure is to provide a layer made of monofilaments between two layers made of multifilament yarns to reduce the stretchability and increase the stiffness of the braid. This allows a comfortable surface to be made of multifilament yarns on each side of the braid.

As explained in the "knit" section, another alternative to a two layer knit is known as a spacer weft knit or a spacer warp knit. In this respect, the spacer yarns are weft or warp knitted, more or less loosely between two layers of weft or warp knitting, interconnecting the two layers and simultaneously acting as a filler. The spacer yarns may comprise the same material as the layer itself, e.g., polyester or other material. The spacer yarns may also be monofilaments, providing a spacer weft or spacer warp knit fabric with stability.

Such spacer weft knit or spacer warp knit, respectively, refers to a three-dimensional weft knit, but must be distinguished from the formed 3D weft knit or formed 3D warp knit described in the section "three-dimensional knit" above for any additional cushioning or protection desired, for example, in certain areas of the upper or tongue of the upper or sole. The three-dimensional structure may be used to create a space between adjacent textile layers or between a textile layer and the foot, thus ensuring ventilation. Further, the layers of the spacer weft knit fabric or the spacer warp knit fabric may include different yarns depending on the positioning of the spacer weft knit fabric on the foot.

The thickness of the spacer weft or warp knit fabric may be set in different regions depending on the function or wearer. For example, different degrees of cushioning may be achieved by regions of different thicknesses. For example, the thin region increases flexibility, thus fulfilling the function of a joint or muscle line.

Furthermore, the layers of the spacing weft knit fabric may include different yarns depending on the location of the spacing weft knit fabric for the foot. In this way, the fabric can be provided with two different colors, for example on the front and back. An upper made with this braid includes different colors on the lateral and medial sides.

Another alternative embodiment of the multilayer structure is a bag or a channel, wherein two textile layers or braids weft-knitted or warp-knitted on two rows of needles are connected to each other only in certain areas, thus creating hollow spaces. Alternatively, the pieces of weft or warp knitted fabric are connected to each other in two separate processes, for example by stitching, gluing, welding or bonding, thus creating voids. Cushioning material may be introduced, for example in the tongue, vamp, heel, sole or other areas, through openings such as foam, eTPU (expanded thermoplastic polyurethane), ePP (expanded polypropylene), expanded EVA (ethylene vinyl acetate) or foam particles, air or gel cushions. Alternatively or additionally, the bag may be filled with a filler wire or spacer braid. In addition, the strands may be pulled through the channels, for example, as a reinforcement to prevent tensile loading in certain areas of the upper. Furthermore, the shoelace may be guided through such a passage. Furthermore, loose threads may be provided in the channel or pocket for the cushion, for example in the area of the ankle. However, it is also possible to use stiffer stiffening elements, such as caps, fins or bone insertion channels or pockets. These can be made of plastic, such as polyethylene, TPU, polyethylene or polypropylene.

Further, the functional design for the braid may also be some variation of the basic textile use. In weft knitting, for example, in certain areas the protuberances, ribs or corrugations may be weft-knitted to achieve reinforcement at these locations. For example, the corrugations may be formed by a pile of stitches on the woven fabric layer. This means that there are more weft or warp stitches on one layer than on the other. Alternatively, a stitch is a weft knitted fabric that is different on one layer than another layer, e.g., a weft knitted fabric that is tighter, wider, or uses different yarns. Thickening occurs in both cases.

Such as ribs, corrugations or similar patterns, may be used on the bottom of a weft-knitted outsole of a shoe to provide a sole pattern and to provide the shoe with better non-slip properties. In order to obtain a fairly thick weft fabric, for example, weft techniques "tuck" or "half-shirts" can be used, which are described in "clothing knowledge", 6 th edition, author h.

The corrugations may be weft or warp knitted, so that there is a connection between the two layers of the two layer weave, or there is no connection between the two layers. The corrugations may be weft knitted as right and left corrugations with or without two sides connected. The structure in the braid is achieved by the uneven ratio of stitches on the front or back of the braid.

Within the framework of the invention, another possibility of a functionally designed braid is to provide openings in the braid already during weft or warp knitting. One embodiment of the present disclosure, which may be combined with other embodiments, refers to an insole comprising a knit. However, this embodiment may also be applied to a stitched sole. Embodiments may be equally applied to outsoles. An insole, stitched sole or outsole is typically provided on the insole. The midsole has cushioning properties. The midsole may for example comprise or consist of a foam material. Other suitable materials are eTPU (expanded thermoplastic polyurethane), ePP (expanded polypropylene), expanded EVA (ethylene vinyl acetate) or foam particles.

The knit of the insole, the stitched sole or the outsole comprises at least one opening, being weft-knitted or warp-knitted during weft-knitting or warp-knitting, respectively, of the knit. The at least one opening enables a foot of a wearer of the footwear to directly contact the midsole. This improves the overall cushioning properties of the shoe, so that the thickness of the midsole can be reduced.

Preferably, the at least one opening is provided in the calcaneus bone region. The arrangement in this position has a particularly positive effect on the damping performance. Another position of the at least one opening is possible.

Yet another possibility of functionally designing the textile within the framework of the invention is to integrate the laces in the textile of the upper. In this embodiment, the upper includes a braid, and when the braid of the upper is weft or warp knitted, the lace is integrated with the braid either warp or weft. In this aspect, the first end of the lace is connected to the braid while the second end is a free end.

Preferably, the first end is joined to the braid of the upper at a transition area of the tongue to a forefoot area of the upper. It is further preferred that the first end of the first strap is attached to the braid of the upper on a medial side of the tongue and the first end of the second strap is attached to the braid of the upper on a lateral side of the tongue. The respective second ends of the two shoelaces are pulled through the lace passages for tying the shoe.

The possibility of speeding up the overall weft or warp knitting of the shoelace is to have all the yarns for the weft or warp knit ends in the transition area from the tongue to the forefoot area of the vamp. The yarn preferably ends at a medial side of the upper on the medial side of the tongue and forms a lace that is connected to the medial side of the tongue. The yarns preferably end at the sides of the upper, which are the sides of the tongue, and form laces that are attached to the sides of the tongue. Preferably, the yarns are cut at a length sufficient for forming the shoelace. The yarn may be twisted or twisted, for example. The respective second ends of the shoelaces are preferably provided with shoelace holders. Optionally, the second end is melted or provided with a coating.

The knitted fabric is particularly stretchable in the stitch direction (longitudinal direction) due to its configuration. This telescoping can be reduced, for example, by subsequent polymer coating of the braid. However, this stretch may also be reduced during the braid manufacturing process. One possibility is to reduce the mesh openings, i.e. to use smaller needles. Smaller stitches generally result in less flexibility of the braid. A fine mesh knit may be used, for example, for an upper (also referred to as a shoe upper). Furthermore, the stretching of the braid may be reduced by weft reinforcement, e.g. a three-dimensional structure. Such a configuration can be located on the medial or lateral side of the upper. In addition, non-stretch yarns, for example, made of nylon, may be laid within the channels along the braid to limit stretching of the non-stretch yarn length.

Colored regions having multiple colors may be created using different lines and/or additional layers. In the transition zone, smaller mesh openings (smaller needle size) are used to allow the paint to flow smoothly through.

Further effects can be achieved by weft insertion (inlay) or jacquard weaving. The inlay is an area where only certain yarns are provided, for example certain colours. The adjacent zones comprise different yarns, for example different colours, and are then connected to each other by a so-called process.

In jacquard weaving, for example, two rows of needles and two different yarns are used in all regions. However, in some areas only one yarn is present on the visible side of the product and the corresponding other yarn is not visible on the other side of the product.

The product of the manufacture of the knitted fabric can be manufactured in one piece on a weft knitting machine or a warp knitting machine. The functional areas can then be produced during weft or warp knitting by means of the corresponding techniques described above.

Alternatively, the product may be combined with portions of the braid, or may contain portions that are not made from the braid. In this respect, each braid segment can be designed with different functions, for example with regard to thickness, moisture insulation, moisture transport, etc.

The upper and/or the sole, for example, may be integrally manufactured, typically from a knit, or may be put together from different knit parts. The whole upper or part of the upper may for example be separated, for example by perforating from a larger piece of fabric. The larger piece of fabric may for example be a circular weft or warp knit or a flat weft or warp knit.

For example, the tongue may be formed as a continuous piece and subsequently joined to the upper, or may be formed as a single piece with the upper. For functional designs, the medial ridge may, for example, improve the resiliency of the tongue and ensure that a distance is created between the tongue and the foot that provides additional ventilation. The lace may be guided through one or more weft channels of the tongue. The tongue may be reinforced with a polymer to achieve stability of the tongue and to prevent, for example, tangling of a very thin tongue. In addition, the tongue also conforms to the shape of the shoemaker's last or foot.

On the upper, for example, only the front portion may be made of a knitted fabric. The remainder of the upper may include different fabrics and/or materials, such as woven fabrics. The anterior portion may, for example, be located only in the area of the toes, extending anteriorly to the toe joints or to the midfoot region. Alternatively, the rear portion of the upper may be made of a knit in the heel region, e.g., additionally may be reinforced by a polymer coating. Generally, a desired area of the upper or heel may be formed as a braid.

The braid may then be coated with, for example, Polyurethane (PU) printing, Thermoplastic Polyurethane (TPU) ribbon, textile reinforcement, leather, and the like. Thus, an upper comprising a knitted fabric in whole or in part can be provided with a plastic heel or toe cap as a reinforcement or marker and apertures for lacing a lace by, for example, sewing, gluing or welding as described below.

Such as sewing, gluing or welding, constitute suitable joining techniques for joining the single fabric and other fabrics or other knitted fabrics. Bonding is another possible method of joining two pieces of fabric. In which two edges of the fabric are connected to each other according to stitches (usually one stitch).

One possible method for weldable fabrics, in particular made of plastic yarns or threads, is ultrasonic welding. Mechanical vibrations in the ultrasonic frequency range are thus transferred to a tool called sonotrode. This vibration is transferred to the fabric which is connected under pressure by the sonotrode. Because of the friction generated, the fabric is heated, softened and finally connected to an ultrasonic generator in the weaving zone. Ultrasonic welding allows for the quick and economical joining of fabrics, particularly with plastic yarns or threads. For example, the joining of the color bands by gluing or by welding additionally reinforces the weld, which is optically more attractive. Furthermore, the comfort of the wearer is increased by avoiding skin sensitivity (particularly at the transition of the tongue).

The attachment to different fabric regions may occur at completely different locations. For exampleFIGS. 5a and 5bThe seams that connect the various fabric regions of the upper may be located at various locations, as shown.FIG. 5a Upper 51 is shown to include two fabric regions 52 and 53. They are sewn to each other. A seam 54 connected to the two fabric regions 52 and 53 extends diagonally from the instep area of the upper to the sole area at the transition from the midfoot to the heel. In fig. 5b, the slot is also diagonally through, but diagonally in the more anterior direction of the toe. Other arrangements of seams and attachment locations are generally conceivable. The seams shown in fig. 5a and 5b may be seams, glue seams, welded seams or bonded seams. Two seams 54 and 55 may be installed on one side of upper 51 or both sides of the upper.

The use of adhesive strips constitutes a further possibility for attaching the fabric regions. It may also be used in addition to existing connections, for example over a seam or a welded seam. The adhesive tape may further perform functions other than the connecting function, such as dust-proof or water-proof. The adhesive tape may include a characteristic that varies according to its length.

An embodiment is shown in figures 6a, 6b and 6c, where the upper 51 is attached to the sole 61 of the shoe by means of adhesive strips. Each of fig. 6a, 6b and 6c shows a cross-section of the shoe and the resulting deformation of the shoe at different locations on the foot. For example, tensile forces are applied on the right side of the shoe in FIG. 6a, while compression is applied on the left side.

The sole 61 of the shoe may be an outsole or a midsole. The upper 51 and the sole 61 are connected to each other by a surrounding adhesive strip 62. The adhesive strip 62 may be of varying elasticity along its length. For example, the adhesive strips 62 may be particularly rigid and not very elastic in the heel area of the shoe to provide the necessary stability to the shoe in the heel area. This may be accomplished by a variation in, for example, the width and/or thickness of the adhesive tape 62. The adhesive tape 62 may generally be configured to be able to receive a certain force at certain areas along the tape. In this way, the adhesive strip 62 not only joins the upper to the sole, but also simultaneously performs a structural reinforcing function.

Fiber

The yarns or threads used in the knit of the present invention each comprise fibers. As mentioned above, elastic structures that are very thin relative to their length are referred to as fibers. Very long fibers, of which the length is hardly limited with respect to their use, are called filaments. The fibers are spun into or wound around a feed or yarn. However, the fibers may also be very long and spun into the yarn. The fibers may be made of natural or man-made materials. Natural fibers are environmentally friendly because they are degradable. Natural fibers include, for example, cotton, wool, alpaca, hemp, coconut fibers, or silk. Wherein the synthetic fibres are polymer-based fibres, e.g. respectively Nylon (Nylon)^TM) Polyester, spandex or spandex, or polyamide fiber (Kevlar)^TM) It can be produced as a classical fiber or as a high-performance or technical fiber.

It is conceivable that the shoe is assembled from a plurality of parts, with weft or warp knitted parts comprising natural yarns made of natural fibres and removable parts, for example an insole, comprising plastic. In this way, the two parts can be configured separately. In this case, the weft knitted section may perform a degradation of waste, while the insole may perform e.g. recycling of material.

As shown in fig. 7, the mechanical and physical properties of the fibers and yarns made therefrom are also determined by the cross-section of the fibers. Examples of different cross-sections, their properties and materials with such cross-sections will be described below.

Fibers having a circular cross-section 710 may be solid or hollow. Solid fibers are the most common type, which are flexible and soft to the touch. A hollow round fiber has the same weight/length as a solid fiber, has a larger cross-section, and is more resistant to bending. An example of a fiber having a circular cross-section is Nylon (Nylon)^TM) Polyester fibers and lyocell fibers.

The fibers having the bone-shaped cross section 730 have the property of absorbing moisture and releasing sweat. Examples of materials having such fibers are acrylic and Spandex fibers (Spandex). The concave areas in the middle of the fibers support the transfer of moisture in the longitudinal direction, which is quickly carried away from a specific place and dispersed.

The following cross-sections are further illustrated in fig. 7:

a polygonal cross section 711 with a pattern; for example: flax;

an elliptical to circular cross-section 712 with overlapping portions; for example: wool;

a flat, oval cross-section 713 with expansion and convolution; for example: cotton;

a circular, serrated cross-section 714 with local striations; for example: artificial silk;

-lima bean cross section 720; a smooth surface;

-a serratia lima bean cross section 721; for example: avril^TMArtificial silk;

a triangular cross-section 722 with rounded edges; for example: silk;

trilobal star cross-section 723; triangular-like fibers having a glossy appearance;

a bar cross section 724 with local striations; the appearance is bright; for example: acetate fibers;

a flat and wide cross section 731; for example: another designed acetate fiber;

a star or hexagonal cross-section 732;

a cross section 733 having a hollow collapsed tubular shape; and

a square cross-section 734 with voids; for example: AnsoiV^TMNylon fibers.

The individual fibers having the relevant characteristics for making the braid of the present invention are described below:

-aramid fibres: good abrasion resistance and good organic solubility; is non-conductive; can resist temperature up to 500 ℃.

Para-aramid fiber: known by the trade name Kevlar^TM、Techova^TMAnd Twaron^TM(ii) a Is excellent inStrength-weight characteristics; high young's modulus and high tensile strength (higher than meta-aramid fiber); low extensibility and low elongation at break (about 3.5%); it is difficult to dye.

-aramid fibres: known trade name Numex^TM、Teijinconex^TM、New Star^TM、X-Fiper^TM。

-polyethylene fibres: the highest impact strength of any known thermoplastic; high resistance to chemical attack, except for oxidizing acids; extremely low hygroscopicity; very low friction coefficient, much lower than nylon^TMAnd acid ester fibers, candelilla; self-lubricating; high wear resistance (15 times that of carbon steel); is nontoxic.

-carbon fibres: very thin fibers, about 0.005-0.010mm in diameter, consisting essentially of carbon atoms; highly stable with respect to size; one yarn is formed of several thousand carbon fibers; high tensile strength; low weight; low thermal expansion; very strong when stretched or bent; thermal and electrical conductivity.

-glass fibers: high surface area to weight ratio; by trapping air, the fiberglass module provides good thermal insulation; thermal conductivity of 0.05W/(m.times.K); the thinnest fibers are strongest because the thinner the fibers are the more flexible; the properties of glass fibers are the same along the fiber and across the cross-section because glass has an amorphous structure; the correlation between the fiber bend diameter and the fiber diameter; thermal, electrical and acoustical insulation; the breaking tensile strength is higher than that of carbon fiber.

Yarn

A variety of different yarns that can be used to make the braid can be used in the present invention. According to what we have defined, a structure of one or more fibres that is long with respect to diameter is called a yarn.

Functional yarns are capable of transporting moisture and thus absorbing perspiration and moisture. They are electrically conductive, self-cleaning, thermally regulating and insulating, flame retardant and ultraviolet absorbing, possibly infrared. They are comfortable to touch. Antimicrobial yarns, such as silver yarns, prevent the formation of odors.

The stainless steel yarn contains fibers made of nylon or polyester fibers mixed with steel. Its characteristics include high wear resistance, high cut resistance, high resistance to thermal wear, high thermal and electrical conductivity, higher tensile strength and high weight.

In fabrics made of woven fabrics, the conductive yarns may be used for integration of electronics. These yarns may for example transmit pulses from a sensor to the device for processing the pulses, or the yarns themselves may have a sensor function and for example measure the current on the skin or a physiological magnetic field. An example of the use of a fabric-based electrode can be found in european patent application EP 1916323.

The melted yarn may be a mixture of thermoplastic and non-thermoplastic yarns. There are generally three types of melted yarns: a thermoplastic yarn surrounded by a non-thermoplastic yarn; a non-thermoplastic yarn surrounded by a thermoplastic yarn; and a yarn of a purely molten thermoplastic material. After heating to the melt temperature, the thermoplastic yarn is combined with a non-thermoplastic yarn (e.g., polyester or nylon)^TM) Melting, hardening the braid. The melting temperature of the thermoplastic yarn is thus determined and is generally lower than the melting temperature of the non-thermoplastic yarns of the hybrid yarn.

The shrink yarn is a two-element yarn. The outer element is a shrink material that shrinks when a defined temperature is exceeded. The inner element is a non-shrink yarn, such as polyester or nylon. The shrinkage increases the stiffness of the fabric material.

Another type of yarn used in knits are luminous or reflective yarns and so-called "smart" yarns. Examples of smart yarns are yarns that react to moisture, heat or cold and thus changing properties, for example shrinking and thus making the stitches smaller or changing the volume and thus increasing the permeability to air. Yarns made of piezoelectric fibers or covered with piezoelectric substances can convert kinetic energy or change under pressure into electrical energy, so that they can supply energy to, for example, sensors, transmitters or accumulators.

The yarn is further typically reworked, e.g., coated, to maintain certain properties, such as stretch, color, or moisture resistance.

Polymer coatings

Because of its structure, weft or warp knits are more elastic and stretchable than woven fabric materials. For certain applications and requirements, for example, in certain areas of the upper or sole according to the invention, the elasticity and stretchability must therefore be reduced in order to achieve sufficient stability.

For this purpose, the polymer layer may be applied to one or both sides of the braid (weft or warp knitted article), but is typically applied to other textile materials. Such a polymer layer leads to a reinforcement and/or stiffening of the braid. On the upper, the elasticity may be supported and/or stiffened and/or reduced, for example, in the toe area, heel area, along lace apertures, lateral and/or medial surfaces, or in other areas. Furthermore, the elasticity, in particular the stretchability, of the braid is reduced. In addition, the polymer layer protects the braid from abrasion. Further, the braid may be provided with a three-dimensional shape by a method of compressing the molded polymer coating.

In the first step of polymer coating, a polymer material is coated on one side of the braid. However, it may be coated on both sides. The material may be applied by spraying, coating with a doctor blade, laying, printing, sintering, ironing or coating. If the polymeric material is in the form of a film, the film is positioned on the web and attached to the web by, for example, heat and pressure. The application method is most importantly spray coating. May be applied by a tool similar to a hot glue gun. Spraying allows the polymer material to be applied uniformly over the thin layer. Furthermore, spraying is a rapid process. Effect pigments, such as color pigments, may be blended into the polymer coating.

The polymer is applied to at least one layer having a thickness preferably in the range of 0.2-1 mm. One or more layers may be applied, thus enabling the layers to have different thicknesses and/or colors. There may be a continuous transition from the region with the polymer coating to the polymer region with the thick coating between adjacent regions of various thicknesses with polymer coatings. In the same way, different polymer materials can be used for the different regions, as will be described below.

During application, the polymeric material adheres to the contact points or crossing points, respectively, of the yarns of the knit on the one hand and between the spaces of the yarns on the other hand, forming a closed polymeric surface on the knit after the processing steps described below. However, such closed polymer surfaces may also be discontinuous in larger mesh openings or pores of the fabric structure, for example, to facilitate ventilation. This also depends on the thickness of the applied material: the thinner the applied polymer material, the more likely the closed polymer surface is to be interrupted. In addition, the polymer material also penetrates and wets the yarn, thus contributing to its hardening.

After the polymeric material is applied, the braid is compressed at high temperature and high pressure. The polymer material melts at this step and melts with the yarns of the fabric material.

In a further optional step, the braid may be pressed into a three-dimensional shape in a compression molding machine. For example, the heel area or toe area of the upper may be three-dimensionally formed by a shoemaker's last. Alternatively, the fabric may engage the foot directly.

After pressing and shaping, the reaction time until hardening is complete may be one to two days, depending on the polymer material used.

The following polymeric materials may be used: a polyester; a polyester-urethane prepolymer; an acrylic acid salt; acetate fibers; a reactive polyolefin; a copolyester; polyamide fibers; a copolyamide fiber; reactive System (with H)₂O or O₂A reactive polyurethane system); a polyurethane resin; a thermoplastic polyurethane resin; and a polymeric dispersant.

A suitable range of polymer material viscosities is from 50 to 80 Pa.s (pascal seconds) at from 90 to 150 ℃. Particularly preferably, a suitable range at 110-150 ℃ is 15-50 pas.

The hardness of the hardened polymeric material preferably ranges from 40 to 60 shore D. Other ranges of hardness are also contemplated depending on the application.

The polymer coating may be used with reasonable success in any desired support function, stiffening, increased abrasion resistance, elimination of stretchability, increased comfort and/or fit to a given three-dimensional shape. It is contemplated that the upper may be formed, for example, by conforming the upper to the unique shape of the wearer's foot, applying the upper with a polymeric material, and then conforming the shape of the foot at elevated temperatures.

Monofilament for reinforcement

As we have defined, a monofilament is a yarn consisting of a single filament, i.e. a single fiber. Thus, monofilaments have a much lower elongation than yarns made from many fibers. This also reduces the stretchability of the braid, which is made of or includes monofilaments and is used in the present invention. The monofilaments are made in particular of polyamide fibres. However, other materials, such as polyester or thermoplastic materials, are also contemplated.

However, the braid made of monofilaments is rather stiff and less stretchable, and such braid does not have desirable surface characteristics such as smoothness, color, moisture transmission, appearance, and various fabric structures as conventional braids have.

This drawback can be overcome by the following braid.

Figure 8 depicts a weft knitted fabric having a weft layer made of a first yarn (e.g. a multi-fibre yarn) and a weft layer made of a monofilament. The monofilament layer is weft knitted into the first yarn layer. The resulting two layer weave is stronger and less stretchable than a layer made of yarns alone. It is even better if the filaments begin to melt slightly, which fuses with the first yarn.

Fig. 8 particularly depicts a front view 81 and a back view 82 of a two-layer braid 80. Both views show a first weft layer 83 made of a first yarn and a second weft layer 84 made of a monofilament. A first fabric layer 83 made of a first yarn is connected to a second layer 84 by stitches 85. Thus, the greater stiffness and less stretchability of second fabric layer 84 made of monofilaments is transferred to first fabric layer 83 made of first yarns.

The filaments may also melt slightly to join to the first yarn layer and limit more stretch. The monofilaments are fused to the first yarn at the attachment points, securing the first yarn relative to the layer made of monofilaments.

Combination of monofilament and polymer coating

As described in the preceding subsection, weft-knitted fabrics with two layers are additionally reinforced by a polymer coating, as described in the section "polymer coating". The polymer material is applied on a weft layer made of monofilaments. In doing so, the polymeric material is not joined with the monofilament material (e.g., polyamide material) because the monofilament has a very smooth and rounded surface, but substantially penetrates the underlying first layer of the first yarn (e.g., polyester yarn). In a subsequent pressing, the polymer material thus melts with the yarns of the first layer and strengthens the first layer. In so doing, the polymeric material has a lower melting point than the first yarns of the first layer and the monofilaments of the second layer. The temperature selected during pressing is such that only the polymeric material melts and the monofilament or first yarn does not melt.

Melting yarn

In order to strengthen and reduce the stretching, the yarns of the knit used according to the invention may additionally or alternatively be melted yarns, fixed to the knit after pressing. There are generally three types of melted yarns: a thermoplastic yarn surrounded by a non-thermoplastic yarn; a non-thermoplastic yarn surrounded by a thermoplastic yarn; a purely molten yarn of thermoplastic material. To improve the bond between the thermoplastic yarns and the non-thermoplastic yarns, the surface of the non-thermoplastic yarns may be textured.

The pressing preferably takes place in the range from 110 to 150 c, particularly advantageously at 130 c. The thermoplastic yarns are at least partially melted during the process and are melted with the non-thermoplastic yarns. After pressing, the braid is cooled so that the bond is hardened and fixed. The melted yarn may be disposed on the upper and/or the sole.

In one embodiment, the melted yarns are weft knitted into the fabric. In the case of multiple layers, the melt yarn may be weft knitted into one, more than one or all of the layers of the woven fabric.

In a second embodiment, the melt yarn may be disposed between two layers of the braid. In doing so, the melted yarn can simply be disposed between the layers. The arrangement between the layers has the advantage that the mould is not coloured during pressing and forming, since there is no direct contact between the molten yarn and the mould.

Thermoplastic fabric for reinforcement

Another possible way to strengthen the braid used in the present invention (e.g., in the upper and/or sole) is to use a thermoplastic fabric. This is a thermoplastic woven or knitted fabric. The thermoplastic fabric is at least partially melted by heating and hardens as it cools. The thermoplastic fabric may be applied, for example, to a surface of the upper or sole (e.g., including the braid) by applying pressure and heat. When it cools down, the thermoplastic fabric hardens and reinforces the upper or the sole, in particular, for example, in the region where it is arranged.

Thermoplastic fabrics are manufactured for reinforcement, particularly in their shape, thickness and structure. Further, its characteristics may vary in some areas. The stitch construction, knit stitches and/or yarns used may be varied to achieve different properties in different regions.

One embodiment of the thermoplastic fabric is a weft or warp knit fabric made from thermoplastic yarns. Additionally, the thermoplastic fabric may include non-thermoplastic yarns. The thermoplastic fabric may be applied to the upper or sole of the shoe, for example, by pressure and heat.

The weft and/or warp of the woven fabric is thermoplastic, which is another embodiment of a thermoplastic fabric. Different yarns may be used in the weft and warp directions of the thermoplastic woven fabric to achieve different properties, such as stretchability in the weft and warp directions.

A spacer weft or a spacer warp knit made of thermoplastic material is another embodiment of a thermoplastic fabric. In this respect, for example only one layer is thermoplastically, for example for attachment to an upper or a sole. Optionally, both layers are thermoplastic to join the sole to the upper.

Thermoplastic weft or warp knit fabrics can be made using the processing techniques for knits described in the "knits" section.

The thermoplastic fabric can be attached to the surface to be partially reinforced under pressure and elevated temperature such that only some areas or only some areas of the thermoplastic fabric are attached to the surface. The other zones or further zones are not connected, so that breathability and/or moisture are maintained, for example. For example, the function and/or design of the upper or sole may be modified accordingly.

Shoe upper

Fig. 9 shows a schematic top view of a first embodiment of an upper 51 according to the present invention. Upper 51 includes a plurality of first portions 91 that are adapted to receive at least one toe of each foot. When a shoe provided with upper 51 according to the present invention is worn by a wearer, the toes of the wearer are located in first portion 72.

The upper 51 in fig. 9 includes five first portions 91, meaning that there is a separate first portion of the plurality of portions 91 for each toe. However, it is also conceivable to assign two or more toes to one single first part.

For example, the big toe may be assigned to a single first portion while the remaining toes are assigned to a common first portion. Accordingly, upper 51 may include a total of two first portions.

The toes may not be assigned to the first portion. For example, the opening in upper 51 may allow one or more toes to be visible from the lateral side.

The upper 51 is configured such that the first portions 91 can move substantially independently of one another to allow the toes to move freely to some extent, i.e., without restriction as in the case of conventional shoes. The toes make independent contact with the ground through the sole. In this regard, in the event that a portion moves, its adjacent portion can move slightly due to the transmission of friction or force on the upper 51 and/or the sole.

The toes may also move largely independently of one another due to the substantially independent free movement of the first portion 91. This creates a natural walking sensation similar to barefoot walking. The toes can move freely and make separate contact with the ground, and can feel the ground. A single toe gripping movement is also possible.

The first portion 91 in fig. 9 forms a braid, and may be made as explained in the section "braid". In the example of fig. 9, forefoot region 92, including first portion 91, forms a knit. The remaining area 93 of the upper 51 need not be formed of a knit because the seam in this area is less annoying. It is contemplated that region 93 could, for example, form a thicker, elastic woven fabric or form another conventional shoe material.

However, it is also conceivable: only first portion 91 of upper 51 is formed of a braid, while other areas of upper 51 are not formed of a braid. Alternatively, the entire upper 51 may be formed of a braided fabric. For example, forefoot region 92 may be weft knitted while remaining regions 93 are warp knitted, or vice versa.

It is contemplated that upper 51 is formed from a single piece of knit fabric. For example, upper 51 may be continuous weft knitted or continuous warp knitted. In this case, there are no regions 92 and 93 that differ in the purpose of weaving. In this case, however, the weft or warp knit structure of regions 92 and 93 or the yarns used may be different. More open stitch construction may be used for toe ventilation in the forefoot region 92, while tighter weft weaves are used for the sides to increase stability. Reinforcements, such as ribs, channels, pockets, etc. may be weft or warp knitted into regions 92 or 93 to accommodate reinforcements or the like. The color band may be weft knitted.

The first portion 91 may be separately manufactured as a braid and then joined together by bonding. During the joining, the edges of the knitted fabric portions are joined together in a course-oriented manner, i.e. stitch-wise joining, so that no thick seams are created. This can be done, for example, on a linking machine.

The first portion 91 may alternatively be made of a single piece of braid. For example, portion 91 may be weft knitted on a circular knitting machine. However, production on flat knitting machines or weft knitting machines is also possible. On flat weft knitting machines, the upper and lower layers of the knit may be simultaneously weft knitted using a row of needles for each layer as described in the section "knit". The two layers may be connected to one another along the contour of the shoe and thereby form a void for the foot. The two layers may not be fully flat weft knitted but three dimensional so that the final shape corresponds to the foot as described in the section "three dimensional knit".

The first portions 91 are manufactured by joining or one-piece, no seam is created between the first portions 91. This means that the connection of the first portion 91 between the toes is done seamlessly. The knitted fabric may include seams in other areas not disposed between the toes.

The first portions 91 may at least partially overlap, e.g.FIG. 10 shows a schematic view of aAs shown. For example, a first portion of big toe 91a partially overlaps an adjacent first portion 91b, the first portion 91b partially overlaps an adjacent first portion 91c, and so on.

Not all of the first portions 91 overlap each other. The at least partially overlapping first portions 91 may for example be made of the smallest first portions 91e that are weft or warp knitted first. The next larger first portion 91d is then weft or warp knitted so as to at least partially overlap the smaller first portion 91 e. This process is repeated until the maximum first portion 91a is reached. The overlapping first portions 91 may be formed by a single weft knitting on a flat type weft knitting machine or a three-dimensional weft knitting machine.

The at least partial overlap of the first portion 91 creates a pleasant sensation between the toes, as the toes are separated by a lesser amount, such that the "multiblock" sensation between the toes is reduced or eliminated.

First portion 91 may include additional yarns, for example, which may be directly weft or warp knitted into a braid. Alternatively, the additional yarns may be later made into a knit, for example, by sewing or embroidery. The additional yarn may be, for example, a stability yarn, improving toe support on first portion 91 and thus reducing or preventing forward toe slip or slip beyond the sides of the sole. The additional yarn may be a melt yarn, a rubber yarn, a yarn with less stretch, or a thicker yarn. For example, there may be multiple wraps of stabilizing yarn. The molten yarn may, for example, melt when heated and harden when cooled. Thus, a hardened, reinforced region is formed. The rubber yarns have a rubber-like surface and a correspondingly high static friction and thus increase adhesion to the ground surface and increase abrasion resistance.

Additional yarns may be provided at the toe tips and extend along the sides of the toes onto the toenails. In this manner, the additional yarn acts like a toe cap, reducing or completely preventing the sliding of the toes and protecting the toes. The additional yarns do not have to be processed in a sheet-like manner. It can also be processed in a thread-like manner, for example weft knitting.

In fig. 9, a first region 94 of the big toe first portion 91 is shown, comprising an elastic yarn. For this reason, the first portion 91 is particularly elastic in this region. The first portion 91 is thus simply adapted to the shape and size of the toes, in particular the length of the toes. It is contemplated that other first portions of other areas of the upper may be formed from elastic yarns. The elastic yarns may be, for example, direct weft or warp knitted into a knit. Alternatively, the elastic yarns may be subsequently processed into a knit, for example, by sewing or weft knitting.

Shoes with removable sole

Fig. 11 shows a shoe having an upper 51 according to the present invention. In addition to upper 51, shoe 111 also includes sole 61. The sole may be made of leather, rubber, or a synthetic material, such as Ethylene Vinyl Acetate (EVA). The sole 61 may be weft or warp knitted, i.e. forming a braid. Upper 51 is secured to sole 61, for example, by adhesive, welding, or stitching. The sole 61 includes two portions 112 corresponding with and connected to a first portion of the upper 91.

The top view of fig. 12 shows each first portion 91 of the upper corresponding to one of each second sole portion 112. It is contemplated that the plurality of first portions of the upper correspond to a single second portion of the sole. For example, the first portion for the big toe may correspond to the second portion, the remaining first portion for the other toes corresponding only to a further second portion of the sole. The shoe has an upper with five first portions and a sole with two second portions.

In the case of shoe 111 shown in fig. 10 and 11, the segments of sole 61 may form a single-piece knit with upper 51. Alternatively, the entire sole 61 and the entire upper 61 may collectively form a single piece of braid. Such a shoe 111 may be manufactured on a weft knitting machine or a warp knitting machine. For the manufacture of braids, reference is made to the section "braids", for example.

The sole 61 and the upper 51 may be weft or warp knitted, respectively, and joined together, for example, by bonding, gluing, weft knitting together, welding, and the like.

The sole 61 may be additionally reinforced as described in the section "polymer coating", "monofilaments for reinforcement", "monofilament and polymer coating composition", "melt yarn" and "thermoplastic fabric for reinforcement", i.e. for example by applying a polymer, a rubber coating, a yarn, a spacer warp knit and/or a spacer weft knit.

The reinforcement may be achieved according to the type of running of the wearer of the shoe. For example, for a runner who prefers to contact the ground with the heel first, the heel area of sole 61 may be correspondingly reinforced.

The thickness of sole 61 may be determined based on the weight of the wearer of footwear 111. For wearers having a greater weight than lighter wearers, a thicker sole 61, for example, may be used.

Alternatively or additionally, the thickness of sole 61 may be determined based on the use of footwear 111 by the wearer. For example, a thicker sole 61 that provides additional cushioning may be more desirable for running shoes than for climbing or casual shoes.

Fig. 13 shows a side view of an embodiment of a shoe 111 that includes an upper 51 of the present invention. Shoe 111 shown in fig. 13 includes sole 61 secured to upper 51. Upper 51 has a forefoot region 92 made of a knit fabric. Region 92 includes a first portion 91 for receiving the toes of a wearer of footwear 111. The first portion 91 is made of a braid. Region 93 of the upper may be made of elastane, nylon, spandex, neoprene, or lycra. Regions 92 and 93 are joined by seam 131. In principle, other techniques for joining, such as sewing, gluing, welding, joining, can also be used.

The first portion 91 is partially coated with a foil (foil)132 for strengthening and improving wear resistance. The foil 132 is a thermoplastic material and is applied to the first portion 91 by heat and pressure. Alternatively, the abrasion resistant yarns may be weft knitted, additionally or alternatively may be a coating, for example applying a polymer coating, PU printing or rubber printing. The melted yarn may be weft-knitted or embroidered afterwards. Instead of foils, other techniques as described above may also be used for strengthening.

For example by PU printing (for example by Kurim, a company specializing in PU coating in the field of the shoe industry), the areas 93 are locally printed on to improve stability. Likewise, region 92, first portion 91, or sole 61 may be printed on to improve stability or optical enhancement.

Fig. 14 shows a bottom view of a shoe 111 according to the present invention, including an upper 51. Shoe 111 includes a base 61 having a second portion 112, second portion 112 being overlapped by a corresponding first portion of the upper (not shown in fig. 14). The sole 61 may be formed as a separate component and joined to the upper 51, for example by gluing. The sole 61 may also be sprayed (e.g., TPU) or bang (e.g., rubber) directly onto the upper 51. Sole 61 may form a coating like upper 51. Sole 61 may be a portion of upper 51 that is weft or warp knit, and is weft or warp knit, for example, as a rubber yarn or a melt yarn.

Sole 61 has a shape that improves the grip of footwear 111. This shape can in principle be adapted to the field of application of the shoe 111. Shoes for rural areas may include rougher and deeper profiles than shoes for towns.

The sole shown in fig. 14 further includes regions where the sole 61 is thinner than other regions. Region 141 is located between the toe region and the ball region and extends along the flexion line of the foot. Because the sole 61 is thinner in this region 141, the second portion 112 of the sole 61 (connected to the first region of the upper) is more likely to break relative to the other regions of the sole 61. The overall freedom of movement of the toes is thus increased.

The sole 61 shown in fig. 14 further includes grooves 142 and 143. The grooves 142 extend generally in the longitudinal direction of the sole 61, while the grooves 143 extend in the transverse direction of the sole 61. Sipes 142 and 143 generally correspond with the natural flexion lines of the foot, although alternative paths for the sipes are also possible.

The grooves 142 and 143 have the effect of making the sole 61 as a whole more elastic, better adapting to the shape of the foot and allowing a more natural walking sensation approximating a barefoot walking.

Claims (20)

1. A method of manufacturing an upper, comprising:

creating stitches of the knit at the first row of needles to form at least a portion of the first layer;

simultaneously creating stitches of the fabric in the second row of needles to form at least a portion of the second layer; and

selectively joining stitches of the knit fabric created in the first row of needles with stitches of the knit fabric created in the second row of needles at an edge, the first layer and the second layer being joined along a contour of the footwear to form a void for the foot;

the method further comprises the following steps: weaving the first layer and the second layer to form at least two first portions, wherein at least one of the at least two first portions is shaped to fit the contour of a single toe of a wearer when the shoe is worn,

wherein the at least two first portions are formed to be movable independently of each other so that toes of a wearer can move independently of each other when the shoe is worn.

2. The method according to claim 1, further comprising weaving the first layer and the second layer three-dimensionally so that a final shape of the upper fits a shape of the foot.

3. The method of claim 1, further comprising knitting the upper as a single knit.

4. The method of claim 1, wherein the at least two first portions comprise five first portions, each first portion shaped to fit the contour of each individual toe of the wearer when the shoe is worn.

5. The method of claim 1, wherein the at least two first portions are formed to seamlessly connect with each other.

6. The method of claim 1, wherein the at least two first portions at least partially overlap.

7. The method of claim 1, further comprising weaving additional yarns in at least a first portion shaped to fit the contours of a single toe of a wearer when the shoe is worn, such that the additional yarns support the single toe.

8. The method of claim 7, wherein the additional yarn forms a toe cap that extends over the toenail and along the side of a single toe of the wearer when the shoe is worn.

9. The method of claim 7, wherein the additional yarn is elastic so that the shape of the first portion is adapted to the contour of the individual toes of the wearer to suit the shape and size of the individual toes.

10. The method of claim 1, further comprising attaching an upper to a sole, wherein the sole includes at least two second portions corresponding to the at least two first portions.

11. The method of claim 10, further comprising knitting at least one section of the sole as a single knit with the upper.

12. The method of claim 10, further comprising knitting the sole and the upper as a single knit.

13. The method of claim 12, further comprising reinforcing the sole with a coating.

14. The method of claim 12, further comprising weaving additional yarns into the sole to reinforce the sole.

15. A method of manufacturing a shoe, comprising:

creating stitches of the knit at the first row of needles to form a first layer of the footwear;

creating stitches of the knit at the second row of needles to form a second layer of the shoe; and

selectively joining stitches of the knit fabric created in the first row of needles at an edge with stitches of the knit fabric created in the second row of needles such that the first layer and the second layer join along a contour of the footwear to form a void for the foot;

wherein the shoe comprises an upper and a sole;

wherein,

a first layer of the shoe comprising a first section of the sole and a first section of the upper, and a second layer of the shoe comprising a second section of the sole and a second section of the upper to collectively form a single piece of braid; or

The first layer of the shoe comprises the upper and the second layer of the shoe comprises a section of the sole to collectively form a single piece of braid.

16. The method of claim 15, wherein where the first layer of the shoe comprises the upper and the second layer of the shoe comprises one segment of the sole, the sole braid comprises at least one portion of the outsole of the shoe.

17. The method of claim 15, further comprising coating at least one portion of the sole.

18. The method of claim 15, wherein at least one portion of the sole comprises melted yarn.

19. The method of claim 15, wherein at least one portion of the sole includes a deep profile to improve grip.

20. The method of claim 15, wherein the number of stitches in at least one row of at least one layer is different from the previous row.

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