DESCRIPTION

TECHNICAL FIELD OF THE INVENTION

[0001] The present invention relates to an inner shoe for a sports footwear, such as for example an inner shoe for a ski boot. Furthermore, the present invention relates to a sports footwear comprising said inner shoe.

BACKGROUND OF THE INVENTION

[0002] Sports footwear, such as for example ski boots, typically comprise a substantially rigid outer shell into which there is generally removably inserted a substantially soft inner shoe.

[0003] The outer shell is adapted to transfer the movements of the body of the user to the ski, while the inner shoe is inserted into the outer shell so as to make the fitting of the sports footwear more comfortable.

[0004] Such inner shoes for sports footwear are generally known in the state of the art. [0005] Typically, the material used to form the inner shoes, or portions thereof, is preferably a foam, or an expanded material generally having open or closed cells, so as to provide desired characteristics, such as appropriate stiffness which allows flexibility together with comfort, lightness, thermal insulation, and the like.

[0006] In particular, the inner shoes for ski boots are manufactured using various types of methods, generally depending on the type of material used.

[0007] For example, the inner shoes may be manufactured by joining portions provided separately and/or by thermoforming.

[0008] The manufacturing of inner shoes, or portions thereof, by thermoforming represents a significant development by virtue of the fact that thermoforming reduces the processing costs and allows to obtain inner shoes, or portions thereof, which are substantially finished immediately after the last thermoforming step, having any desired shape depending on the shape of the foot with which they are operatively associated.

[0009] However, manufacturing by thermoforming inner shoes, or portions thereof, requires using thermoplastic material, limiting the choice of the type of materials as a result.

[0010] As a matter of fact, the inner shoes, or portions thereof, may be manufactured by thermoforming typically starting from flat sheets made of thermoplastic material, preferably expanded, which are obtained by moulding or extruding. Such flat sheets made of thermoplastic material, such as for example polyethylene (PE) or ethylene-vinyl- acetate (EVA) copolymer, possibly cut-out, are subjected to a thermoforming step so as to substantially thermally soften or melt the material, press the latter, and subsequently cool it to obtain a desired three-dimensional shape (that is, not exclusively planar) which is adapted to receive the foot of the user or portions thereof, such as for example the malleolar region of the foot.

[0011] Otherwise, the non-thermoplastic materials cannot be processed by thermoforming given that they do not provide for temperatures for softening or melting the material so as to obtain a desired three-dimensional shape following pressing and subsequent cooling, like it instead happens in the case of thermoplastic materials as mentioned above.

[0012] Therefore, such non-thermoplastic materials require providing for other types of manufacturing methods such as the removal of material (for example cutting, scraping, milling, or the like) to obtain a desired three-dimensional shape adapted to receive the foot of the user.

[0013] As a matter of fact, the inner shoes, or portions thereof, may be manufactured starting from sheets made of non-thermoplastic material, preferably expanded, such as for example polyurethane (PU) or polyurethane-based agglomerated material. Such sheets, possibly cut-out, are subjected to a step of surface removal of material so as to obtain a desired three-dimensional shape.

[0014] With respect to the thermoforming techniques, the techniques which provide for removing the material disadvantageously increase the processing costs/complexity and generate high amounts of waste material from the removing step.

[0015] However, it would be advantageous to use non-thermoplastic materials for manufacturing inner shoes, or portions thereof, given that they offer further and different characteristics or advantages with respect to thermoplastic materials.

[0016] For example, with respect to the thermoplastic materials, the polyurethane-based non-thermoplastic materials offer better comfort characteristics. Furthermore, with respect to the thermoplastic materials, polyurethane-based non-thermoplastic materials offer greater durability of the resilience characteristics given that they do not have the tendency to flatten or be compressed over time after multiple stresses.

[0017] Furthermore, in recent years producers and consumers have become more conscious of the need to develop solutions with lower environmental impact for a more sustainable use of resources, preferring products and processes which provide for recycling or reusing materials.

[0018] Therefore, there arises the need to provide solutions which allow to use the materials obtained from recycling and/or reuse.

[0019] As a result, there arises the need to provide a solution that at least overcomes one of the drawbacks described above.

SUMMARY OF THE INVENTION

[0020] The task of the present invention is to provide an inner shoe for a sports footwear, such as for example an inner shoe for a ski boot, which provides for a construction adapted to allow the manufacturing thereof by thermoforming using materials that are not exclusively of the thermoplastic type.

[0021 ] In the context of the task outlined above, an object of the present invention relates to an inner shoe which provides for a construction which allows to obtain a desired three- dimensional shape adapted to receive the foot of the user.

[0022] A further object relates to an inner shoe which provides for a construction adapted to allow a wide range of the materials with which it is formed.

[0023] A further object relates to an inner shoe which provides for a construction adapted to allow to use high amounts of materials obtained from recycling and/or reuse.

[0024] A further object relates to an inner shoe which provides for a construction adapted to provide comfort.

[0025] A further object relates to an inner shoe which provides for a construction adapted to provide lightness.

[0026] A further object relates to an inner shoe which provides for a construction having a degree of stiffness adapted to simultaneously provide appropriate support and flexibility. [0027] A further object relates to an inner shoe which provides for an alternative construction with respect to those known to date in the state of the art.

[0028] A further object relates to an inner shoe which provides for a construction that is simple to design and manufacture.

[0029] The aforementioned tasks and others which will be more apparent hereinafter in the description, are attained through an inner shoe as defined in claim 1 , and a sports footwear comprising it. Preferred embodiments are defined in the dependent claims.

BRIEF DESCRIPTION OF THE FIGURES

[0030] The further characteristics and advantages of the inner shoe for a sports footwear, according to the present invention, will become more apparent in the following description relating to embodiments provided purely by way of non-limiting example with reference to the following figures, wherein:

- Fig. 1 shows a lateral view of a sports footwear comprising an inner shoe, according to a first preferred embodiment of the present invention;

- Fig. 2 shows a lateral view of the inner shoe of Fig. 1 , according to the first preferred embodiment of the present invention;

- Fig. 3 shows an enlarged cross-section of a part of the body of the inner shoe, taken along line A-A of Fig. 2;

- Fig. 4 shows an enlarged cross-section of a part of the body of an inner shoe, according to a second preferred embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0031] In the description below there will be used expressions such as “horizontal”, “vertical”, “upper”, “lower”, “front”, “rear” or the like; the person skilled in the art will have no difficulty understanding that such expressions refer to the orientation or arrangement of the inner shoe and the components thereof as shown in the attached figures.

[0032] Furthermore, in the description below reference will be made to an inner shoe for a ski boot. However, the invention may also apply to inner shoes for various types of ski boots, such as for example boots for mountaineering, alpine skiing, freeride and freetouring, as well as other types of sports footwear, such as for example snowboard boots, cross-country ski boots, mountain or rock-climbing boots, ice or roller skate boots, and the like.

[0033] Fig. 1 shows a sports footwear 1000, such as for example a ski boot, according to a preferred embodiment of the present invention. The sports footwear 1000 comprises a substantially rigid outer shell 200 which is configured to preferably removably receive - therein - a substantially soft inner shoe 100.

[0034] With reference to Fig. 2, there is shown the inner shoe 100, according to a first preferred embodiment of the present invention, of the sports footwear 1000 of Fig. 1 .

[0035] The inner shoe 100 is made of substantially soft and foldable material. The inner shoe 100 provides for an approximately sock-like shape which is tubular in a crosssection, and approximately L-shaped in a longitudinal cross-section.

[0036] Still with reference to Fig. 2, the inner shoe 100 includes a body 10 defining a cavity 12 configured to receive - in operating conditions - the foot of a user. In particular, the body 10 of the inner shoe 100 is shaped so that it can be inserted, preferably removably, into the shell 200 of the sports footwear 1000. [0037] The body 10 of the inner shoe 100 provides for one or more wall elements substantially adapted to define the cavity 12.

[0038] In particular, in the present embodiment, the body 10 includes a sole wall element 14 and an upper wall element 16, that is respectively a base part adapted to operatively receive the sole of the foot, and an upper part adapted to at least partially operatively cover the rest of the foot and preferably the lower part of the leg of the user.

[0039] The upper wall element 16 is connected to the sole wall element 14 so as to substantially define the cavity 12. In particular, the upper wall element 16 and the sole wall element 14 each provide for a respective inner surface, substantially defining the cavity 12, and a respective outer surface opposite to the inner one.

[0040] The upper wall element 16 and the sole wall element 14 may provide for different types of constructions.

[0041] For example, the upper wall element 16 may be defined by a single wall element adapted to cover the foot, or it may be defined by a plurality of wall elements or portions, provided separately and subsequently joined or connected to each other.

[0042] Similarly, the sole wall element 14 may be defined by a single wall element adapted to cover the sole of the foot, or it may be defined by a plurality of wall elements or portions, provided separately and subsequently joined or connected to each other.

[0043] Alternatively, the upper wall element 16 and the sole wall element 14 may be defined by a single wall element adapted to cover the entirety of the foot of the user.

[0044] Typically, the upper wall element 16 comprises a lower portion 16L, adapted to cover the foot, and an upper portion 16U, adapted to substantially cover the lower part of the leg of the user.

[0045] Preferably, the lower portion 16L in turn comprises a front portion 16F, an intermediate portion 16M and a rear portion 16R which are connected to each other extending - in this order - in the horizontal direction from the tip toward the heel of the foot of the user.

[0046] The upper portion 16U substantially extends in the vertical direction starting from the malleolar region from the rear portion 16R of the lower portion 16L. The upper portion 16U provides for an upper opening 18U and generally a front opening 18F connected to each other. Furthermore, the upper portion 16U preferably comprises a tab portion 16T adapted to engage the front opening 18F, and which is substantially fixed at the front portion16F of the lower portion 16L.

[0047] According to the present invention, in particular with reference to Fig. 3 which shows an enlarged schematic view of a cross-section of a part of the body 10 taken along line A-A of Fig. 2, at least one of said portions of at least one of the upper wall element 16 and of the sole wall element 14 provides for a multilayer structure 20 including a first layer 22 and a second layer 24 coupled to each other. In the present embodiment, the multilayer structure 20 provides for an arrangement wherein the second layer 24 is substantially interposed between the first layer 22 and the cavity 12 of the body 10.

[0048] The first layer 22 comprises a thermoplastic flexible material (i.e. a thermoformable flexible material). The first substantially sheet-like layer 22 has a first distal face 22a and a first coupling face 22b opposite to said first distal face 22a.

[0049] The second layer 24 comprises a non-thermoplastic agglomerated flexible material (i.e. a non-thermoformable agglomerated flexible material). The second substantially sheet-like layer 24 has a second distal face 24a and a second coupling face 24b opposite to said second distal face 24a.

[0050] In particular, said first layer 22 and said second layer 24 are coupled by mutually joining the respective first coupling face 22b and second coupling face 24b, preferably substantially in their entirety.

[0051] In the present invention, the expression “agglomerated material” is used to indicate a flexible solid material which comprises a disorderly (that is, not-orderly) conglomerate of parts and/or granules and/or fibres, preferably obtained as industrial scraps or processing by-products, which are superficially coupled to each other possibly through a joining agent or binding compound/composition. Such parts and/or granules and/or fibres may provide for shapes and/or dimensions which are homogeneous or inhomogeneous with respect to each other. In other words, the expression “agglomerated material” is used to indicate a solid material which is obtained from parts and/or granules and/or fibres made of the same material or different materials, attributing them a certain cohesion preferably by means of compression, with or without adding substances provided with joining or binding properties, so as to allow to conform it in flexible sheets of desired thickness. An example of non-thermoplastic agglomerated flexible material is the so-called flexible expanded polyurethane agglomerate or “rebonded polyurethane foam”.

[0052] Advantageously, in this condition the inner shoe 100 provides for a construction adapted to allow the manufacturing thereof by thermoforming, using materials that are not exclusively of the thermoplastic type.

[0053] As a matter of fact, the first layer 22 and the second layer 24 being joined to each other, the latter can be conferred a desired three-dimensional shape by subjecting the multilayer structure 20 to thermoforming. In particular, the desired three-dimensional shape obtained by thermoforming the first layer 22 (made of thermoplastic material) is substantially copied by the second layer 24 (made of non-thermoplastic material).

[0054] In the present embodiment, the first layer 22 consists of said thermoplastic flexible material. In this condition, advantageously, the multilayer structure 20 has a construction that is simple to manufacture, starting from a pre-formed sheet made of thermoplastic flexible material.

[0055] In the present embodiment, the second layer 24 consists of said nonthermoplastic agglomerated flexible material. In this condition, advantageously, the multilayer structure 20 has a construction that is simple to manufacture, starting from a pre-formed sheet made of non-thermoplastic agglomerated flexible material.

[0056] Preferably, the first 22b second 24b coupling faces, respectively of the first layer 22 and of the second layer 24 are joined to each other by means of an adhesive compound or an adhesive composition. In this condition, advantageously, the multilayer structure 20 has a construction that is simple to manufacture starting from two pre-formed sheets made of any desired thermoplastic flexible material and non-thermoplastic agglomerated flexible material, by suitably selecting the type of adhesive compound or adhesive composition.

[0057] In particular, there may be provided for a forming method which firstly provides for interposing said adhesive compound or adhesive composition between the first layer 22 and the second layer 24 - provided distinct from each other- and subsequently a step for thermoforming the multilayer structure 20 which, besides providing a desired three- dimensional shape, completes the adhesion of the layers by pressing. Advantageously, this condition allows to join the first 22 and second 24 layers of the multilayer structure 20 and substantially thermoform them in a single step, with ensuing decrease in the complexity and manufacturing costs.

[0058] In a preferred embodiment, said adhesive compound or adhesive composition comprises a water-based polyurethane adhesive. This selection provides an effective joining of the first 22 and second 24 layers, especially when they are respectively made of ethylene-vinyl-acetate copolymer and polyurethane-based material.

[0059] In the present embodiment, the thermoplastic flexible material and/or nonthermoplastic agglomerated flexible material are expanded materials. Advantageously, this condition allows to provide comfort and lightness to the inner shoe 100. [0060] In a possible embodiment, the thermoplastic flexible material is selected from the group comprising thermoplastic elastomers, such as for example styrene and butadiene copolymers (TPE-S), polyolefin (TPO), co-polyesters (COPE), co-polyamides (PEBA), polyurethanes (TPU) and combinations thereof. In the present preferred embodiment, the thermoplastic flexible material is selected from the group comprising polyethylene, ethylene-vinyl-acetate copolymer, thermoplastic polyurethane, and combinations thereof. These thermoplastic materials are effectively thermoformable, preferably in the form of expanded materials, guaranteeing a degree of stiffness of the multilayer structure 20 which is adapted to simultaneously provide support and flexibility for the portions of the upper 14 and/or sole 16 wall elements of the body 10 of the inner shoe 100.

[0061] In particular, the thermoplastic flexible material preferably has a hardness comprised between 30 and 60 Shore A, or between 40 and 50 Shore A. Optionally, the thermoplastic flexible material preferably has a density comprised between about 0.1 and 0.6 g/cm ³ , or about 0.3 g/cm ³ . In the present embodiment, the thermoplastic flexible material is formed starting from a sheet made of material having, before the thermoforming step, a hardness comprised between 30 and 60 Shore A, or between 40 and 50 Shore A, and/or a density comprised between about 0.1 and 0.6 g/cm ³ , or about 0.3 g/cm ³ . Advantageously, this condition allows to obtain an appropriate balancing between stiffness of the portions of the wall elements of the body 10 (portions of the sole 14 and/or upper 16 elements), and lightness of the inner shoe 100.

[0062] Preferably, the non-thermoplastic agglomerated flexible material is a polyurethane-based agglomerated flexible material. Advantageously, this condition allows to increase the durability of the resilience characteristics of the multilayer structure 20 reducing the tendency thereof to flatten or be compressed over time after multiple stresses.

[0063] In particular, the non-thermoplastic agglomerated flexible material preferably has a density comprised between about 0.1 and 0.3 g/cm ³ , or about 0.2 g/cm ³ . Advantageously, this condition allows to obtain an appropriate balancing between the stiffness of the portions of the wall elements of the body 10, comfort and lightness of the inner shoe 100. Furthermore, with such density range the non-thermoplastic agglomerated flexible material of the second layer 24 provides for a very high foldability adapted to obtain and maintain any desired three-dimensional shape following the thermoforming of the thermoplastic flexible material of the first layer 22 of the multilayer structure 20. [0064] In the most preferred embodiment, the thermoplastic flexible material is ethylene- vinyl-acetate copolymer, and the non-thermoplastic agglomerated flexible material is a polyurethane-based material. Advantageously, this combination of materials provides an appropriate balancing between the stiffness of the portions of the wall elements of the body 10, comfort and lightness of the inner shoe 100. In particular, the ethylene-vinyl- acetate copolymer provides an elastic and/or mechanical behaviour which is particularly adapted to the low temperatures, that is to the typical use temperatures of the show 100, and at the same time the polyurethane-based material increases the comfort thereof.

[0065] Preferably, the thermoplastic flexible material and/or the non-thermoplastic agglomerated flexible material are at least partially recycled. Advantageously, this condition allows to increase the content of the recycled or reused material which is comprised in the inner shoe 100.

[0066] In particular, when an ethylene-vinyl-acetate copolymer is used as the thermoplastic flexible material, the first layer 22 may contain a by weight percentage of recycled material which is very high with respect to other thermoplastic materials, possibly greater than 70% of the total weight of the layer.

[0067] Furthermore, given that the non-thermoplastic agglomerated flexible material is preferably obtained from industrial scraps or processing by-products, the second layer 24 may contain any desired weight percentage of recycled or recovered material, possibly up to 100% of the total weight of the layer.

[0068] In particular, when polyurethane-based material such as non-thermoplastic agglomerated flexible material is used, the second layer 24 may be formed with widely available and easily obtainable material given that it is used in many industries, such as for example the furnishing industry, regarding which there arises the need to recycle or reuse end-of-life products/materials.

[0069] Therefore, advantageously, the inner shoe 100 according to the present invention provides for a construction adapted to allow the use of high amounts of materials which can be obtained recycling or reuse, having a wide range of choice on the type and source. [0070] It is clear that with respect to what has been described so far, further embodiments of the inner shoe 100 are possible without departing from the claimed scope of protection.

[0071] In particular, in the description above, the inner shoe 100 comprises a body 10 in which at least one portion of at least one of the sole 14 and/or upper 16 wall elements, provides for a multilayer structure 20 comprising two first 22 and second 24 layers. However, the multilayer structure 20 may comprise further layers.

[0072] In particular, with reference to Fig. 4, in a second embodiment, the second distal face 24a of the second layer 24 may be coupled with a third layer or lining 26 preferably flexible. This condition allows to provide the multilayer structure 20 with further characteristics.

[0073] The third flexible layer or lining 26 may be coupled by at least partially covering the second layer 24 so as to act as a humidity barrier, and/or increase the abrasion resistance characteristics thereof, and/or provide desired aesthetic characteristics, or the like. For example, the third layer or lining 26 may comprise a mesh-like element made of polyamide (PA) so as to increase the abrasion resistance characteristics.

[0074] Furthermore, the multilayer structure 20 in the attached drawings was shown with an orientation which provides for the second layer 24 substantially interposed between the first layer 22 and the cavity 12 of the body 10. However, there may be provided for a further embodiment in which the multilayer structure 20 is oriented so that the first layer 22 is substantially interposed between the second layer 24 and the cavity 12 of the body 10.

[0075] Furthermore, in the description above and in the attached drawings the upper wall element 16 of the body 10 is defined substantially by a single body. However, this embodiment shall not be deemed as limiting.

[0076] For example, each portion of the upper element 16 (lower 16L, upper 16U, front 16F, intermediate16M, rear 16R, and tab portion 16T) may be provided separately and subsequently joined to the others, for example by gluing or stitching. In particular, one or more of said portions of the upper element 16 may provide for said multilayer structure 20 according to the present invention, and other portions of the upper element 16 may not provide for said multilayer structure 20.

[0077] Alternatively, each portion of the upper element 16 (lower 16L, upper 16U, front 16F, intermediate 16M, rear 16R, and tab portion 16T) may be an insert of said upper element 16.

[0078] Furthermore, the multilayer structure 20 in Figs. 3 and 4 has been shown as a substantially planar structure for the sake of simplicity. However, the multilayer structure 20 may provide for any desired three-dimensional shape depending on the shape of the foot, or a portion of the latter, with which it is operatively associated.

[0079] In the light of the above, it is clear that significant results have been achieved, overcoming the drawbacks of the prior art, allowing to obtain an inner shoe 100 for a sports footwear 1000 which provides for a construction adapted to allow the manufacturing thereof by thermoforming using materials that are not exclusively of the thermoplastic type.

[0080] Furthermore, the inner shoe 100 according to the present invention provides for a construction which allows to obtain a desired three-dimensional shape adapted to receive the foot of the user.

[0081] Furthermore, the inner shoe 100 according to the present invention provides for a construction adapted to allow a wide range of materials with which it can be formed.

[0082] Furthermore, the inner shoe 100 according to the present invention provides for a construction adapted to allow the use of high amounts of materials obtained from recycling and/or reuse.

[0083] Furthermore, the inner shoe 100 according to the present invention provides for a construction adapted to provide comfort.

[0084] Furthermore, the inner shoe 100 according to the present invention provides for a construction adapted to provide lightness.

[0085] Furthermore, the inner shoe 100 according to the present invention provides for a construction having a degree of stiffness adapted to provide appropriate support and flexibility at the same time.

[0086] Lastly, the inner shoe 100 according to the present invention provides for a construction that is simple to design and manufacture.

[0087] Naturally, the materials and equipment used to implement the present invention, as well as the shape and dimensions of the individual components, may be the most appropriate depending on the specific requirements.