SOLE ELEMENT, FOOTWEAR ARTICLE COMPRISING SUCH A SOLE ELEMENT AND METHODS FOR MANUFACTURING SUCH A SOLE ELEMENT AND SUCH A FOOTWEAR ARTICLE

Description

TECHNICAL FIELD

The present disclosure relates to the sole assembly elements comprising one or several textile sole elements comprising one or several entirely or at least partly hot-melted yarn(s), as well as the footwear articles comprising such sole assembly elements, and the methods for manufacturing such sole assembly elements, and footwear articles comprising them.

BACKGROUND

Conventional footwear articles generally comprise a sole upper and structure. The upper is secured to the sole structure and forms a void inside the footwear article to comfortably receive and secure a foot. The sole structure is secured to a lower area of the upper, and operatively disposed between the ground, and the upper. In the footwear articles for the practice of a sport, the sole structure can comprise an outsole and a midsole. The midsole often comprises a polymer foam material that absorbs the shocks with the ground during an impact in order to mitigate the effects on the foot and the leg during walking, running or other activities. The sole structure can also comprise a lining positioned in the vicinity of the lower surface of the foot to improve the comfort of the footwear article. The soles are usually fixed to the uppers using a construction called Strobel construction during which the different sole elements (insole, midsole and outsole in particular) are assembled. Conventional shoe manufacturing methods require dozens of steps, and produce numerous scraps from materials cuttings.

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

One solution consists in eliminating the stitching steps necessary for the three-dimensional shaping of the initially planar upper. The upper can thus be obtained by hot shaping a knitted sock or several superimposed knitted socks and comprising thermofusible yarns. One or several injected sole assembly elements is/are fixed, for example by bonding, to the lower part of the upper.

The sole structure must provide numerous functions, in particular cushioning, wear resistance, recovery and comfort functions, in a differentiated manner depending on the regions of the sole structure coming into contact with the foot. A sole structure whose weight is adjustable according to the practiced sports and to the type of wearer, and is aesthetic, is also sought.

There is therefore a need for a sole assembly element that is simple to manufacture, has good mechanical performance, can be functionalized as desired in the choice of the materials, colors, or their locations, and offers a wide choice in its form, in particular in the possible sole cavities and/or in the three-dimensional shapes.

There is also a need for a sole assembly element with a lowered CO2 balance taking into account its manufacturing method and the materials necessary for its manufacture.

DETAILED DESCRIPTION

The present disclosure overcomes all or part of the aforementioned problems in that it relates, according to a first aspect, to a sole assembly element comprising at least one textile sole element comprising one or several at least partly hot-melted yarn(s). The textile sole element comprises at least one housing and particles disposed in the housing.

Advantageously, the combination of particles with a flexible textile sole element before the melting (at least in part) of the (at least partly) thermofusible yarn(s) it comprises, in particular before thermocompression, allows distributing, and possibly molding, the particles in one or several housing(s).

In addition, one or several housing(s) make(s) it possible to contain a determined volume of particles without them leaking outside the sole assembly element.

The manipulation of particles and their arrangement in an injection molded sole element are complex operations to implement, and therefore unreliable or difficult to industrialize.

The use of a textile sole element comprising a textile pocket comprising one or several at least partly thermofusible yarn(s), or several textile pockets each comprising one or several at least partly thermofusible yarn(s), receiving (in particular each one) particles, makes it possible to manipulate and place the particles in a localized manner via a reliable industrial method, particularly a method for thermoforming or thermocompressing a textile sole element.

In a first embodiment, the sole assembly element is fixed to an upper of a footwear article, particularly to the lower border of the upper, in particular by stitching (for example by a conventional strobel-type construction) and/or by bonding, for example using a bonding agent.

In a second embodiment, the sole assembly element is fixed to an at least partly textile upper and comprising one or several at least partly thermofusible yarn(s) during the step of thermoforming, particularly during the step of molding by thermocompression, the upper, allowing the melting or the softening of the at least partly thermofusible yarns of the upper. Preferably, the sole assembly element is fixed to the upper, particularly at least partly textile and thermoformed more particularly thermocompressed upper, via at least partly hot-melted yarns of the sole assembly element and/or of the upper. In this case, the at least partly hot-melted yarns of the sole assembly element or of the upper can be re-activated, that is to say melted or softened, thus promoting the bonding with the upper. Preferably, the footwear article manufacturing method then comprises two thermocompression and/or thermoforming steps, a first step of thermocompressing at least the textile sole element, then a second step of thermoforming or thermocompressing the at least partly textile upper during which the sole assembly element undergoes the step of thermoforming or thermocompressing the at least partly textile upper.

In a third embodiment, the sole assembly element is configured to be removably disposed in the foot-receiving void of the upper of a footwear article. The sole assembly element can in this case be separated from the upper of the footwear article. The sole assembly element can act as a midsole and/or an insole.

In a fourth embodiment, the sole assembly element is thermocompressed or thermoformed during the step of thermocompressing or thermoforming an at least partly textile upper comprising at least partly thermofusible yarns.

The sole assembly element can comprise part of the thermocompressed or thermoformed upper, for example at least part of the sole portion of the thermocompressed or thermoformed upper.

Sole Assembly Element

Advantageously, the sole assembly element comprises a longitudinal axis (Ls), particularly extending between its rear edge and its front edge. The longitudinal axis (Ls) is preferably substantially parallel to the longitudinal axis (L) extending between the heel and the forefoot of a footwear article.

Advantageously, the sole assembly element comprises a transverse axis (Ts), particularly extending between its lateral edge and its medial edge. The transverse axis (Ts) is preferably substantially parallel to the transverse axis (T) extending between the medial and lateral edges of a footwear article.

Preferably, the longitudinal axis (Ls) is intersecting, in particular substantially perpendicular to, the transverse axis (Ts).

In one embodiment, the sole assembly element is configured to form part or all of a sole structure of a footwear article. In one embodiment, the sole assembly element is at least a portion of an outsole, and/or at least a portion of a midsole, and/or at least a portion of an insole.

In one embodiment, the sole assembly element comprises (is) an outsole, and/or a midsole, and/or an insole.

When the sole assembly element is an outsole and a midsole, the sole assembly element performs the functions of an outsole and of a midsole.

The sole assembly element can comprise an outsole, particularly comprising at least one injected polymer material, and a midsole comprising an at least partly hot-melted textile sole element or several at least partly hot-melted textile sole elements.

The sole assembly element can comprise an outsole comprising a first textile sole element and a midsole comprising a second textile sole element, particularly the first textile sole element is different from the second textile sole element. Generally, the sole assembly element can comprise one or several at least partly hot-melted textile sole element(s).

In one embodiment, the sole assembly element is a heel sole assembly element, particularly extending between a lateral edge and a medial edge of the sole assembly element and/or extending between a rear edge of a heel region of the sole assembly element and a front edge of a heel region of the sole assembly element.

In one embodiment, the sole assembly element is a heel and midfoot sole assembly element, particularly extending between a lateral edge and a medial edge of the sole assembly element and/or between a rear edge of a heel region of the sole assembly element and a front edge of a midfoot region of the sole assembly element.

In one embodiment, the sole assembly element is a heel, midfoot and forefoot sole assembly element, particularly extending between a lateral edge and a medial edge of the sole assembly element and/or or extending between a rear edge of a heel region of the sole assembly element and a front edge of a forefoot region of the sole assembly element.

In one embodiment, the sole assembly element substantially extends between a medial edge and a lateral edge substantially corresponding to the medial and lateral edges of the foot.

The sole assembly element can comprise one or several sole assembly member(s), particularly not comprising hot-melted yarns.

The members(s) may be one or several studs, particularly arranged for the practice of soccer, rugby or athletics. The stud(s) can be configured to be screwed, for example into a textile sole element.

The stud(s) can be obtained by an additive or subtractive manufacturing method in three dimensions, for example by three-dimensional printing. This arrangement makes it possible to manufacture tailor-made studs according to the practice of the user.

The sole assembly member can be a hard toe (particularly configured to protect the front end of the footwear article), or a counter, in particular a heel counter, or a device for reinforcing one or several region(s) for the passage of a lace.

The sole assembly element can comprise a textile sole element, or several textile sole elements according to the present disclosure, for example two or three textile sole elements, particularly identical or different.

The textile sole elements can be stacked, or juxtaposed possibly by overlapping.

When the sole assembly element comprises several textile sole elements, the textile sole elements can be fixed together via one or several at least partly hot-melted yarn(s) of at least one of the textile sole elements, or two textile sole elements.

Preferably, the sole assembly element comprises substantially opposite inner and outer faces.

The outer face of the sole assembly element is preferably oriented towards the ground, and possibly configured to come directly into contact with the ground, particularly when the sole assembly element comprises (is) part of an outsole or an outsole.

The inner face of the at least one sole assembly element is preferably oriented facing the bottom of the wearer's foot.

Preferably, the sole assembly element is a sole assembly element for a sports shoe.

The sole assembly element and/or the textile sole element can comprise a molded sole cavity, comprising one or several negative and/or positive cavity/cavities, disposed on its/their outer face(s).

In one embodiment, the sole assembly element and/or the textile sole element has/have a substantially full molded volume.

In one embodiment, the sole assembly element and/or the textile sole element is/are thermocompressed.

Textile Sole Element

A first textile sole element and/or a second textile sole element can each comprise any one of the properties defined in the present text with regard to a textile sole element.

Preferably, the textile sole element comprises substantially opposite inner and outer faces.

The outer face of the textile sole element is preferably oriented towards the ground, and possibly configured to come directly into contact with the ground, particularly when the textile sole element comprises (is) part of an outsole or an outsole.

The inner face of the at least one textile sole element is preferably oriented facing the bottom of the wearer's foot.

Advantageously, the textile sole element comprises a longitudinal axis (ls), particularly extending between its rear edge and its front edge. The longitudinal axis (ls) is preferably substantially parallel to the longitudinal axis (L) extending between the heel and the forefoot of a footwear article.

Advantageously, the textile sole element comprises a transverse axis (ts), particularly extending between its lateral edge and its medial edge. The transverse axis (ts) is preferably substantially parallel to the transverse axis (T) extending between the medial and lateral edges of a footwear article.

Preferably, the longitudinal axis (ls) is intersecting, in particular substantially perpendicular to, the transverse axis (ts).

Preferably, the transverse axes (Ts) and (ts) are substantially parallel.

Preferably, the longitudinal axes (Ls) and (ls) are substantially parallel.

The textile sole element can be one or several knit(s), or one or several fabric(s), or one or several non-woven(s), or one or several braid(s), or one or several network(s) of yarn(s)/fiber(s), or a combination thereof.

The network of yarn(s)/fiber(s) can be obtained by additive manufacturing for example.

The textile sole element can be knitted on a flat knitting machine or a circular knitting machine, in particular on a warp knitting machine or a Raschel knitting machine.

Preferably, the textile sole element is knitted on a small diameter circular knitting machine, that is to say having a diameter less than or equal to approximately 150 mm or 200 mm.

The textile sole element comprises one or several at least partly hot-melted yarn(s), optionally with at least one or several at least partly non-hot melt, or non-hot-melted yarn(s).

Advantageously, a textile sole element comprises one or several at least partly hot-melted textile portion(s).

A textile sole element is preferably a textile piece of unitary textile construction, for example a knitted piece of unitary knitted construction or a woven piece of unitary woven construction.

In one embodiment, the textile sole element comprises an upper textile layer and a lower textile layer, particularly fixed along their medial and lateral borders, and possibly along their rear and front borders. Preferably, the upper textile layer and/or the lower textile layer each comprise(s) one or several at least partly hot-melted or hot-melted yarn(s).

The fixing can be obtained by welding (for example ultrasonic, high-frequency or thermal welding) or by stitching (for example using an at least partly thermofusible/hot-melted yarn).

The textile sole element can comprise a housing, in particular textile housing or several housings, in particular textile housing(s), for example two or three housings.

In one embodiment, (each) housing comprises (particularly is delimited by):

• • an upper partition, particularly comprising at least a portion of the upper textile layer of the textile sole element, and/or
  • a lower partition, particularly comprising at least a portion of the lower textile layer of the textile sole element.

The upper and lower partitions can be connected, particularly, fixed together, along their peripheral edges, and/or are fixed together via one or several lateral partition(s) extending between the upper and lower partitions.

The upper and lower partitions of a housing can be fixed together by stitching or by welding (for example ultrasonic, thermal, high-frequency welding). The stitching can be performed with an at least partly hot-melted yarn (particularly at least partly thermofusible yarn with its transformation by thermoforming or by thermocompression).

Preferably, the upper partition and/or the lower partition and/or the lateral partition(s), comprise(s) (consist(s) of) one or several at least partly hot-melted or hot-melted yarn(s).

Two housings can comprise one or several common lateral partition(s).

In one embodiment, the textile sole element is/comprises a textile tubular part, such as a tube, in particular a knitted tube, comprising open front and rear ends. One of the front or rear ends can be closed by knitting or by stitching or by welding (for example ultrasonic, high-frequency or thermal welding). The end left open allows the filling of the textile sole element with particles, then this filling end is closed, for example by stitching or by welding (for example ultrasonic, thermal, high-frequency welding).

In one embodiment, the textile sole element comprises one or several elongated housing(s) extending along the longitudinal axis (ls) and/or the transverse axis (ts) of the textile sole element, for example two or three elongated housings.

In one embodiment, the textile sole element comprises one or several vertical housing(s) extending between the outer and inner faces of the textile sole element, for example two or three vertical housings.

Preferably, the at least one housing or each of the housings receives particles.

One or several housing(s) can house a functional member, for example a cellular material, for example a foam, or a reinforcing plate, possibly in combination with particles or without particles.

The cellular material, particularly the foam, can be thermoformed or thermocompressed.

A housing preferably receives a determined amount and/or volume of particles.

The textile sole element can comprise a first housing receiving a first amount of particles, and a second housing receiving a second amount of particles, the amount of particles disposed in the first housing can be identical to or different from the amount of particles disposed in the second housing. The particles in the first housing can be identical to or different from the particles in the second housing.

In one embodiment, the textile sole element is a cushioning element. Particularly, the textile sole element absorbs shocks and possibly has recovery properties. These functions are particularly provided by the particles that the textile sole element comprises.

The textile sole element can be in whole or in part a heel cushioning element.

The textile sole element can be a junction element configured to ensure the junction between the heel region and the forefoot region of a sole structure of a footwear article, particularly disposed in the midfoot region of a sole structure of a footwear article. This junction element provides dimensional stability, facilitates the roll of the foot, and prevents sagging of the arch of the foot.

The textile sole element can be all or part of a forefoot cushioning element, particularly comprising a sole cavity configured to provide grip with the ground.

In one embodiment, the at least one textile sole element is a heel textile sole element, particularly extending between a lateral edge and a medial edge of the textile sole element and/or extending between a rear edge of a heel region and a front edge of a heel region of the textile sole element.

In one embodiment, the at least one textile sole element is a heel and midfoot textile sole element, particularly extending between a lateral edge and a medial edge of the textile sole element and/or extending between a rear edge of a heel region of the textile sole element and a front edge of a midfoot region of the textile sole element.

In one embodiment, the at least one textile sole element is a heel, midfoot and forefoot textile sole element, particularly extending between a lateral edge and a medial edge of the textile sole element and/or extending between a rear edge of a heel region of the textile sole element and a front edge of a forefoot region of the textile sole element.

In one embodiment, the textile sole element comprises a lateral longitudinal housing opening out onto the lateral edge of the sole assembly element or of the footwear article, and comprising first particles. The textile sole element can also comprise a medial longitudinal housing opening out onto the medial edge of the sole assembly element or of the footwear article, and comprising second particles. The first particles preferably have a lower hardness (Shore A) than the hardness (Shore A) of the second particles. This arrangement allows the medial housing to provide more support and rigidity to the inside of the foot than the lateral housing.

In one embodiment, the at least one housing is a textile housing in textile connection with the textile sole element.

In one embodiment, the at least one housing is at least partly or entirely delimited by the textile sole element.

The textile sole element can comprise several housings, particularly several textile housings in textile connection with the textile sole element. Preferably each of the housings receives particles.

In one embodiment, the textile sole element and the at least one housing, in particular textile housing, are of unitary textile, particularly knitted or woven, construction.

In one embodiment, the housing is at least partly delimited by one or several yarn(s) of an upper textile layer and/or of a lower textile layer of the textile sole element.

In one embodiment, the housing comprises one or several at least partly hot-melted yarn(s), particularly is delimited at least partly by one or several at least partly hot-melted yarn(s).

The sole assembly element and/or the textile sole element and/or the housing(s) each comprise(s) at least one viewing window, particularly comprising one or several at least partly hot-melted yarn(s), allowing visualizing for the wearer of all or part of the particles from the outside of the sole assembly element.

Preferably, the viewing window is transparent and/or translucent, more preferably comprises one or several at least partly hot-melted transparent and/or translucent yarn(s).

In one embodiment, the textile sole element comprises/consists of one or several at least partly thermofusible or at least partly hot-melted yarn(s), and/or one or several at least partly non-thermofusible or at least partly non-hot-melted yarn(s), in particular of one or several non-thermofusible or non-hot-melted yarn(s).

In one embodiment, the ratio of the mass of the hot-melted material coming from the at least partly hot-melted yarn(s) to the total mass of a textile sole element (particularly without the particles) is greater than or equal to 30%, preferably greater than or equal to 40%, preferably greater than or equal to 50%, particularly greater than or equal to 60%, more particularly greater than or equal to 80%, in particular greater than or equal to 90%, for example of the order of 95%-100%.

In one embodiment, the textile sole element consists of one or several hot-melted yarn(s).

In one embodiment, the ratio of the mass of the hot-melted material coming from the at least partly hot-melted yarn(s) to the total mass of a textile sole element (particularly without the particles) is less than or equal to 80%.

In one embodiment, the textile sole element forms a structure comprising several housings. Preferably, the structure comprises (consists of) one or several at least partly hot-melted yarn(s), in particular of one or several hot-melted yarn(s).

The housings can be communicating or non-communicating (that is to say the receiving volumes of the housings can be communicating or non-communicating).

In one embodiment, the particles are disposed in a closed housing or possibly in a housing in communication (in particular fluid communication) with one or several other housing(s) thus forming a closed assembly, so as to prevent any leakage of the particles outside the sole assembly element.

The at least one textile sole element can comprise one or several elastic yarn(s), such as defined in the present text.

The textile sole element can comprise one or several textile pocket(s), before its thermoforming and/or its thermocompression. In this case, preferably, the pockets are manufactured by fixing according to one or several fixing area(s) the upper and lower textile layers of the textile sole element. The fixing area(s) can be obtained by stitching or by knitting or by welding (thermal or ultrasonic or high-frequency welding).

The textile sole element can comprise one or several pockets, molded by thermoforming and/or thermocompression forming one or several housing(s).

Yarn(s) According to the Present Text

The yarn(s) can be: one or several at least partly thermofusible yarns; or one or several at least partly hot-melted yarn(s); or one or several non-thermofusible yarn(s); or one or several non-hot-melted yarn(s), or a combination thereof.

The yarn(s) can be one or several monofilament yarn(s), and/or one multifilament yarn(s) and/or one or several spun fiber yarn(s), and/or one elongated element(s) (for example a ribbon or a braid), or a combination thereof.

Preferably, an at least partly hot-melted yarn is a multifilament yarn or a monofilament yarn.

The yarn(s) may be of different colors or be of the same color, possibly transparent or opaque.

The monofilament yarn(s) preferably has/have a diameter greater than or equal to 0.01 mm and less than or equal to 5 mm, more preferably a diameter greater than or equal to 0.1 mm and less than or equal to 2 mm.

The multifilament yarn(s) and/or spun fiber yarn(s) and/or monofilament yarn(s) preferably has/have a count greater than or equal to 10 dtex and less than or equal to 1,000 dtex, more preferably greater than or equal to 30 dtex and less than or equal to 500 dtex.

The at least partly thermofusible/hot-melted yarn(s), particularly the monocomponent monofilament yarn(s), has/have a count comprised between 300 dtex and 900 dtex (bounds included), more particularly comprised between 400 dtex and 800 dtex (bounds included), in particular of the order of 600 dtex.

The multi-filament yarn(s) can be one or several textured yarn(s) FDY (Full Drawn Yarn), DTY (Draw Textured Yarn) or POY (Partially Oriented Yarn), or a mixture of them.

An at least partly thermofusible or at least partly hot-melted yarn can be a yarn comprising at least two components A and B, in particular of the two-component type, a first thermofusible or hot-melted component A, particularly having a melting temperature less than or equal to the heating temperature Tc during a thermocompression or thermoforming step (particularly described below), and a second non-thermofusible or non-hot-melted component B, particularly having a melting or degradation temperature higher than the heating temperature Tc during a thermocompression or thermoforming step (particularly described below).

A thermofusible or hot-melted yarn can be a monocomponent yarn, particularly whose melting temperature is less than or equal to the heating temperature Tc during a thermocompression or thermoforming step (particularly described below).

The at least partly thermofusible or hot-melted yarn(s) according to the present disclosure can comprise a first component A, particularly thermofusible or hot-melted component, chosen among: polyurethanes, in particular thermoplastic polyurethanes, in particular their elastomers; polyamides, such as polyamide 6 or 66; polyolefins, such as polypropylene (PP) or polyethylene (PE); preferably among polyurethanes and polyolefins, more preferably among polyurethanes.

According to the present disclosure, the at least partly thermofusible or at least partly hot-melted, or at least partly non-thermofusible or at least partly non-hot-melted, or non-thermofusible or non-hot-melted yarn(s), can comprise a component B, particularly non-thermofusible or non-hot-melted component, chosen among polyolefins, such as high-density polyethylene, polyamides, such as polyamide 4-6, polyesters, such as polyethylene terephthalate or polybutylene terephthalate.

The yarn(s) (particularly multi-filament and/or mono-filament and/or spun yarn(s)) which are non-thermofusible or non-hot-melted, or at least partly thermofusible or at least partly hot-melted, or whose overall melting or overall degradation temperature is higher than the heating temperature Tc during a thermocompression or thermoforming step (particularly described below), comprise(s) one or several material(s) chosen among:

• • a first list of synthetic materials comprising (possibly consisting of): polyesters, in particular polyethylene terephthalate or polybutylene terephthalate; polyamides, such as PA 6, PA 66, PA 4-6, PA 12; polyolefins, such as polypropylene, polyethylene, PEEK (polyetheretherketone), PEUHMW (very high molecular weight polyethylene); aramids, in particular meta-aramid or para-aramid; elastomers, in particular polyesters or polyurethane, or a mixture thereof; vinyl acetates; polyacrylics, such as polyacrylonitrile; elastanes, or a mixture thereof; and/or
  • a second list of materials, particularly natural materials or derived from regenerated natural materials, comprising (possibly consisting of): cotton, viscose, linen, sisal, wool, jute, silk, hemp; and/or
  • a third list of inorganic materials comprising (possibly consisting of): carbon, mineral fibers, such as rock fiber, glass, preferably carbon.

The elastic yarn(s) in the present text may be made of elastane.

The elastic yarn(s) can be an elastic core yarn, for example elastane, covered with one or several covering yarn(s), for example wrapped or twisted or applied by an air jet method. The covering yarn(s) can be chosen among any one of the first, second or third lists mentioned above.

Particles According to the Present Text

The particles can comprise powder particles and/or granule particles and/or bead particles.

The particles can comprise beads in one or several expanded polymer(s), for example made of expanded polyurethane, of expanded polyamide, such as expanded PEBA (polyether block amide), or expanded EVA (ethylene vinyl acetate).

The particles can be in a synthetic material, a natural material, or a mixture thereof.

The beads can be of substantially spherical shape, or have substantially the same size or be of different sizes.

The particles can comprise cardboard particles and/or wood-based particles.

The particles can comprise particles derived from recycled shoe sole(s) and/or shoe upper(s) and/or shoe(s). The shoe soles and/or the shoe uppers or the shoes are recycled and crushed to form the particles. Preferably, these are sole(s) and/or upper(s) and/or shoe(s) coming from sports shoe(s).

In one embodiment, the particles occupy at least 10%, preferably at least 30% or 40%, more preferably at least 50% or 60%, in particular at least 70% or 80%, of the total volume of the at least a textile sole element, or of the sole assembly element.

In one embodiment, the particles occupy at most 95%, preferably at most 90%, of the total volume of the at least one textile sole element, or of the sole assembly element.

In one embodiment, the particles occupy at least 90%, preferably at most 95%, of the total volume of the at least one textile sole element or of the sole assembly element.

The particles can have different or similar sizes and/or shapes.

The particles can have a size of the order of a nanometer or of a micrometer.

Preferably, the particles can comprise, in particular consist of, particles whose at least one dimension is greater than or equal to 0.01 mm and less than or equal to 30 mm; particularly greater than or equal to 0.1 mm, more particularly greater than or equal to 1 mm.

The particles can comprise (or consist of) particles in one or several material(s) selected from any one of the first, second or third lists of materials described above for the yarn(s).

In one embodiment, the sole assembly element and/or the textile sole element each comprise(s) approximately at least 25 g of particles, preferably approximately at least 50 g of particles, more preferably approximately at least 75 g of particles, particularly approximately between 75 g and 125 g of particles (upper and lower bounds included).

In one embodiment, the sole assembly element and/or the textile sole element each comprise(s) approximately at most 200 g of particles, preferably approximately at most 175 g of particles, more preferably at most 150 g of particles, preferably at most 125 g of particles.

Preferably, the particles are mobile, that is to say able to move slightly relative to each other, particularly as a function of the free volume available in the housing (the free volume being the volume not occupied by the particles).

Definitions According to the Present Text

In the present text, it is understood by “one or several at least partly thermofusible or at least partly hot-melted yarn(s)”, that part or all of the yarn(s) is thermofusible or hot-melted.

In the present text, it is understood by “one or several at least partly thermofusible or at least partly hot-melted textile sole element(s)” that part or the entire textile sole element(s) is thermofusible or hot-melted.

When part of a yarn or of a textile sole element is hot-melted, a non-hot-melted textile skeleton of the yarn or of the textile sole element remains visible on the sole assembly element or of the footwear article. The hot-melted part is in the form of a coating or a lining.

When a yarn or a textile sole element is entirely hot-melted, the hot-melted textile structure forms a coating or lining and/or a polymeric layer (particularly consisting of the component A defined above).

In the present text, it is understood by “hot-melted” any thermofusible material, particularly textile material, which has been melted by the addition of heat during the manufacture of the sole assembly element or of the footwear article described below.

It is understood by “textile piece of unitary textile, particularly knitted or woven, construction” that the textile piece is integral, in particular at the outlet of a textile loom. The unitary piece can comprise one or several stitch(es) or other fixing area(s) but it is/they are used for its shaping and/or the finishing of at least one of its edges.

It is understood by “thermocompressed” any element to which heat and pressure are applied in a combined manner, particularly so as to melt the at least partly thermofusible yarn(s).

It is understood by “thermocompressed” any element to which heat and pressure are applied in a combined manner, particularly so as to melt the at least partly thermofusible yarn(s).

It is understood by “thermoforming” any element to which heat is applied, particularly in order to melt or soften the at least partly thermofusible yarn(s) so as to set the element in a given shape.

In the present text, it is understood by “sole cavity” all of the negative and/or positive cavity/cavities disposed on the outer face of the textile (in particular thermocompressed) sole element or on the outer face of the sole assembly element or disposed on an inner surface of the mold structure described in the present text.

In the present text, it is understood by “positive cavity” any element projecting outside (in particular towards the ground in use) the outer face of the textile sole element or of the sole assembly element (in particular corresponding substantially to a negative cavity on an inner surface of the mold structure). This is for example a protrusion, such as a stud or a heel pad or an adherent projection.

In the present text, it is understood by “negative cavity” any recessed element (in particular projecting towards the underside of the foot in use) of the outer face of the textile sole element or of the sole assembly element (in particular corresponding substantially to a positive cavity on an inner surface of the mold structure). This is for example a recess in the outer face, like a groove.

In the present text, it is understood by “at least partly” of an object substantially the entirety of this object or only part of this object.

In the present text, particularly with reference to a sole assembly element and/or a textile sole element and/or a footwear article, it is understood by “heel region” the natural heel region of the wearer's foot; by “midfoot region” the natural midfoot region of the user; by “forefoot region” the natural forefoot region of the wearer; by “medial edge” the natural medial edge of the wearer's foot; by “lateral edge” the natural lateral edge of the wearer's foot.

In one variant, the textile sole element comprises a knitted tubular part.

Preferably, the knitted tubular part is knitted on a circular knitting machine, in particular of small diameter.

Preferably, the textile sole element consists of a knitted tubular part.

In one embodiment, the textile sole element is a knitted sock, particularly comprising a knitted tubular part and a heel area, particularly the heel area is a bent area of the textile sole element.

Preferably, the knitted tubular part comprises one or several at least partly hot-melted yarn(s).

In one variant, the textile, in particular knitted, sole element comprises several housings which are textile, in particular knitted, housings and particles disposed in each of the textile housings, the textile housings each comprise one or several at least partly hot-melted yarn(s).

Advantageously, the housings are textile housings in textile connection with the upper and lower textile layers of the textile sole element.

Preferably, the housings form a particle receiving assembly which is closed. This arrangement prevents the particles disposed in the housings from escaping from the housings.

In one variant, the particles comprise at least partly hot-melted particles.

Advantageously, the particles comprise at least partly thermofusible particles, particularly comprise particles at least part of which has a melting or softening temperature less than or equal to the thermoforming or thermocompression temperature described below.

The particles can comprise particles which are bonded to each other and possibly with one or several at least partly hot-melted yarn(s) of the housing(s) receiving the particles.

In one embodiment, the particles comprise particles having a melting or softening temperature of less than or equal to 220° C. or 200° C., preferably less than or equal to 180° C.

In one variant, the particles comprise particles having a melting or softening temperature, or a degradation temperature, higher than or equal to 200° C., preferably higher than or equal to 220° C.

Advantageously, these particles are not hot-melted.

Advantageously, these particles have a melting or softening temperature, or a degradation temperature, higher than the heating temperature during the step of thermocompressing the sole assembly element, and/or higher than the heating temperature during the step of thermoforming or thermocompressing the textile upper.

Advantageously, the particles comprise particles which are then mobile.

This arrangement makes it possible to improve cushioning, for example when the particles are/comprise cushioning particles.

In one variant, the particles comprise particles having at least one dimension greater than or equal to 1 mm, preferably less than or equal to 30 mm, more preferably less than or equal to 20 mm, in particular less than or equal to 12 mm.

The particles can have at least one dimension greater than or equal to 1 mm and less than or equal to 10 mm, particularly greater than or equal to approximately 3 mm, more particularly less than or equal to approximately 8 mm.

Preferably, at least 50% by number of the particles have a size greater than or equal to 1 mm and less than or equal to 20 mm, preferably less than or equal to 10 mm.

In the present text, it is understood by “approximately a given value” that the value is indicated to within +/−5%.

In one variant, the particles comprise cushioning particles.

Preferably, the particles comprise particles able to elastically deform in a reversible manner. The particles can undergo deformation, for example deformation by compression when running or any deformation generally encountered when practicing a sport, and substantially recover their initial shapes after suppression of the deformation.

The cushioning particles can be for example wood sawdust particles and/or expanded polymer beads.

In one variant, the particles comprise elastic particles.

It is understood by “elastic particle” any particle comprising (in particular consisting of) an elastic material.

In the present text, it is understood by “elastic material” any material able to deform, particularly to elongate, under a certain deformation (inherent in the practice of a sport), then to substantially recover its initial shape without significant residual deformation.

The cushioning particles can be elastic particles.

The elastic material can be chosen among elastomers, for example polyurethane elastomers, polychloroprene elastomers (neoprene, chloroprene, etc.), nitrile elastomers, ethylene-vinyl acetate (EVA) elastomers, silicone elastomers, natural rubbers, butyl-based rubbers, styrene-based (for example styrene-butadiene based) rubbers, styrene block elastomers (for example TPE-S), thermoplastic polyamide block elastomers, for example polyether block amides (PEBA), ether-ether block thermoplastic elastomers (for example Hytrel®), polyolefin elastomers, and elastanes, and mixtures thereof, preferably among polyurethane elastomers and/or polyolefin elastomers, for example ethylene-vinyl acetate (EVA) elastomers or polyethylene or polypropylene elastomers.

The elastomers can be thermosetting or thermoplastic elastomers.

The elastic particles can be beads in one or several expanded polymer(s) as described above, particularly in one or several expanded elastomer(s) (the elastomers being as described above).

In one variant, the particles comprise at least partly biosourced particles, particularly wood particles.

It is understood by “biosourced particle” any particle, in particular recycled or virgin particle, resulting from the implementation, at least partly, of at least one renewable natural resource, particularly of animal or plant origin.

It is understood by “at least partly biosourced particles”, particles that are entirely biosourced or particles only part of which is biosourced.

In one embodiment, the particles comprise/are cardboard particles.

The cardboard is thus, at least partly, biosourced; it can indeed comprise chemical compounds which have been used for its transformation and shaping, but it also comprises a biosourced cellulosic part.

In one variant, the particles comprise wood particles.

Advantageously, the wood particles are biosourced particles.

In one embodiment, the particles are wood chips or wood sawdust.

The wood is preferably sawdust or wood chips from beech wood and/or oak wood.

In one variant, the particles comprise particles derived from at least one recycled and crushed element.

The recycled and crushed element is preferably chosen among textiles (for example socks, undershirts), shoes, particularly shoes for the practice of a sport (for example soccer, hiking shoes, etc.), inflatable fittings for tires (for example inflatable fittings for motorized vehicles and/or fittings for cycles, etc.), boots (particularly in a synthetic or natural elastomer material).

Advantageously, these particles are not linked together, particularly are not bonded together.

In one variant, the particles comprise mobile particles.

Advantageously, these particles can move slightly relative to each other, which improves the quality of the cushioning.

In one variant, the at least one housing comprises one or several void(s) between the particles.

Indeed, when the particles have at least one dimension of the order of mm and/or have an irregular shape, empty spaces are present between the particles disposed in the at least one textile pocket before the step of thermocompressing the at least one textile sole element. The distribution and volumes of these voids are modified, particularly the volumes are reduced, after thermocompression, but these voids can partially remain.

These spaces are advantageously spaces in which the particles can deform and/or move, which improves the cushioning properties.

When there are several housings, they can each comprise one or several void(s) between the particles.

In one variant, the housing, in particular textile housing, is a longitudinal housing, particularly extends at least partly in a heel region of the sole assembly element or at least partly in a forefoot region of the sole assembly element.

The housing can be a longitudinal housing extending in the heel region of the sole assembly element, for example between the rear edge of the heel region and a front edge of the heel region, that is to say on the line of the midfoot region.

The housing can be a longitudinal housing extending in the forefoot region of the sole assembly element, for example between a rear edge of the forefoot region, and the front edge of the forefoot region.

The housing can also be a longitudinal housing extending in the mid-foot region of the sole assembly element, for example between the rear edge of the mid-foot region, and the front edge of the mid-foot region.

The sole element can also comprise several longitudinal housings substantially parallel to each other, and each receiving particles.

The housing(s) can be longitudinal and/or transverse and/or vertical.

In one variant, the textile sole element extends at least partly in a heel region of the sole assembly element, at least partly in a midfoot region of the sole assembly element, and at least partly in a forefoot region of the sole assembly element, and the textile sole element extends between a medial edge and a lateral edge of the sole assembly element.

Advantageously, the textile sole element and/or the sole assembly element has/have the general shape of a classic sole, and thus faces the entire lower surface of the user's foot.

In one variant, the at least one housing, in particular textile housing, is a transverse or longitudinal housing, particularly extends at least partly in a heel region of the sole assembly element and/or at least partly in a forefoot region of the sole assembly element and/or at least partly in a midfoot region of the sole assembly element.

The transverse housing preferably extends between the medial edge and the lateral edge of the sole assembly element.

Preferably, the at least one longitudinal housing extends substantially parallel to the longitudinal axis Ls or ls or L.

Preferably, the at least one transverse housing extends substantially parallel to the transverse axis ts or Ts or T.

In one variant, the at least one textile, in particular knitted, sole element is thermocompressed.

Advantageously, the textile sole element being thermocompressed, the pressure and the heat applied, in particular in a combined manner, make it possible to mold the textile sole element according to a determined configuration, and to form inner and/or outer faces with negative and/or positive cavity/cavities.

The present disclosure relates, according to a second aspect, to a footwear article comprising a sole assembly element according to any one of the variants of embodiment, or embodiments, or definitions according to the first aspect of the present disclosure.

Advantageously, the footwear article comprises an upper, particularly as described in the present text.

Advantageously, the sole assembly element can be fixed to the upper of the footwear article, particularly in an irreversible manner, or can be fixed to the upper in a removable manner so as to be separated from the upper of the footwear article.

The sole assembly element can thus be disposed on demand in the foot-receiving void formed by the upper. The footwear article is preferably a footwear article for the practice of a sport.

The upper can be an upper comprising a covering part wrapping all or part of the top of the foot but not comprising a sole part coming under the foot of the wearer of the footwear article.

The upper can be an upper comprising a covering part wrapping all or part of the top of the foot, and comprising a sole part coming under the foot of the wearer of the footwear article, preferably the sole part is in textile connection with the covering part.

The upper can comprise a textile tubular, particularly knitted, part or several textile tubular, preferably knitted, parts, the tubular parts being at least partly superimposed. Preferably, the tubular part(s) each comprise(s) one or several at least partly hot-melted yarn(s).

In one embodiment, the upper comprises at least a first knitted sock, and optionally a second knitted sock and/or a textile tubular part, which are particularly substantially superimposed.

The (first) sock and/or the second sock each comprise(s) one or several at least partly hot-melted yarn(s).

The upper can be a textile upper of unitary textile construction, particularly unitary knitted construction.

The tubular part and/or the first sock and/or the second sock can be a textile piece of unitary textile construction, particularly a knitted piece of unitary knitted construction.

The expressions “first sock” and “sock” are used interchangeably and therefore equivalent in the present text.

The footwear article comprises a rear edge, a front edge, a medial edge and a lateral edge, the rear and front edges being disposed between the medial and lateral edges.

The footwear article preferably comprises a longitudinal axis L extending between its rear edge and its front edge, and passing between the medial and lateral edges.

The footwear article preferably comprises a transverse axis T extending between the medial edge and the lateral edge, and passing between the front and rear edges.

Preferably, the longitudinal axis L is intersecting, particularly substantially perpendicular to, the transverse axis T.

Preferably, the rear edge of the footwear article corresponds to the rear edge of the foot, the front edge corresponds to the front edge of the foot, the lateral edge corresponds to the outer edge of the foot, and the medial edge corresponds to the inner edge of the foot.

The footwear article comprises a sole structure comprising a heel region, a midfoot region, and a forefoot region.

In one variant, the footwear article comprises an upper comprising at least a first textile element comprising a knitted tubular part, and the knitted tubular part comprises one or several at least partly hot-melted yarn(s).

The first textile element can be the textile tubular part and/or the first sock and/or the second sock described above.

In one variant, the first textile element is a knitted sock, and the sole assembly element is at least a part of a midsole and/or of an outsole.

In one variant, the at least one textile sole element of the sole assembly element is in textile, in particular knitted, connection with the first textile element of the upper.

Advantageously, the textile sole element and the first textile element of the upper are of unitary textile construction, particularly of unitary knitted construction.

In a first embodiment, the first textile element of the upper is a knitted sock, and the textile sole element is in textile connection with the knitted sole part of the knitted sock.

The knitted sole part of the sock can thus form all or part of the upper textile layer of one or several housings, and the textile sole element can be the lower textile layer of the housing(s).

In a second embodiment, the first textile element is a knitted sock and comprises a through opening, and the textile sole element comprises a knitted tubular part in connection, in particular knitted connection, with the through opening.

The through opening can be disposed in the heel region or the forefoot region of the knitted sole part of the knitted sock. Preferably, the tubular part of the textile sole element comprises a through opening in connection, in particular knitted connection, with the through opening of the knitted sole part.

The knitted tubular part of the textile sole element can also comprise another through opening. Preferably the through opening(s) of the knitted tubular part is/are closed, particularly by knitting or using a stitching or a welding (for example ultrasonic, high-frequency or thermal welding) to form a housing. One or several fixing areas, for example by stitching or by welding, can be arranged on the knitted tubular part to form another housing or several other housings, each receiving particles.

In one variant, the first textile element comprises a first knitted sock and a second knitted sock which are substantially at least partly superimposed.

Preferably, the ratio of the mass of the melted material derived from the at least partly hot-melted yarn(s) to the total mass of the first knitted sock is less than or equal to 50%.

Preferably, the ratio of the mass of the melted material derived from the at least partly hot-melted yarn(s) to the total mass of the second knitted sock is greater than or equal to 80%, more preferably greater than or equal to 90%, in particular greater than or equal to 95%, for example of the order of 100%.

Preferably, the first knitted sock is oriented facing the void of the footwear article receiving the foot.

Preferably, the second knitted sock is oriented towards the outside of the footwear article.

The footwear article can comprise at least one sole assembly element disposed between the sole part of the second knitted sock and an outsole.

The footwear article can comprise a midsole disposed between the sole part of the second knitted sock and at least one sole assembly element, preferably the sole assembly element is an outsole or forms at least part of an outsole.

In one sub-variant, the first textile element comprises a first knitted sock and a second knitted sock, and the sole assembly element is disposed between the sole part of the first knitted sock and the sole part of the second knitted sock.

Advantageously, the second knitted sock accommodates in its interior volume the textile sole assembly element and the first textile sock.

In one variant, the footwear article comprises a foot-receiving void configured to receive a foot, and the sole assembly element is removable and configured to be disposed in the foot-receiving void.

In one embodiment, the sole assembly element is a midsole and/or an insole.

The present disclosure relates, according to a third aspect, to a method for manufacturing a sole assembly element, in particular according to any one of the variants of embodiment, embodiments or definitions according to the first aspect of the present disclosure and/or to the second aspect of the present disclosure, comprising:

• • (i) providing at least one textile sole element comprising one or several at least partly thermofusible yarn(s) and comprising at least one pocket, and particles;
  • (ii) disposing the particles in the at least one pocket;
  • (iii) molding the textile sole element comprising one or several at least partly thermofusible yarn(s);
  • (iv) obtaining a sole assembly element comprising at least the textile sole element comprising one or several at least partly hot-melted yarn(s) and at least one housing receiving the particles.

Preferably, step (iii) is a thermocompression molding step.

Preferably, the textile sole element is disposed in a mold structure comprising a sole cavity to be imparted to the textile sole element, particularly to its outer face. Then, the textile sole element is heated to a heating temperature Tc higher than or equal to the melting temperature of the thermofusible material of the at least partly thermofusible yarn(s) that the textile sole element comprises, and a pressure is applied to the textile sole element so as to force it according to the cavity of the mold structure, the melted material derived from the yarn(s) flows into the cavity. The melted material, derived from the at least partly thermofusible yarn(s) of the housing, closes and consolidates at least partly the housing.

Depending on the sole cavity of the mold structure, it is possible to subdivide the at least one pocket into several thermocompressed housings. The particles are then distributed in the different housings. It is also possible that the textile sole element comprises several textile pockets, possibly each filled of/comprising particles, or at least one of the pockets of which comprises particles, and that step (iii) participates in the final shaping of these pockets by the melting of the at least thermofusible yarn(s) they comprise for the formation of several housings.

Preferably, a pocket is subdivided into several communicating housings (that is to say the volumes for receiving these housings communicate together).

Preferably, the textile sole element comprises at least two textile pockets, and the at least partly hot-melted textile sole element comprises at least two non-communicating housings (that is to say whose receiving volumes do not communicate together). In this case, a pocket can comprise several housing communicating together.

The pressure can be applied for example using an inflatable bladder, for example made of silicone or in a very elastic material capable of recovering its initial shape after deformation.

Alternatively, the pressure can be applied in a conventional manner using a press.

Preferably, one or several textile sole element(s), and possibly one or several sole member(s), is/are disposed in the mold structure. Heating is performed to the temperature Tc in order to melt the thermofusible material of the yarn(s), and the inflatable bladder is inflated (for example the inflation pressure is from 4 to 6 bars) or a pressure via a press is applied (also applying approximately 4 to 6 bars) to directly or indirectly press the textile sole element(s) against the sole cavity of the mold structure.

The heating temperature Tc is preferably higher than or equal to 150° C. and less than or equal to 220° C., more preferably less than or equal to 200° C., preferably less than or equal to 190° C., for example between 170° C. and 190° C.

The temperature Tc is determined as a function of the softening or melting temperature of the thermofusible material(s) of the at least partly thermofusible yarn(s) used.

Preferably, during step (ii), the at least one pocket comprises a filling opening for disposing particles therein. Then, when the pocket comprises the particles, the filling opening is closed, in particular by stitching or by welding (ultrasonic, thermal or high-frequency welding).

In one embodiment, the textile sole element is a textile pocket, of unitary textile, in particular knitted, construction. Particularly, the pocket comprises an opening for filling the pocket with particles. The filling opening is closed, for example by stitching or by welding (ultrasonic, high-frequency, thermal welding, etc.).

In one embodiment, the textile sole element comprises several textile pockets, in particular of unitary textile construction with the textile sole element. Preferably, each of the pockets comprises a filling opening. The filling openings are closed, by stitching or by welding (ultrasonic, high-frequency, thermal welding, etc.).

The pockets can receive particles. One or several pockets can receive a functional member, for example foam.

In one embodiment, (each) pocket comprises:

• • at least a portion of the upper textile layer of the textile sole element, and/or
  • at least a portion of the lower textile layer of the textile sole element.

The upper and lower layers can be fixed together along their peripheral edges, for example by knitting, by stitching or by welding (thermal or ultrasonic or high-frequency welding).

Preferably, the upper and lower textile layers of the sole element are substantially opposite. The lower layer is preferably oriented facing the ground, and the upper layer is preferably oriented facing the underside of the foot.

In one variant, step (iii) comprises disposing the at least one textile sole element in a mold structure comprising a sole cavity; and heating the at least one textile sole element so as to melt the at least partly thermofusible yarn(s) and substantially mold the sole cavity on an outer face of the textile sole element.

In one variant, the at least one pocket comprises one or several at least partly thermofusible yarn(s), and the at least one pocket is molded during step (iii) so as to form at least two housings receiving the particles.

The two housings are preferably communicating housings, as defined in the present text.

The present disclosure relates, according to a fourth aspect, to a method for manufacturing a footwear article, in particular according to any one of the variants of embodiment and embodiments according to a second aspect, comprising:

• • (i) providing at least one textile sole element comprising one or several at least partly thermofusible yarn(s) and comprising at least one pocket, particles, and at least one first textile element comprising a tubular part comprising one or several at least partly thermofusible yarns(s);
  • (ii) disposing the particles in the at least one pocket;
  • (iii) molding the at least one textile sole element comprising one or several at least partly thermofusible yarn(s);
  • (iv) molding the at least one first textile element comprising one or several at least partly thermofusible yarn(s);
  • step (iii) and step (iv) are carried out separately or carried out in a single molding step;
  • (v) obtaining a footwear article comprising a sole assembly element comprising at least the textile sole element comprising one or several at least partly hot-melted yarn(s), and at least one housing receiving the particles, and comprising an upper comprising the at least one first textile element comprising one or several at least partly hot-melted yarn(s).

As described with reference to the first aspect of the present disclosure, the sole assembly element can be thermocompressed in a first step, then the first textile element of the upper can be thermocompressed or thermoformed in a second step, and the sole assembly element can then be fixed to the upper. The fixing can be performed by stitching and/or by bonding or by welding (for example: thermal or ultrasonic or high-frequency welding).

The sole assembly element can also be thermocompressed, then fixed to the upper during the thermoforming or the thermocompression of the latter. The melted or softened material derived from the yarns, from the sole assembly element and/or from the upper acts as a bonding agent.

The sole assembly element can also be thermocompressed at the same time as the thermocompression step carried out on the at least one first textile element. In this case, the mold structure is adapted to receive the textile sole element(s) as well as the first textile element of the upper. The mold structure can thus comprise two or three mold parts forming a molding volume configured to receive a foot-shaped preform. The first textile element of the upper is thus disposed on the preform, and the textile sole element(s) is/are disposed between the sole part of the preform, and one or several mold parts.

The thermocompression comprises the combined application of heat to melt the at least partly thermofusible yarn(s) (for example at a temperature comprised between 150° C. and 220° C., in particular between 180° C. and 190° C.), and of the pressure (for example between 4 bars to 6 bars). During cooling, the textile sole element(s) and/or the first textile element of the upper is/are held, possibly under the application of a pressure (for example between 4 and 6 bars), in the mold structure, and is/are stiffened to the shape of the mold structure.

The thermoforming comprises the application of heat to soften the at least partly thermofusible yarn(s) of the first textile element of the upper previously disposed on a foot-shaped preform. Upon cooling, the upper is consolidated and stiffened to the shape of the preform.

The definitions, variants of embodiment, and embodiments according to the first, second, third and fourth aspects can be combined with each other, independently of each other, unless otherwise specified.

Particularly, the particles and/or textile sole element and/or sole assembly element and/or yarn(s) according to the second and/or third and/or fourth aspect(s) of the present disclosure is/are defined according to any one of the variants, embodiments and definitions with reference to the first aspect of the present disclosure.

DESCRIPTION OF THE DRAWINGS

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

FIG. 1 schematically illustrates, in a side view, a first example of a textile sole element not comprising particles, before thermocompression, according to the present disclosure;

FIG. 2 schematically illustrates, according to section plane II-II, the first example of a textile sole element of FIG. 1, before thermocompression, according to the present disclosure;

FIG. 3 schematically represents, in side view, the first example of a textile sole element represented in FIG. 1 comprising particles, before thermocompression;

FIG. 4 schematically represents, in perspective, the first example of a textile sole element represented in FIG. 1 after thermocompression;

FIG. 5 schematically represents, according to the section plane V-V of FIG. 4, the first example of a textile sole element after thermocompression;

FIG. 6 schematically represents, in top view, a second example of a textile sole element according to the present disclosure without particles, and before thermocompression;

FIG. 7 schematically represents the second example of a textile sole according to the section plane VII-VII represented in FIG. 6;

FIG. 8 schematically represents, in top view, a third example of a textile sole element according to the present disclosure, before thermocompression;

FIG. 9 schematically represents the third example of a textile sole element according to the section plane IX-IX, before thermocompression;

FIG. 10 schematically represents the third example of a textile sole element, after thermocompression;

FIG. 11 schematically represents the third example of a textile sole element according to the section plane XI-XI, after thermocompression;

FIG. 12 schematically illustrates, in side view, a first example of an assembly comprising a sole assembly element according to the present disclosure for the manufacture of a footwear article, before thermocompression;

FIG. 13 schematically illustrates, in side view, a second example of an assembly comprising a sole assembly element according to the present disclosure for the manufacture of a footwear article, before thermocompression;

FIG. 14 schematically illustrates, in side view, a first example of a footwear article after thermocompression;

FIG. 15 schematically illustrates, in bottom view, the first example of a footwear article after thermocompression.

DETAILED DESCRIPTION

FIG. 1 represents a first example of a textile sole element 10, not thermocompressed and empty, comprising a knitted tubular part 12. In this specific example, the knitted tubular part 12 has a cross section of a substantially constant diameter d11 over its entire length l11. The tubular part 12 comprises an open front end 14 and an open rear end 16 and forms in this specific example a single pocket. The tubular part 12 comprises one or several at least partly thermofusible yarn(s), particularly consists of thermofusible yarn(s), for example monofilament or multifilament yarn(s) made of thermofusible polyurethane (for example whose melting temperature is of the order of 130° C.). The diameter d11 and the length l11 of the tubular part are determined according to the regions of the foot to be covered and to the desired properties. In this specific example, the length l11 substantially corresponds to the length of a foot of a given size and the diameter d11 substantially corresponds to the width of a foot of a given size. The textile sole element 10 comprises a heel region, a midfoot region and a forefoot region. The textile sole element 10 comprises a longitudinal axis ls1 and a transverse axis ts1, substantially perpendicular to each other.

The tubular part 12 comprises an upper textile layer 18 and a lower textile layer 20, represented in FIGS. 2 and 3, and delimiting a knitted pocket 22. The upper 18 and lower 20 layers are substantially opposite to each other and fixed together along their lateral 18a, 20a and medial 18b, 20b borders by knitting (or by stitching or by welding). The front end 14 is closed according to a fixing area 14a, which can be made during the knitting of the tubular part 12 or by stitching or by welding (ultrasonic, high-frequency, thermal welding for example). Then, the tubular part 12, forming the knitted pocket 22, is filled with a determined amount of particles 30. The open rear end 16 is then closed according to a fixing area 16a, which can be made similarly to the fixing area 14a. As a specific example, the textile sole element 10 comprising particles 30 which are wood sawdust, weighs approximately 100 g.

The textile sole element 10 can then undergo a thermocompression molding step during which, the textile sole element 10 being disposed in a mold structure, heat is applied so as to melt the at least partly thermofusible yarn(s) and a pressure is applied so as to mold the textile sole element 10 to the shape of a sole cavity of the mold structure. The heating temperature Tc is for example of the order of 200-220° C. and the pressure applied is of the order of 4 to 6 bars. The pressure can be applied by an inflatable bladder or using a conventional press.

A sole assembly element 40 is thus obtained comprising a textile sole element 11 comprising one or several at least partly hot-melted, in this specific example completely hot-melted, yarn(s) as well as several housings 50, 51, 52, 53 in which the particles 30 have been distributed under the effect of the pressure exerted. The textile sole element 11 comprises an upper textile layer 19 comprising one or several at least partly hot-melted yarn(s) forming its outer face 41, and a lower textile layer 21 comprising one or several at least partly hot-melted yarn(s) forming its inner face 42.

The textile sole element 11 has a thickness e1. The housings 52 and 53 are represented in more detail in FIG. 5. The housing 52 comprises an upper partition 52a, a lower partition 52b and lateral partitions 52c, 52d, 52e, 52f, 52g, each of these partitions consists of one or several hot-melted yarn(s). Likewise, the housing 53 comprises an upper partition 53a, a lower partition 53b and lateral partitions 53c, 53d, 53e, each of these partitions consists of one or several hot-melted yarn(s). It would also be possible that these partitions comprise non-hot-melted, and/or partially hot-melted yarns, depending on the desired properties. The partitions can be different from each other due to the yarns they comprise. The housings 50-53 communicate with each other. The housing 52 communicates with the housing 53. The air, and possibly particles if they are mobile, can thus flow from the housing 52 towards the housing 53, and the two other housings 50 and 51. In this specific example, the sole cavity of the mold structure and the pressure applied during pressing are determined so as to form grooves (negative cavities) according to the outer face 41 and to the inner face 42 of the sole assembly element 40. A groove 46 thus separates the upper partitions 52a and 53a, and a groove 56 separates the lower partitions 52b and 53b.

The textile sole element 11 comprises a rear edge 11a, a lateral edge 11b, a medial edge 11c and a front edge 11d. In this specific example, the rear border 11a extends from the heel region 12a towards the front border 11d of the forefoot region 12c by passing through the midfoot region 12c. The lateral edge 11b corresponds to the lateral edge of a footwear article and the medial edge 11c corresponds to the medial edge of a footwear article.

The sole assembly element 40 comprises a longitudinal axis Ls1 substantially parallel to the longitudinal axis ls1 of the textile sole element 11 (identical to that of the non-thermocompressed textile sole element 10), and a transverse axis Ts1 substantially parallel to the transverse axis ts1 of the textile sole element 11 (identical to that of the non-thermocompressed textile sole element 10).

The number, size and configuration of the housings 50-53 vary depending on the properties and aesthetics sought.

It is also possible to thermocompress the textile sole element 10 at the same time as a first textile element of an upper as will be described below.

In this specific example, the outer 41 and inner 42 faces of the sole assembly element 11 comprise a sole cavity. It is possible that only one of the two faces 41 and 42 comprises a sole cavity while the other is substantially smooth.

The particles 30 can be wood sawdust, for example with a size on average from 1 mm to 3 mm.

The particles 30 can alternatively be beads in an expanded polymer, particularly made of expanded polyurethane or expanded polyamide. The beads are distinct/separated from each other during the filling of the pocket, and are molded following thermocompression so as to be at least partly hot-melted. The beads form a functional insert providing cushioning and ensuring the midsole function. The outsole function is ensured at least partly by the at least partly hot-melted textile layer 21. One or several additional outsole element(s) can be attached according to one of the faces of the sole assembly element 40.

The second example of textile sole element 70 differs from the first example of textile sole 10 due to its general shape. The textile sole element 70 is a knitted tubular part but whose cross section varies so as to substantially follow the general shape of a foot. The tubular part forms a single knitted pocket 75 whose front 72 and rear 74 ends can be open at the outlet of the knitting machine. One of the two ends is however closed during knitting, or after knitting by stitching or by welding (thermal or ultrasonic or high-frequency welding) but before the filling with particles 80. The end left open is then closed (by stitching or by welding) after the filling with particles 80. The ends 72 and 74 are closed according to fixing areas 72a and 74a. The textile sole element 70 comprises an upper textile layer 85 and a lower textile layer 90 each comprising one of the at least partly thermofusible yarns, particularly consist of thermofusible yarns.

The textile sole element 70 has a longitudinal axis ls2, and a transverse axis ts2.

The textile sole element 70 can be thermocompressed in an equivalent manner to the textile sole element 10 so as to form a textile sole element comprising one or several at least partly hot-melted yarn(s) and several housings communicating together.

The particles 80 can be similar to the particles 30.

The third example of textile sole element 100 is a knitted tubular part whose cross section varies in order to have a general foot shape and having two front 100a and rear 100b ends. The textile sole element 100 comprises pockets 105, 107 and 109 delimited by the lateral 101 and medial 102 edges as well as the fixing areas, particularly knitted areas 110 and 115. The pockets 105, 107 and 109 are longitudinal pockets extending parallel to the longitudinal axis ls3 of the textile sole element 100. The longitudinal axis ls3 is substantially perpendicular to the transverse axis ts3 of the textile sole element 100.

The textile sole element 100 comprises an upper textile layer 120 and a lower textile layer 122 in connection along their medial 102 and lateral 101 borders by knitting. The upper and lower layers 120 and 122 are in connection, knitted connection or connection via stitching or welding (thermal, ultrasonic, or high-frequency welding), with each other also according to fixing areas 110 and 115. The pockets 105, 107 and 109 are filled respectively with particles 90, 92 and 94, for example from a front or rear open end 100a or 100b of the textile sole element 100 or one or several other filling opening(s) provided for this purpose. The open end(s) for the filling, once the textile sole element 100 comprising the particles 90, 92 and 94, is/are closed.

Each pocket 105, 107 and 109 comprises a determined amount of particles, which can be identical or different from one pocket to another. The textile sole element 100 has a thickness e2. The textile sole element 100, and therefore the upper and lower layers 120 and 122, consist of preferably thermofusible yarns, for example monofilament or multifilament yarns made of polyurethane. The textile sole element 100 undergoes a thermocompression step as described above with a mold structure having a specific sole cavity. The obtained sole assembly element 130 comprises a textile sole element 133 comprising one or several at least partly hot-melted, preferably entirely hot-melted, yarn(s). The textile sole element 133 comprises housings 132, 134 and 136 which are longitudinal because they are disposed parallel to the longitudinal axis ls3 of the textile sole element 133 and to the axis Ls3 of the sole assembly element 130. These housings 132, 134 and 136 comprise particles 30 which are distributed as a function of the pressure exerted. In this specific example, each pocket is thermocompressed into a housing. It is possible, depending on the cavity of the mold structure, that a pocket is thermocompressed so as to form several housings which are communicating.

The housings 132, 134 and 136 are in this embodiment non-communicating.

In FIG. 11, it is observed that the housing 136 comprises an upper partition 136a, a lower partition 136b and lateral partitions 136c and 136d. The upper partition 136a comprises a portion of the upper textile layer 120 which is wholly or partly hot-melted. The lower partition 136b comprises a portion of the lower textile layer 122, which is wholly or partly hot-melted. The lateral partitions comprise portions of the wholly or partly hot-melted upper and/or lower layers 122 and 120.

The particles 90, 92 and 94 can be similar or different in colors or natures. The upper and/or lower partitions of the housings 132, 134 and 136 can be transparent in order to visualize the particles.

The particles 90, 92 and 94 can thus be waste recycled from sports shoes and/or textiles for clothing. After thermocompression of the textile sole element 130, the particles can comprise partly hot-melted particles and non-hot-melted particles and therefore mobile relative to each other.

The textile sole element 133 extends into a heel region 142 of the sole assembly element 130, into a midfoot region 152 of the sole assembly element 130, and a forefoot region 162 of the sole assembly element 130. The textile sole element 133 extends between the medial edge 138 and the lateral edge 139 of the sole assembly element 130. The textile sole element 133 therefore comprises a heel region 140, a midfoot region 150 and a forefoot region 160.

The textile sole element 133 could be arranged differently and comprise only a heel region, or a heel region and a midfoot region. In this case, the configuration of the textile sole element 100 is arranged accordingly.

The at least partly hot-melted textile sole element 40 or 133 or sole element 70 can be fixed to an upper by stitching and/or by bonding, for example by implementing a Strobel type construction, and/or by welding (thermal or ultrasonic or high-frequency welding) reactivating the fusible material. This textile sole element can also be fixed to an upper comprising one or several at least partly thermofusible yarn(s) during the thermoforming of the upper for the shaping of the upper, or can also be thermocompressed into a single step during the thermalcompression of the upper.

The first example of assembly 300 for the manufacture of a footwear article having a longitudinal axis L1 is represented in FIG. 12 before thermocompression. This assembly 300 comprises a first textile element which is a knitted sock 310 comprising one or several at least partly thermofusible yarn(s), a textile sole element 320, such as the textile sole element 10, 70 or 100. The textile sole element 320 comprises in this specific example, a heel region, a midfoot region and a forefoot region, and extends between medial and lateral edges. The textile sole element 320 could however comprise only a heel region or a forefoot region.

The assembly 300 is disposed in a mold structure comprising at least one sole cavity. The mold structure is configured to receive the textile sole element 320 and the knitted sock 310. Heat is applied to melt the fusible material of the yarns and a pressure is applied to an inflatable bladder (for example of the order of 4-6 bars) disposed in the internal foot-receiving volume of the sock 310. The obtained footwear article (not represented) advantageously comprises an upper comprising one or several at least partly hot-melted yarn(s), and a sole assembly element comprising one or several at least partly hot-melted yarn(s), and one or several housing(s) each receiving particles. The sole assembly element can be the sole assembly element 40 of FIGS. 4 and 5 or the sole assembly element 130 of FIGS. 10 and 11. It is possible to attach an outsole along certain parts of the outer face of the sole assembly element to improve the abrasion resistance of the sole assembly element.

The second example of assembly 400 for the manufacture of a footwear article is represented in FIG. 13 before thermocompression. This assembly 400 comprises a first textile element which is a first internal knitted sock 410 disposed in the foot-receiving volume of a second external knitted sock 420. The first sock 410 and the second sock 420 can be two separate socks or in knitted connection at their openings for introducing the foot. The assembly 400 also comprises a textile sole element 430 disposed between the sole part 415 of the first sock 410 and the sole part 425 of the second sock 420. In this specific example, the first sock comprises more than 50% by mass, particularly approximately 80% by mass, relative to its total mass of thermofusible textile material. The second sock comprises less than 50% by mass relative to its total mass of thermofusible textile material, for example of the order of 30%. The assembly 400 is disposed in a mold structure (not represented) comprising a first receiving region for receiving the textile sole element, and sole parts 415 and 425, and a second receiving region for receiving at least partly the first and second socks 410 and 420. Heat is applied to melt the fusible material of the yarns and a pressure is applied to an inflatable bladder (for example of the order of 4-6 bars) disposed in the interior of the foot-receiving volume of the second sock 420. The assembly 400 is thus sandwiched between the mold structure and the inflatable bladder, particularly in the shape of a foot. The assembly 400, still disposed in the mold structure, is left to cool to be set and stiffened. Then, the assembly 400 is demolded. The obtained sole assembly element (not represented) thus comprises the at least partly hot-melted sole part 425 and textile sole element 430. It is possible to attach an outsole along some parts of the outer face of the sole part 425 comprising at least partly hot-melted yarns to improve the abrasion resistance of the sole assembly element. The sole part 425 can comprise one or several at least partly thermofusible yarn(s) having a significant count (dtex) or comprise two superimposed knitted textile layers each comprising one or several at least partly thermofusible yarn(s) in order to provide a significant amount of hot-melted material. This arrangement makes it possible to reinforce the outer face of the sole assembly element. The assembly 400 can also comprise a sole member, for example an injected plate, particularly disposed in the heel region of the assembly, disposed between the sole part 425 of the second sock 420 and the textile sole element 430. The assembly 400 can also comprise a sole member, for example a shock-absorbing gel plate, particularly disposed in the heel or forefoot region, and disposed between the textile sole element 430 and the sole part 415 of the first sock 410.

The first example of footwear article 500 represented in FIGS. 14 and 15 comprises an upper 510 and a sole assembly element 520. The upper 510 is obtained by thermoforming an assembly comprising a first knitted inner sock and a second knitted outer sock receiving in its interior volume the first knitted inner sock. The sole assembly element 520 can be a thermocompressed sole assembly element independently of the assembly intended to form the upper, such as the sole assembly element 40 or 130. The sole assembly element 520 is represented in FIG. 15 viewed along its outer face 521. In this specific example, the sole assembly element 520 comprises five housings 522 to 526 each comprising particles 540-544 visible through the substantially transparent or translucent upper partitions of the housings 522-526. The sole assembly element 520 is then fixed by bonding or by stitching to the upper 510. The sole assembly element 520 can also be fixed to the upper during thermoforming or thermocompression of the partly textile assembly intended to form the upper 510. The hot transformation of the partly textile assembly intended to form the upper, reactivates the fusible material derived from the at least partly thermofusible yarn(s) of the sole element 520, possibly with the possible application of pressure, which makes it possible to fix the sole assembly element 520 to the sole part of the upper 510.

The particles 540-544 can be similar or different (colors, compositions, etc.), preferably the particles are wood sawdust particles whose size is comprised between 1 mm and 8 mm. The housings 522-526 are preferably communicating and thus form a closed assembly receiving the particles. The housings are however partially separated by grooves forming lateral partitions as described with reference to FIG. 5.