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EP-4736700-A1 - SHOE COMPONENT CO-MOLDED WITH PHYSICALLY FOAMED MIDSOLE AND METHOD OF MANUFACTURING THE SAME

EP4736700A1EP 4736700 A1EP4736700 A1EP 4736700A1EP-4736700-A1

Abstract

A shoe component (100, 200, 300) co-molded with a physically foamed midsole includes a composite outsole (10, 40, 50) and a physically foamed midsole (20). The composite outsole (10, 40, 50) includes a base layer (11, 41, 51) and a mesh layer (12, 42, 52) having has a first surface (121, 421, 5231) and a second surface (122, 422, 5211) that face oppositely. The first surface (121, 421, 5231) has a first surface structure (123, 423, 5232) and is engaged with the base layer (11, 41, 51). The second surface (122, 422, 5211) has a second surface structure (124, 424, 5212) different from the first surface structure (123, 423, 5232). A bottom surface of the physically foamed midsole (20) partially enters the second surface structure (124, 424, 5212) to generate an anchor effect with the mesh layer (12, 42, 52). A method of manufacturing a shoe component (100, 200, 300) is provided.

Inventors

  • YANG, TSUNG-LIN
  • CHANG, Yu-Ta

Assignees

  • Feng Tay Enterprises Co., Ltd.

Dates

Publication Date
20260506
Application Date
20241105

Claims (15)

  1. A shoe component (100, 200, 300) co-molded with a physically foamed midsole, comprising: a composite outsole (10, 40, 50) comprising a base layer (11, 41, 51) and a mesh layer (12, 42, 52) co-molded with the base layer (11, 41, 51), wherein the base layer (11, 41, 51) has a first top surface (111, 411, 511) and a first bottom surface (112, 412, 512); the first bottom surface (112, 412, 512) is adapted to contact a ground; the mesh layer (12, 42, 52) has a first surface (121, 421, 5231) and a second surface (122, 422, 5211) that face opposite directions; the first surface (121, 421, 5231) has a first surface structure (123, 423, 5232); the second surface (122, 422, 5211) has a second surface structure (124, 424, 5212); the first surface structure (123, 423, 5232) is different from the second surface structure (124, 424, 5212); the first surface (121, 421, 5231) is engaged with the first top surface (111, 411, 511) of the base layer (11, 41, 51); and a physically foamed midsole (20) formed from a supercritical fluid through physical foaming, wherein the physically foamed midsole (20) has a second top surface (21) and a second bottom surface (22); a part of the second bottom surface (22) enters the second surface structure (124, 424, 5212) of the second surface (122, 422, 5211) to generate an anchor effect with the mesh layer (12, 42, 52).
  2. The shoe component (100, 200, 300) as claimed in claim 1, wherein the mesh layer (12, 42, 52) is a yarn fabric; the first surface structure (123, 423, 5232) is selected from the group consisting of a plurality of high-density pores (123a, 423a, 5232a), a plurality of loops (423b, 5232b), a thermoplastic film (423c), and a combination thereof; the second surface structure (124, 424, 5212) is selected from the group consisting of a plurality of low-density pores (124a, 424a, 5212a), a plurality of loops (424b), and a combination thereof.
  3. The shoe component (100, 200, 300) as claimed in claim 2, wherein the plurality of high-density pores (123a, 423a, 5232a) of the first surface (121, 421, 5231) are defined as 70 or more pores per square centimeter; the plurality of low-density pores (124a, 424a, 5212a) of the second surface (122, 422, 5211) are defined as 60 or less pores per square centimeter.
  4. The shoe component (100, 200, 300) as claimed in claim 3, wherein the thermoplastic film (423c) is bonded with the mesh layer (12, 42, 52) by heating and softening a thermoplastic film material; a thickness of the thermoplastic film (423c) ranges from 0.05 mm to 1 mm; the first top surface (111, 411, 511) of the base layer (11, 41, 51) is bonded with the thermoplastic film (423c) through heating and melting.
  5. The shoe component (100, 200, 300) as claimed in any one of claims 1 and 2, wherein no adhesive layer is provided between the second surface (122, 422, 5211) of the composite outsole (10, 40, 50) and the second bottom surface (22) of the physically foamed midsole (20).
  6. The shoe component (100, 200, 300) as claimed in claim 5, further comprising a woven shoe upper (30), wherein the woven shoe upper (30) is engaged with the second top surface (21) of the physically foamed midsole (20); the woven shoe upper (30) has a third bottom surface (31); a part of the second top surface (21) of the physically foamed midsole (20) enters the third bottom surface (31) to generate an anchor effect with the woven shoe upper (30); no adhesive layer is provided between the second top surface (21) and the third bottom surface (31).
  7. The shoe component (100, 200, 300) as claimed in claim 1, wherein both the base layer (11, 41, 51) and the physically foamed midsole (20) comprise a first thermoplastic material; the first thermoplastic material is selected from the group consisting of thermoplastic polyurethane (TPU), polyamide, polyester, ionomer, and a combination thereof; the base layer (11, 41, 51) is a foamed body or a non-foamed body; the mesh layer (12, 42, 52) comprises a second thermoplastic material; the second thermoplastic material is selected from the group consisting of polyester, thermoplastic polyurethane (TPU), and a combination thereof.
  8. The shoe component (100, 200, 300) as claimed in claim 7, further comprising a woven shoe upper (30), wherein the woven shoe upper (30) is engaged with the second top surface (21) of the physically foamed midsole (20); the woven shoe upper (30) comprises a third thermoplastic material; the third thermoplastic material is selected from the group consisting of polyester, thermoplastic polyurethane (TPU), polyamide, polyethylene terephthalate (PET), and a combination thereof.
  9. The shoe component (100, 200, 300) and claimed in claim 8, wherein the mesh layer (12, 42, 52) is made of polyester or thermoplastic polyurethane (TPU); the physically foamed midsole (20) is made of polyester or thermoplastic polyurethane (TPU); the woven shoe upper (30) is made of polyester or thermoplastic polyurethane (TPU); no adhesive layer is provided between the mesh layer (12, 42, 52) and the physically foamed midsole (20) and between the physically foamed midsole (20) and the woven shoe upper (30).
  10. The shoe component (100, 200, 300) as claimed in claim 1, wherein the base layer (11, 41, 51) is a thermosetting material; the thermosetting material is selected from the group consisting of thermosetting polyurethane, rubber, and a combination thereof; the base layer (11, 41, 51) is a foamed body or a non-foamed body.
  11. A method of manufacturing a shoe component (100, 200, 300) co-molded with a physically foamed midsole, comprising: step S1: providing a composite outsole (10, 40, 50), wherein a mesh layer (12, 42, 52) of the composite outsole (10, 40, 50) has a first surface (121, 421, 5231) and a second surface (122, 422, 5211) that face opposite directions; the first surface (121, 421, 5231) has a first surface structure (123, 423, 5232); the second surface (122, 422, 5211) has a second surface structure (124, 424, 5212); the first surface structure (123, 423, 5232) is different from the second surface structure (124, 424, 5212); a base layer (11, 41, 51) of the composite outsole (10, 40, 50) is engaged with the first surface (121, 421, 5231) by co-molding; step S2: placing the composite outsole (10, 40, 50) into a foaming mold (400) and reserving a foaming space (430); injecting a thermoplastic foaming fluid, which comprises a supercritical fluid, into the foaming space (430) of the foaming mold (400), wherein before the thermoplastic foaming fluid is injected into the foaming mold (400), an air pressure in the foaming mold (400), which is preset, ranges from 5 bar to 50 bar; and step S3: releasing the air pressure in the foaming mold (400) to foam the thermoplastic foaming fluid through the supercritical fluid to form a physically foamed midsole (20), wherein a part of the physically foamed midsole (20) enters the second surface structure (124, 424, 5212) of the second surface (122, 422, 5211) of the mesh layer (12, 42, 52) to generate an anchor effect with the mesh layer (12, 42, 52), thereby obtaining a shoe component (100, 200, 300).
  12. The method as claimed in claim 11, wherein the mesh layer (12, 42, 52) is a yarn fabric; the first surface structure (123, 423, 5232) is selected from the group consisting of a plurality of high-density pores (123a, 423a, 5232a), a plurality of loops (423b, 5232b), a thermoplastic film (423c), and a combination thereof; the second surface structure (124, 424, 5212) is selected from the group consisting of a plurality of low-density pores (124a, 424a, 5212a), a plurality of loops (424b), and a combination thereof.
  13. The method as claimed in claim 11, wherein in step S1, the composite outsole (10, 40, 50) is provided by placing the mesh layer (12, 42, 52) into an injection mold, injecting an outsole material into the injection mold, and solidifying the outsole material to form the base layer (11, 41, 51) to engage the base layer (11, 41, 51) with the first surface (121, 421, 5231) of the mesh layer (12, 42, 52), thereby obtaining the composite outsole (10, 40, 50).
  14. The method as claimed in claim 11, wherein in step S1, the composite outsole (10, 40, 50) is provided by directly printing an outsole material on the first surface (121, 421, 5231) of the mesh layer (12, 42, 52) by using a 3D printing apparatus, and solidifying the outsole material to form the base layer (11, 41, 51) to engage the base layer (11, 41, 51) with the mesh layer (12, 42, 52), thereby obtaining the composite outsole (10, 40, 50).
  15. The method as claimed in any one of claims 11, 12, and 13, wherein in step S2, a woven shoe upper (30), which fits around a last (4201) in advance, is placed into the foaming mold (400) and the composite outsole (10, 40, 50) is placed in a bottom cavity of the foaming mold (400); when the foaming mold (400) is activated to close, a third bottom surface (31) of the woven shoe upper (30) faces the second surface (122, 422, 5211) of the composite outsole (10, 40, 50), and the foaming space (430) is formed between the woven shoe upper (30) and the composite outsole (10, 40, 50).

Description

BACKGROUND OF THE INVENTION Technical Field The present invention relates generally to a shoe component structure and a manufacturing technology, and more particularly to a shoe component co-molded with a physically foamed midsole and a method of manufacturing the same. Description of Related Art A conventional shoe basically includes a sole, an upper, an insole, etc. The sole is typically composed of an outsole and a midsole. In a conventional method of manufacturing shoes, the upper, the midsole, the outsole, and other components are manufactured individually; complicated roughing treatment is performed on a surface of the upper, a surface of the midsole, and a surface of the outsole in a manual way; an adhesive is coated on the roughed surface of the upper, the roughed surface of the midsole, and the roughed surface of the outsole; then the upper and the outsole are adhered to two opposite sides of the midsole to form a shoe product. However, the conventional method of manufacturing shoes includes complicated processing procedures and requires massive manpower cost in roughing, applying the adhesive, adhering, and other processing procedures, which lower the overall production efficiency. Moreover, the chemical adhesive used in applying the adhesive has a certain degree of poison and causes harms to health when workers are exposed to the chemical adhesive in long term. Additionally, when a foamed midsole of the conventional shoe is adhered to the outsole through the adhesive, a quality and a composition of the adhesive affect an adhesion effect and an adhesion strength between the foamed midsole and the outsole. If a peel strength and the adhesion effect between the foamed midsole and the outsole are not satisfactory, the foamed midsole and the outsole might be easily detached from each other and cause injury if a user performs a high-intensity exercise for a long time while wearing the sole. A conventional midsole typically is a chemically foamed body. Before the foamed midsole is adhered to the outsole or the upper, the foamed midsole is placed in an oven for solidifying. During solidifying, the size constriction rate of the foamed midsole might become unstable easily, which might cause different toe springs across the foamed midsole. As a result, when the foamed midsole is adhered to the outsole or the upper in the subsequent processing procedures, mismatching of the sizes might be easily resulted and excessive adhesive might be present at an adhesion between the foamed midsole and the outsole or the upper, which increase the defect rate of the method of manufacturing shoes. Moreover, a chemically foamed midsole is typically made by performing injection foaming with a reduced mold which is reduced significantly in terms of scale based on an end product. After the injection and at a moment of opening the reduced mold, an intermediate in the reduced mold suddenly expands to a foamed body with a volume, which is a multiple of a volume of the reduced mold, duo to different pressures. Then, the foamed body is processed upon requirements. As the injection chemical foaming involves special volume changes, the chemically foamed midsole could not be co-molded with other shoe components during the midsole injection process. For example, if the chemically foamed midsole is required to be co-molded with the outsole, the chemically foamed midsole is taken out after opening the mold; then, the chemically foamed midsole is processed preliminarily and then is co-molded with the outsole or other shoe components under high temperature and high pressure. Recently, the midsole could be manufactured by injection physical foaming, wherein the physically foamed midsole does not require a reduced mold, as is necessary for the chemically foamed midsole. The physically foamed midsole could be manufactured by performing injection physical foaming on a mold cavity having the same size as the end product of the foamed midsole. Although the physically foamed midsole could be co-molded with other shoe components, an adhesion strength of a resulted product might not meet the standard requirement. The reason is that temperature and pressure during injection physical foaming are not sufficient for good adhesion between the physically foamed midsole and other shoe components placed in the mold cavity. As a result, although the physically foamed midsole could be co-molded with other shoe components, the adhesion strength between different shoe components, including an adhesion strength between the physically foamed midsole and an outsole formed by co-molding, still has room for improvement. BRIEF SUMMARY OF THE INVENTION In view of the above, the primary objective of the present invention is to provide a shoe component co-molded with a physically foamed midsole and a method of manufacturing the same, wherein the shoe component is engaged with other shoe components through physical anchor effect to improve an engaging strength between an