Shoe or apparel with additive manufactured element

<u>1. Technical field</u>

0001The present invention relates generally to a shoe or an apparel, to a method for manufacturing a shoe or an apparel and to an apparatus suitable for the manufacturing of a shoe or an apparel.

<u>2. Prior art</u>

0002Shoes and apparels, in particular sports shoes and sports apparels, are often manufactured from a plethora of different materials that meet highly diverse functional requirements, depending on the specific type of shoe or apparel and the respective application.

0003For example, a sports shoe usually comprises an upper and a sole. The upper may be formed of various materials, such as warp- or weft-knitted fabrics, wovens, natural or synthetic leather, or rubber, which shall provide for sufficient flexibility, breathability, waterproofness, and/or stabilization of the foot. The sole usually comprises a midsole and an outsole, for example from a thermoplastic material such as polyurethane or thermoplastic rubber, and may be secured to the upper by means of stitching, bonding, and/or mold injection.

0004Sports apparels, in particular protective gears such as shin guards, arm protectors, back protectors, knee pads for knee protection, protective headwear, or gloves, may be also provided from different materials, such as stretchable textile materials that adapt to the wearer's anatomy and thus provide a comfortable fit, and stiff materials that protect parts of the wearer's body, such as the elbow, the knee, the back, the head or the hand. For example, <patcit id="pcit0001" dnum="US9005710B"><text>US 9,005,710</text></patcit> relates to a method of three-dimensional printing and assembly of an article of apparel, footwear, or equipment. Specifically, the method relates to an article of footwear having an upper that includes 3D printing directly onto at least a first portion of an upper material and a sole formed by 3D printing onto at least a second portion of the upper material.

0005<patcit id="pcit0002" dnum="US7047668B"><text>US 7,047,668</text></patcit> relates to an article of footwear with an upper having a substrate layer and a polymer layer. The polymer layer is formed of a polymer material that infiltrates the substrate layer and is thereby secured to the substrate layer.

0006<patcit id="pcit0003" dnum="US20160168756A"><text>US 2016/0168756</text></patcit> relates to compositions of nonwoven, fibrous films or membranes based on superfine fibers for use in construction of articles. In particular, layers may be used to form a composite structure, and the layers may the bound together by (fusion) bonding, ultrasonic welding, chemical bonding, and stitching.

0007<patcit id="pcit0004" dnum="EP2630885A"><text>EP 2 630 885</text></patcit> relates to a material for a shoe upper comprising an inner polyurethane layer, an outer polyurethane layer, and a textile reinforcing layer arranged between the inner polyurethane layer and the outer polyurethane layer. The textile reinforcing layer comprises apertures through which the inner polyurethane layer and the outer polyurethane layer are connected to each other.

0008Further prior art is disclosed in <patcit id="pcit0005" dnum="WO2011080779A1"><text>WO 2011/080 779 A1</text></patcit>, <patcit id="pcit0006" dnum="DE102014116624A1"><text>DE 10 2014 116 624 A1</text></patcit>, <patcit id="pcit0007" dnum="DE60122007T2"><text>DE 601 22 007 T2</text></patcit> and <patcit id="pcit0008" dnum="WO2012006747A1"><text>WO 2012/006 747 A1</text></patcit>.

0009However, the combinations of textile materials and thermoplastic materials known from the prior art may have the disadvantage that the functional properties of the textile material are lost, when it is infiltrated with or glued to the thermoplastic material. For example, in case thermoplastic material is injection-molded, the textile material, which serves as substrate for the molding process, may suffer from thermic stress. Additional, laborious and cost-inefficient stitching and/or gluing steps may be required to secure the thermoplastic material to the textile material. Moreover, after injection-molding, gluing or stitching, the textile material cannot freely move or even stretch in the processed regions and eventually loses important functions, such as breathability and flexibility.

0010It is therefore an object of the present invention to provide a shoe or apparel which removes or at least reduces the described disadvantages of the prior art. It is a further object to provide a method for the manufacturing of a corresponding shoe or apparel, and to provide an apparatus for the manufacturing.

<u>3. Summary of the invention</u>

0011According to a first aspect of the present invention, this problem is at least partially solved by a shoe or apparel, comprising a first material layer with a first plurality of protrusions, a flexible layer with a plurality of apertures, and a second material layer, wherein the flexible layer is positioned between the first material layer and the second material layer, and wherein each protrusion of the first plurality of protrusions of the first material layer extends through at least one aperture of the plurality of apertures of the flexible layer and is connected to the second material layer.

0012By providing the first material layer with protrusions that extend through the apertures of the flexible layer, the flexible layer is not influenced by the connection to the second material layer. In particular, further functional properties of the flexible material, such as breathability, and/or stretchability are maintained. Thus, the flexible layer can provide for a sufficient ventilation and can adjust to the shape of the foot or the body of the person wearing the shoe or apparel over the whole surface the flexible layer is covering.

0013Moreover, by connecting the protrusions of the first material layer to the second material layer, while sandwiching the flexible layer, the flexible layer is secured between the first material layer and second material layer via the protrusions in a highly durable and resistant manner.

0014The flexible layer is not connected to the first material layer and the second material layer, and thereby can freely move between the first material layer and the second material layer. Thus, the flexible layer is restricted in its movement only by the protrusions extending through the apertures of the textile layer.

0015The flexible layer may freely move in a direction parallel to the first and the second material layer, wherein the movement is substantially limited to a distance determined by a plurality of gaps, each gap being formed between each protrusion and each aperture, through which the protrusion extends.

0016Furthermore, the flexible layer may freely move in a direction perpendicular to the first and second material layer, wherein the movement is limited to a distance determined by the plurality of protrusions of the first material layer or the distance between the first and second material layer.

0017Such a construction of the flexible layer being not connected to the material layers has the advantage that the flexible layer maintains its full flexibility. This can be of importance for sports shoes or sports apparels that are provided from functional textiles and that adapt to the wearer's foot or body to provide a comfortable fit.

0018The first material layer and the second material layer may not infiltrate the flexible layer outside the plurality of apertures. The apertures may each comprise a cross-sectional area ranging from 9 mm² to 100 mm².

0019At least one protrusion may have a cross-sectional area, which is at least 20 % smaller, preferably at least 40 % smaller, more preferably at least 60 % smaller, most preferably at least 80% smaller than the cross-sectional area of the aperture, through which the at least one protrusion extends. Thereby, the flexible layer maintains a high degree of movability and can well adapt to the movements of the wearer's body parts, for example the foot or the arm.

0020The flexible layer may freely stretch between the first material layer and the second material layer. Thus, the natural stretch of the flexible layer can be maintained at least to some extent, despite the first and second material layer being arranged on both sides of the flexible layer.

0021The protrusions of the first plurality of protrusions of the first material layer may each have a length ranging from 1 mm to 10 mm.

0022By providing protrusions with lengths in a range of 1 to 10 mm, the distance to the second material layer may be varied across the area of connection. Said distance between the first and the second material layer can, therefore, provide for an anatomic fit of the two material layers to the foot or the body of the person wearing the shoe or apparel.

0023The protrusions may each comprise a cross-sectional area ranging from 4 mm² to 80 mm². By varying the areas of the protrusions of the first material layer, the strength of the connection to the second material layer can be varied across the area of connection. In particular those regions that usually encounter high loads during wearing, e.g. regions of the sole during running, may be reinforced by providing connecting protrusions of increased cross-sectional area.

0024The protrusions of the first plurality of protrusions of the first material layer may be arranged to yield densities ranging from 0.5 to 5 protrusions per cm².

0025In particular those areas of the first and second material layer, which usually encounter high loads during wearing, can be reinforced by means of a higher density of protrusions.

0026The protrusions may also have varying shapes, such as cylinders and/or cuboids. The protrusions may be hollow or solid.

0027The first material layer and/or the second material layer may have a three-dimensional shape.

0028The three-dimensional shape is to be understood independent from the plurality of protrusions. For example, the first material layer or the second material layer may be formed as a midsole and may be three-dimensionally shaped to support the arch region of the foot, which is a particularly sensitive region of the foot. The three-dimensional shape, thus, supports the wear comfort and prevents fatigue and injuries.

0029The three-dimensional shaped first material layer and/or the second material layer may each have a thickness ranging from 1 mm to 30 mm along a lateral axis and/or a longitudinal axis of the first material layer and/or second material layer.

0030The thickness of the respective material layers can influence the mechanical properties of the material layers, in particular their flexibilities. By locally varying the thickness, regions that require a certain stiffness may be provided with a thicker material layer. Other regions, which require a certain flexibility to provide for a comfortable fit to the wearer, may be provided with a thinner material layer.

0031The flexible layer may have dimensions which extend beyond the first and/or second material layer. The dimensions of the first and the second material layer may also differ.

0032The flexible layer, the first material layer and the second material layer may, thus, provide different regions of a shoe or an apparel. The flexible layer may, for example, provide at least partially a shoe upper, while the first material layer provides at least partially a shoe midsole and the second material layer provides at least partially a shoe outsole. In another example, the flexible may provide at least partially a sports top, while the first and the second material layers provide at least partially reinforcement regions, e.g. for the elbow or the back.

0033The flexible layer may comprise a textile material, natural leather, synthetic leather, and/or rubber. The flexible layer may consist of a textile material, natural leather, synthetic leather, or rubber.

0034The textile material of the flexible layer may comprise elastic yarns. The elastic yarn may, preferably, comprise elastane or rubber.

0035By providing the flexible layer with elastic yarns, the flexible layer can adjust to the wearer's anatomy and increase the wearing comfort. For example, when the flexible layer is a portion of a shoe upper, the wearing comfort of the shoe as a whole is increased.

0036The textile material of the flexible layer may be formed from natural and/or synthetic yarns. The textile is preferably breathable, and can be impermeable to water or dirt.

0037The textile material of the flexible layer may be knitted or woven.

0038In particular, the textile material of the flexible layer may be weft-knitted. Weft-knitting has the advantage that the flexible layer can be relatively easily provided with specific structures, such as the plurality of apertures. For example, a weft-knitted textile can be provided with various weft-knitted patterns in various areas on the textile. The textile material may be flat weft-knitted. In flat weft-knitting, a certain yarn, such as an elastic yarn, can be used in certain areas of the weft-knitted textile material.

0039Alternatively, the textile material of the flexible layer is warp-knitted. Textiles may be cost-effectively and quickly manufactured on a warp-knitting machine.

0040The textile material of the flexible layer may be also woven. Woven textiles are easy to produce, and have durable properties.

0041It is possible that the textile material of the flexible layer comprises a melting yarn. A melting yarn may be fused by heating. The melting yarn hardens, when it is subsequently cooled down. This may be, for example, important, when the flexible layer is a portion of a shoe upper. By means of melting yarns, the textile material of the flexible layer may be specifically stiffened, in particular outside the region, where the flexible layer is sandwiched between the first and the second material layer. Higher stability by regionally stiffening the flexible layer may be especially important in the heel area, the toe area, and the lateral midfoot area.

0042The plurality of apertures in the flexible layer may be provided during the manufacturing process, e.g. during knitting or weaving.

0043Alternatively or in addition, the flexible layer may be laser-cut to provide the plurality of apertures. Laser cutting the flexible layer, e.g. comprising natural or synthetic yarns, natural or synthetic leather, has the advantage that the apertures can be provided with shapes and/or dimensions which would not be possible by a knitting or weaving process. Furthermore, the apertures can be fabricated with a high precision and in a cost-efficient automatic manner. In particular where the flexible layer comprises synthetic yarns or leather, laser cutting results in a small seal, which inhibits frazzling at the boundaries.

0044The first material layer and/or the second material layer may comprise at least one thermoplastic material.

0045Thermoplastic materials are easy to process and allow the manufacture of a variety of complex structures. In particular, thermoplastic materials are robust, durable, and light-weight, and therefore well suited to applications in shoes and/or apparels.

0046The first and second material layer may comprise the same thermoplastic material. Preferably, the first and the second material layer may each comprise at least one thermoplastic material with a similar or the same melting temperature.

0047In particular, the first material layer and/or the second material layer may comprise thermoplastic rubber (TPR), polyurethane (PU), elastomeric polyurethane (EPU), polylactic acid (PLA), and/or ethylene vinyl acetate (EVA).

0048The first material layer and/or the second material layer may comprise a metal material. For example, an aluminum alloy, such as AlSi10Mg, 239, or a metal material comprising Ti6Al4 V might be used. In general, materials used may include metals such as aluminum, titanium, steel (e.g., maraging steel, stainless steel) or the like, alloys such as aluminum alloys (e.g., AlSiMg), titanium alloys (e.g., Ti64, Ti6AlV4), cobalt chrome alloys (e.g., CC MP1), nickel alloys (e.g., IN718, NiCr19Fe19NbM03), super-alloys, composites, thermoplastics, thermosets, and/or combinations thereof.

0049In the context of the present invention, materials like ceramic, polymers, a printed composite and a combination of two or more materials may be used as well.

0050The first material layer and/or the second material layer may be integrally provided as a single piece.

0051By integrally manufacturing the first material layer and/or the second material layer as a single piece, very durable materials can be provided. In particular, by manufacturing the first material layer and the second material layer as a single piece, no further bonding agents are required to connect the plurality of protrusions of the first material layer to the second material layer. Furthermore, by providing the first and the second material layer as a single piece, both layers are able to interact in an optimum manner, and exerted forces can be directly transmitted between the two material layers. Moreover, the manufacture of the two material layers as a single piece is easy and cost-effective, since there is no need for separate manufacturing, aligning the two material layers and connecting them, for example by gluing.

0052It is also possible for the first and the second material layer being provided as a single piece that the first material layer and/or the second material layer is not a continuous layer. In particular, the first material layer and/or the second material layer may be provided as a plurality of reinforcing areas that are connected by the plurality of protrusions, as described further below.

0053The first material layer and the second material layer may be manufactured in a single additive manufacturing process.

0054The use of an additive manufacturing process allows customization of the first and the second material layers to the individual anatomy of the foot or the body of a future wearer. Integrally manufacturing first and the second material layers as a single piece does not exclude that other portions of e.g. a shoe or apparel may be created using other manufacturing processes including other 3D manufacturing processes.

0055Suitable additive manufacturing processes include stereolithography (SLA), selective laser sintering (SLS), fused deposition modeling (FDM), multi-jet modeling (MJM), 3-dimensional printing (3DP) or continuous liquid interface production (CLIP), which may be in particular applied for the processing of thermoplastic materials. It is further possible that the additive manufacturing process comprises laser sintering of the above-mentioned metal materials.

0056The second material layer may also comprise a second plurality of protrusions.

0057The protrusions of the second plurality of protrusions may have lengths ranging from 1 to 10 mm, and/or densities ranging from 0.5 to 5 protrusions per cm², and/or cross-sectional areas ranging from 4 to 80 mm².

0058The effects described above in relation to the first material layer also apply to the second material layer.

0059At least one protrusion of the second plurality of protrusions of the second material layer may extend through at least one aperture of the plurality of apertures of the flexible layer and may be connected to the first material layer.

0060In this regard, protrusions of the first material layer may be connected to protrusions of the second material layer. It is also possible, that the protrusions of the second material layer connect to the first material layer outside the first plurality of protrusions. By providing both the first material layer and the second material layer with protrusions, the points where the two layers connect may be flexibly chosen. Moreover, the distance between the first and the second material layer and the strength of connection may vary along the connecting portions.

0061The second plurality of protrusions may extend in the direction opposite to the first material layer and the flexible layer. In this regard, at least one protrusion of the second plurality of protrusions may extend through at least one aperture of a second plurality of apertures of a second flexible layer and may be connected a third material layer.

0062The second flexible layer may have the same properties as the flexible layer that is positioned between the first material layer and the second material layer. The third material layer may have the same properties as the first material layer and/or the second material layer.

0063By providing a further structure comprising a second flexible layer and a third material layer, the overall structure can be extended to multiple functional layers. The layers may meet different functionalities, such as waterproofness, breathability, and so forth. The first material layer and/or the second material layer may comprise a network of reinforcing struts.

0064By providing reinforcing struts, the first and/or second material layer can be provided as a very light layer. In particular, when the network of reinforcing struts is provided as a single piece, manufactured in an additive manufacturing process, both small weight and durability can be achieved.

0065The reinforcing struts may be interconnected by a plurality of nodes. The nodes may interconnect multiple reinforcing struts. In particular, the nodes may comprise an X-shaped cross-sectional form.

0066Nodes can distribute forces acting on the network of reinforcing struts in a largely isotropic manner und thus lead to a stabilization of the network with regard to any forces acting in a direction within the plane in which the cross-section is taken.

0067The first material layer and/or the second material layer may comprise a pattern of reinforcing areas.

0068In particular, the reinforcing areas may be geometrically arranged, such as in the form of hexagons, squares or circles. Each reinforcing area may be connected to at least one protrusion of the first and/or the second material layer. Each reinforcing area may comprise a surface area which is larger than the cross-sectional area of the aperture that the at least one protrusion connected to the reinforcing area is extending through.

0069The reinforcing areas may each comprise a surface area ranging from 9 to 225 mm². In particular, the size of the reinforcing areas may be adapted to the wearer's anatomy. The reinforcing areas may be, for example, of smaller diameter in regions that require a high flexibility.

0070The reinforcing areas of the first or second material layer may be provided as individual areas that are not connected with each other. By providing reinforcing areas that are not connected with each other within one material layer, an even higher flexibility of the shoe or apparel can be obtained. In particular, both the first and the second material layer may comprise a pattern of reinforcing areas, each reinforcing area being only connected to at least one protrusion of the first and/or second material layer.

0071Alternatively, the first material layer may comprise a pattern of reinforcing areas or reinforcing struts, and the reinforcing areas or struts may be provided as individual areas or struts that are only connected with each other by the protrusions connecting the first and second material layer. In this embodiment, the second material layer may, for example, comprise a network of interconnected reinforcing struts.

0072The present invention also relates to a shoe, in particular a sports shoe, comprising an upper and a sole, wherein the flexible layer forms a portion of the upper.

0073The first material layer and/or the second material layer may form a shoe sole, in particular a shoe midsole, a shoe insole or a shoe outsole.

0074The first material layer may form the shoe outsole or insole and the second material layer may form the shoe midsole.

0075The first material layer and/or the second material layer may form at least one reinforcing element of the shoe upper.

0076The reinforcing element of the first material layer or second material layer may be at least one of a toe cap, lateral side wing, medial side wing, and/or a heel cap.

0077The shoe may further comprise a releasable insole.

0078The present invention also relates to an apparel, in particular a sports apparel, wherein the first material layer and/or the second material layer forms at least one reinforcing element of the apparel. The first material layer and/or the second material layer may enhance the anti-abrasion properties of the apparel.

0079The apparel may be an outer-layer apparel, in particular a protective garment, such as a shin guard, an arm protector, a knee pad for protection of the knee or knee protector, protective headwear, a back protector, and/or a glove.

0080The present invention also relates to a method of manufacturing a shoe or apparel, comprising the steps: <ol id="ol0001" compact="compact"><li>a. manufacturing a first material layer with a first plurality of protrusions;</li><li>b. manufacturing a flexible layer with a plurality of apertures;</li><li>c. positioning the flexible layer onto the first material layer, such that each protrusion of the first plurality of protrusions of the first material layer extends through at least one aperture of the plurality of apertures of the flexible layer;</li><li>d. manufacturing a second material layer;</li><li>e. connecting each protrusion of the first plurality of protrusions of the first material layer to the second material layer.</li></ol>

0081In the following, further advantageous embodiments for the method of manufacturing a shoe or apparel are described. The specific effects of these embodiments, that are explained above in the context of the manufactured shoe or apparel, also apply to the embodiments of the method according to the invention.

0082During manufacturing, the first material layer and the second material layer may not infiltrate the flexible layer outside the plurality of apertures.

0083The flexible layer may be manufactured to comprise apertures with a cross-sectional area ranging from 9 mm² to 100 mm².

0084During manufacturing, the flexible layer may not be connected to the first material layer and the second material layer, and thereby can freely move between the first material layer and the second material layer.

0085At least one protrusion may be manufactured to have a cross-sectional area, which is at least 20 % smaller, preferably at least 40 % smaller, more preferably at least 60 % smaller, most preferably at least 80% smaller than the cross-sectional area of the aperture, through which the at least one protrusion extends.

0086The flexible layer may freely stretch between the first material layer and the second material layer.

0087The protrusions of the first plurality of protrusions of the first material layer may each be manufactured to comprise a length ranging from 1 mm to 10 mm.

0088The protrusions may each be manufactured to comprise a cross-sectional area ranging from 4 mm² to 80 mm².

0089The protrusions of the first plurality of protrusions of the first material layer may be manufactured to yield densities ranging from 0.5 to 5 protrusions per cm².

0090The protrusions may be manufactured in varying shapes, such as cylinders and/or cuboids.

0091The first material layer and/or the second material layer may be manufactured to comprise a three-dimensional shape. Again, the three-dimensional shape is to be understood independent from the plurality of protrusions.

0092The three-dimensional shaped first material layer and/or the second material layer may be manufactured to have a thickness ranging from 1 mm to 30 mm along a lateral axis and/or a longitudinal axis of the first material layer and/or second material layer.

0093The flexible layer may be manufactured to have dimensions which extend beyond the first and/or second material layer. The dimensions of the first and the second material layer may also differ.

0094The flexible layer may comprise a textile material, natural leather, synthetic leather, and/or rubber. The flexible layer may consist of a textile material, natural leather, synthetic leather, or rubber.

0095An elastic yarn may be used to manufacture the textile material of the flexible layer. The elastic yarn may, preferably, comprise elastane or rubber.

0096Natural and/or synthetic yarns may be used to manufacture the textile material of the flexible layer. The textile is preferably breathable, and can be impermeable to water or dirt.

0097The textile material of the flexible layer may be knitted or woven. Alternatively, the textile material of the flexible layer may be warp-knitted.

0098The textile material of the flexible layer may be also woven.

0099A melting yarn may be used to manufacture the textile material of the flexible layer.

0100The plurality of apertures in the flexible layer may be provided during the manufacturing process, e.g. during knitting or weaving.

0101Alternatively or in addition, the flexible layer may be laser-cut to provide the plurality of apertures.

0102The first material layer and/or the second material layer may be manufactured from at least one thermoplastic material.

0103The first and second material layer may be manufactured from the same thermoplastic material. Preferably, the first and the second material layer may be manufactured from at least one thermoplastic material with a similar or the same melting temperature.

0104In particular, the first material layer and/or the second material layer may be manufactured from thermoplastic rubber (TPR), polyurethane (PU), elastomeric polyurethane (EPU), polylactic acid (PLA), and/or ethylene vinyl acetate (EVA).

0105The first material layer and/or the second material layer may be manufactured to comprise a metal material. For example, an aluminum alloy, such as AlSi10Mg, 239, or a metal material comprising Ti6Al4 V might be used. In general, materials used may include metals such as aluminum, titanium, steel (e.g., maraging steel, stainless steel) or the like, alloys such as aluminum alloys (e.g., AlSiMg), titanium alloys (e.g., Ti64, Ti6AlV4), cobalt chrome alloys (e.g., CC MPi), nickel alloys (e.g., IN718, NiCr19Fe19NbMo3), super-alloys, composites, thermoplastics, thermosets, and/or combinations thereof. Materials like ceramic, polymers, a printed composite and a combination of two or more materials may be used as well.

0106The first material layer and/or the second material layer may be manufactured as a single piece.

0107It is also possible for the first and the second material layer being provided as a single piece that the first or the second material layer is manufactured as a continuous layer. In particular, the first and/or the second material layer may be provided as a plurality of reinforcing areas, as described further below.

0108The first material layer and the second material layer may be manufactured in a single additive manufacturing process.

0109In particular, at least step e) may comprise an additive manufacturing process step, preferably steps a), d) and e) may comprise an additive manufacturing process step.

0110Suitable additive manufacturing processes include stereolithography (SLA), selective laser sintering (SLS), fused deposition modeling (FDM), multi-jet modeling (MJM), 3-dimensional printing (3DP) or continuous liquid interface production (CLIP), which may be in particular applied for the processing of thermoplastic materials. It is further possible that the additive manufacturing process comprises laser sintering of the above-mentioned metal materials.

0111The second material layer may also be manufactured to comprise a second plurality of protrusions.

0112The protrusions of the second plurality of protrusions may be manufactured to comprise lengths ranging from 1 to 10 mm, and/or densities ranging from 0.5 to 5 protrusions per cm², and/or cross-sectional areas ranging from 4 to 80 mm².

0113At least one protrusion of the second plurality of protrusions of the second material layer may be manufactured to extend through at least one aperture of the plurality of apertures of the flexible layer and may be connected to the first material layer.

0114Protrusions of the first material layer may be connected to protrusions of the second material layer. It is also possible, that the protrusions of the second material layer connect to the first material layer outside the first plurality of protrusions.

0115The second plurality of protrusions may be manufactured to extend in the direction opposite to the first material layer and the flexible layer. In this regard, at least one protrusion of the second plurality of protrusions may extend through at least one aperture of a second plurality of apertures of a second flexible layer and may be connected a third material layer.

0116The second flexible layer may have the same properties as the flexible layer that is positioned between the first material layer and the second material layer. The third material layer may have the same properties as the first material layer and/or the second material layer.

0117The first material layer and/or the second material layer may be manufactured to comprise a network of reinforcing struts.

0118The reinforcing struts may be interconnected by a plurality of nodes. The nodes may interconnect multiple reinforcing struts.

0119The first material layer and/or the second material layer may be manufactured to comprise a pattern of reinforcing areas.

0120In particular, the reinforcing areas may be geometrically arranged, such as in form of hexagons, squares or circles.

0121Each reinforcing area may be connected to at least one protrusion of the first and/or the second material layer. Each reinforcing area may comprise a surface area which is larger than the cross-sectional area of the aperture that the at least one protrusion connected to the reinforcing area is extending through.

0122The reinforcing areas may each be manufactured to comprise a surface area ranging from 9 to 225 mm².

0123The reinforcing areas may be provided as individual areas that are not connected with each other.

0124Alternatively, the first material layer may comprise a pattern of reinforcing areas or reinforcing struts, and the reinforcing areas or struts may be provided as individual areas or struts that are only connected with each other by the protrusions connecting the first and second material layer. In this embodiment, the second material layer may, for example, comprise a network of interconnected reinforcing struts.

0125According to the method, a shoe may be manufactured, comprising an upper and a sole, wherein the flexible layer forms a portion of the upper.

0126The first material layer and/or the second material layer may be manufactured to form a shoe sole, in particular a shoe midsole, a shoe insole or a shoe outsole.

0127The first material layer may be manufactured to form the shoe outsole or insole and the second material layer may form the shoe midsole.

0128The first material layer and/or the second material layer may be manufactured to form at least one reinforcing element of the shoe upper.

0129The reinforcing element of the first material layer or second material layer may be manufactured to comprise at least one of a toe cap, lateral side wing, medial side wing, and/or a heel cap.

0130"Layer" in the context of the present invention, such as material layer, refers to a structure comprising a substantially planar surface, which is arranged substantially parallel to another substantially planar surface. The planar surface of the layer does not need to be formed as a continuous surface, but may, for example, consist of a plurality of smaller elements, such as struts or areas, that are not connected to each other within the planar surface. Instead, those smaller elements may be connected to each other outside of the planar surface. For example, the smaller elements may be connected to each other via connected protrusions extending from the smaller elements.

<u>4. Brief description of the figures</u>

0131Aspects of the present invention will be explained in more detail with reference to the accompanying figures in the following. These figures show: <dl id="dl0001"><dt>Fig. 1 a, b:</dt><dd>schematic representations of structures comprising a first material layer with protrusions, a flexible layer with apertures, and a second material layer according to the present invention;</dd><dt>Fig. 1 c, d:</dt><dd>schematic representations of protrusions according to the present invention;</dd><dt>Fig. 2 a:</dt><dd>schematic representation of a further structure comprising a first material layer, a flexible layer, and a second material layer according to the present invention;</dd><dt>Fig. 2 b:</dt><dd>schematic representation of a further structure comprising a first material layer, a flexible layer, a second material layer, a second flexible layer and a third material layer, which can be used for the present invention;</dd><dt>Fig. 2 c:</dt><dd>schematic representation of a further structure comprising a first material layer with protrusions and a second material layer with protrusions, which can be used for the present invention;</dd><dt>Fig. 3:</dt><dd>schematic representation of a structure comprising a first material layer with reinforcing struts and a second material layer with reinforcing areas, which can be used for the present invention;</dd><dt>Fig. 4 a, b:</dt><dd>a schematic representation of a shoe according to the present invention;</dd><dt>Fig. 5:</dt><dd>an embodiment of a shoe sole shown in different perspectives, which can be used for the present invention;</dd><dt>Fig. 6 a-c:</dt><dd>embodiments of parts of a shoe, which can be used for the present invention; and</dd><dt>Fig. 7:</dt><dd>a further embodiment of a structure, which can be used for the present invention.</dd></dl>

<u>5. Detailed description of currently preferred embodiments</u>

0132In the following, embodiments and variations of the present invention are described in more detail by means of a shoe and an apparel, in particular a sports shoe and a sports apparel. It is, however, emphasized that the present invention is not limited to this.

0133It is also mentioned that in the following only individual embodiments of the invention can be described in more detail. The skilled person will realize, however, that the features and design options described in relation to these specific embodiments may also be modified or combined in a different manner within the scope of the invention, and that individual features may also be omitted if these seem dispensable in a given case.

0134The use of a multilayered composition, comprising a first material layer with a plurality of protrusions, a flexible layer with a plurality of apertures and a second layer, allows to equip a shoe or apparel with different materials that are stably connected. Importantly, the connection of the different materials does not influence their individual properties. The flexible layer, which may form, for example a shoe upper or a sports top, may be equipped with different functional properties, such as bendability, stretchability, permeability to air and water, thermoconductivity, thermal capacity, moisture absorption, abrasion resistance, hardness and thickness.

0135<figref idref="f0001"><b><u>Fig. 1a</u></b></figref> shows a schematic representation of a structure according to the present invention. A first material layer <b>101</b> comprises a plurality of protrusions <b>111.</b> The protrusions <b>111</b> extend through the apertures <b>112</b> of the flexible layer <b>102</b> and are connected to the second material layer <b>103</b>. The apertures of the flexible layer are slightly larger than the protrusions of the first layer, such that a small gap is formed between the apertures and the protrusions. Thereby, the flexible layer is not connected to the first and second material layer and can freely move in a planar direction within a distance that is determined by the gap between each protrusion and the corresponding aperture (indicated by the dotted bidirectional arrow).

0136<figref idref="f0001"><b><u>Fig. 1b</u></b></figref> shows a related schematic representation, wherein regular-sized protrusions <b>111</b> of the first material layer <b>101</b> extend through the apertures of the flexible layer <b>102</b>. The protrusions can be chosen with a length that is significantly larger than the thickness of the flexible layer. Thereby, the flexible layer can also freely move within a distance that is determined by the length of the protrusions (indicated by the dotted bidirectional arrow).

0137The protrusions can be formed in various shapes. For example, the protrusions <b>111</b> of the first material layer <b>101</b> can be formed in a cylindric shape, as schematically represented in <figref idref="f0002"><b><u>Fig. 1c</u></b></figref>. Hollow structures, e.g. hollow cylinders are conceivable, as depicted in <figref idref="f0002"><b>Fig. 1c</b></figref>. In principle, the protrusions can also be formed in solid structures, such as solid cylinders (not shown).

0138The protrusions <b>111</b> of the first material layer <b>101</b> can be also formed as solid or hollow cuboids, for example, as shown in <figref idref="f0002"><b>Fig. 1d</b></figref>.

0139<figref idref="f0003"><b><u>Fig. 2a</u></b></figref> shows a further schematic representation of a structure according to the present invention, wherein also the second material layer <b>203</b> comprises a plurality of protrusions <b>223</b> that extend through the apertures <b>112</b> of the flexible layer <b>102</b>. The protrusions <b>223</b> may be connected to the protrusions <b>111</b> of the first material layer <b>101</b>, but may also be connected to the first material layer outside the regions of protrusions.

0140<figref idref="f0003"><b><u>Fig. 2b</u></b></figref> shows another schematic representation of a structure, wherein the protrusions <b>223</b> of the second material layer <b>203</b> extend through a second flexible layer <b>232</b> with apertures <b>242</b> and connects to a third material layer <b>231</b>. It is conceivable that the protrusions <b>223</b> of the second material layer are not positioned on top of the protrusions <b>111</b> of the first material layer. Alternatively, as shown in <figref idref="f0003"><b>Fig. 2c</b></figref>, the protrusions <b>111</b> of the first material layer <b>101</b> and the protrusions <b>223</b> of the second material layer <b>203</b> can be aligned on top of each other.

0141<figref idref="f0004"><b><u>Fig. 3</u></b></figref> shows a schematic representation of the first and the second material layers (<b>101</b>, <b>103</b>). The flexible layer is positioned between the first and the second material layer (not shown). In this example, the first material layer <b>101</b> comprises a network of reinforcing struts <b>331</b>, wherein the struts are interconnected by a plurality of nodes <b>333</b>. The nodes interconnect three reinforcing struts. The first and the second material layer comprise a network of reinforcing elements <b>331</b> and reinforcing areas <b>332</b> that are connected by means of protrusions of the first material layer. The protrusions can be localized at the nodes of the network. In principle, the network of reinforcing struts can be of a regular or irregular structure. For example, longer and shorter struts can be 3D-printed, such that the overall network comprises zones of higher stability (shorter struts) and zones of higher flexibility (longer struts). The density of the protrusions, being localized at the nodes, can vary from about 0.5 to 5 protrusions per cm². The reinforcing areas <b>332</b> can have various shapes, in this case hexagons. However, also different shapes, such as circles or squares, are conceivable (not shown).

0142Different materials may be employed for the first and second material layers, as well as for the flexible layer. The network of reinforcing struts <b>331</b> and the reinforcing areas <b>332</b> can be manufactured in a 3D-printing process as a single piece, for example from polylactic acid, TPU or other polymer filaments. Other 3D printed materials for the first and second material layers include acrylonitrile butadiene styrene, nylon, ceramic, gypsum, metals.

0143The flexible layer <b>102</b> with apertures <b>112</b> may be weft-knitted or warp-knitted. The apertures <b>112</b> can be arranged in patterns, wherein the apertures comprise different cross-sectional areas, ranging from 10 mm² to about 70 mm². In particular, weft-knitted textiles may be provided with a range of functional properties and used in the present invention in an advantageous manner. A weft-knitting technique allows to manufacture textiles with structures with apertures in those regions, where the first material layer shall extend through the textile layer. Further, the yarn may be varied in certain areas of the textile layer to adjust, for example, locally the stiffness of the textile. According to the invention, also more than one textile layer with a plurality of apertures may be positioned between the first and the second material layer. The additional textile layers may be connected to each other by means of sewing, gluing, welding or linking, for example, but in principle, all textile layers that are sandwiched between the first and the second material layer, do not need to be connected mechanically to each other. Multiple textile layers between the first material layer and the second material layer can be in particular relevant for increasing the stability and solidness of, for example, a shoe upper.

0144The structures of the first and the second material layers (<b>101</b>, <b>103</b>) may be pre-designed using available CAD model software. The pattern of the apertures of the textile layer <b>102</b> can be pre-designed in line with the CAD-model of the first and the second material layer. For example, the textile layer can be weft-knitted to comprise a pattern of apertures. The apertures allow that the protrusions of the first material layer extend through to connect to the second material layer.

0145The structures according to the present invention can be used for the manufacturing of shoes. In this context, <figref idref="f0005"><b><u>Fig. 4a</u></b></figref> illustrates a shoe insole. The shoe insole comprises a material layer with a pattern of reinforcing areas <b>332</b>. The reinforcing elements are formed as hexagons of a uniform surface area of about 100 mm². The reinforcing areas further comprise protrusions <b>111</b>, shown as black circles within the reinforcing areas. In this example, the protrusions have varying cross-sectional areas ranging from about 4 mm² to 80 mm². The protrusions are arranged, such that regions of the foot requiring a high stability, e.g. the medial site and the heel region, are in particular supported by protrusions with larger cross-sectional areas.

0146<figref idref="f0005"><b><u>Fig. 4b</u></b></figref> illustrates schematically a shoe <b>400</b> according to the invention. The flexible layer <b>102</b> forms at least partially the shoe upper. The second material layer <b>103</b> forms the shoe insole, and is connected to the first material layer <b>101</b> by means of protrusions (not shown) that extend through apertures of the flexible layer. The first material layer <b>101</b> forms the shoe midsole and is three-dimensionally shaped to support the anatomy of the foot. The second material layer extends beyond the first material layer and supports the medial side wing and the heel region. It is conceivable that a further material layer is connected to the second material layer by means of protrusions of the second material layer (not shown). In particular, the further material layer can provide reinforcing elements, such as a heel or a toe cap. In this case, the flexible layer <b>102</b> is not only sandwiched between the midsole, formed by the first material layer <b>101</b>, and the insole, formed by the second material layer <b>103</b>, but also between the insole and the reinforcing elements formed by a further material layer.

0147The first and or the second material layer may be formed of highly flexible material, as shown in <figref idref="f0006"><b><u>Fig. 5</u></b></figref>. In this example, a material layer is 3D-printed from polylactic acid, TPU or other polymer filament, in the form of a shoe sole. As described above with respect to <figref idref="f0003">Fig. 2</figref>, other potential 3D printed materials include for example acrylonitrile butadiene styrene, nylon, ceramic, gypsum, or metals. The material layer is three-dimensionally shaped and comprises a network of reinforcing struts. Thereby, the material is extremely flexible and light-weight, providing a high comfort for the wearer. During manufacturing of a shoe sole, a flexible layer is added onto the protrusions of the sole to form the shoe upper, and a second material layer directly printed on top of the protrusions (not shown).

0148<figref idref="f0007 f0008"><b><u>Fig. 6a</u></b> to <b><u>Fig. 6c</u></b></figref> show further embodiments for the manufacture of a shoe, wherein the flexible layer <b>102</b> provides at least partially the shoe upper. The apertures of the flexible layer can vary from loosely knitted (<figref idref="f0007"><b><u>Fig. 6a, b</u></b></figref>) to fine-gauge knitted fabrics (<figref idref="f0008"><b><u>Fig. 6c</u></b></figref>). In these embodiments, the first material layer <b>101</b> is formed from hexagonal or round reinforcing areas <b>332</b> prepared from polylactic acid, which are 3D-printed. The individual reinforcing areas <b>332</b> are not connected with neighboring reinforcing areas within the first material layer. The reinforcing areas comprise protrusions that extend through the flexible layer <b>102</b> to connect to a second material layer on the opposite side of the flexible (not shown). In this embodiment, the second material layer also comprises a pattern of individual reinforcing areas <b>332</b> that are not connected with the neighboring areas within the second material layer. Thus, each reinforcing area of the first material layer is connected to a reinforcing area of the second material layer via one protrusion. Alternatively, it is also conceivable to provide the second material layer as a network of interconnected reinforcing struts. The reinforcing areas can be in particular located at sensitive parts of the foot, such as the toe region, as shown in <figref idref="f0007"><b><u>Fig. 6a</u></b> and <b><u>Fig. 6b</u></b></figref>, or at the arch region, as shown in <figref idref="f0008"><b><u>Fig. 6c</u></b></figref>. Finally, <figref idref="f0008"><b><u>Fig. 7</u></b></figref> shows an embodiment for the manufacture of an apparel, wherein the flexible layer comprises symmetrically arranged apertures <b>112</b> at a density of about 1 aperture per cm², through which the first material layer <b>101</b> is connected to the second material layer via protrusions (not shown). The first material layer is formed from reinforcing areas <b>332</b> of a round shape that have a cross-sectional area of about 100 mm². In this embodiment, the second material layer is also formed from reinforcing areas <b>332</b> of round shape, with each reinforcing area not connected to neighboring reinforcing areas of the second material layer, but connected to a reinforcing area <b>332</b> of the first material layer via one protrusion (not shown). The protrusions are centrally arranged within each reinforcing area of the first material layer (not shown). The flexible layer comprises elastic yarns to provide a sufficient stretchability and, thus, comfort to the wearer. The apparel can be in particular an arm or knee protector.

0149In the following, further embodiments are described to facilitate the understanding of the invention: <ol id="ol0002"><li>1. Shoe or apparel (100), comprising: <ol id="ol0003" compact="compact"><li>a. a first material layer (101) with a first plurality of protrusions (111);</li><li>b. a flexible layer (102) with a plurality of apertures (112);</li><li>c. a second material layer (103);</li><li>d. wherein the flexible layer (102) is positioned between the first material layer (101) and the second material layer (103), and</li><li>e. wherein each protrusion of the first plurality of protrusions (111) of the first material layer (101) extends through at least one aperture of the plurality of apertures (112) of the textile layer (102) and is connected to the second material layer (103),</li><li>f. wherein the flexible layer (102) is not connected to the first material layer (101) and the second material layer (103), and thereby can freely move between the first material layer (101) and the second material layer (103).</li></ol></li><li>2. Shoe or apparel (100) according to the preceding embodiment, wherein the flexible layer (102) can freely stretch between the first material layer (101) and the second material layer (103).</li><li>3. Shoe or apparel (100) according to one of the preceding embodiments, wherein the protrusions of the first plurality of protrusions (112) of the first material layer (101) are arranged in densities of protrusions ranging from 0.5 to 5 protrusions per cm².</li><li>4. Shoe or apparel (100) according to one of the preceding embodiments, wherein the first material layer (101) and/or the second material layer (103) have a three-dimensional shape.</li><li>5. Shoe or apparel (100) according to one of the preceding embodiments, wherein the first material layer (101) and/or the second material layer (103) comprise at least one thermoplastic material.</li><li>6. Shoe or apparel (100) according to one of the preceding embodiments, wherein the first material layer and/or the second material layer (101,103) comprise thermoplastic rubber (TPR), polyurethane (PU), elastomeric polyurethane (EPU), polylactic acid (PLA), and/or ethylene vinyl acetate (EVA).</li><li>7. Shoe or apparel (100) according to one of the preceding embodiments, wherein the first material layer and/or the second material layer (101, 103) are integrally provided as a single piece.</li><li>8. Shoe or apparel (100) according to one of the preceding embodiments, wherein the first material layer and the second material layer (101, 103) are manufactured in a single additive manufacturing process.</li><li>9. Shoe or apparel (200) according to one of the preceding embodiments, wherein the second material layer (203) comprises a second plurality of protrusions (223).</li><li>10. Shoe or apparel (200) according to the preceding embodiment, wherein at least one protrusion of the second plurality of protrusions (223) of the second material layer (203) extends through at least one aperture of the plurality of apertures (112) of the flexible layer (102) and is connected to the first material layer (101).</li><li>11. Shoe or apparel (200) according to one of the preceding embodiments 9 or 10, wherein at least one protrusion of the second plurality of protrusions (223) of the second material layer (203) extends through at least one aperture of a plurality of apertures (242) of a second flexible layer (232) and is connected to a third material layer (231).</li><li>12. Shoe or apparel (300) according to one of the preceding embodiments, wherein the first material layer and/or the second material layer comprise a network of reinforcing struts (331).</li><li>13. Shoe or apparel (300) according to one of the preceding embodiments, wherein the first material layer and/or the second material layer comprise a pattern of reinforcing areas (332).</li><li>14. Shoe or apparel (300) according to the preceding embodiment, wherein the reinforcing areas (332) comprise surface areas ranging from 9 mm² to 225 mm².</li><li>15. Shoe (400), in particular a sports shoe, according to one of the preceding embodiments, comprising an upper and a sole, wherein the flexible layer (102) forms a portion of the upper.</li><li>16. Shoe according to the preceding embodiment, wherein the first material layer and/or the second material layer forms a shoe sole, in particular a shoe midsole, a shoe insole or a shoe outsole.</li><li>17. Shoe according to one of the preceding embodiments 15 or 16, wherein the first material layer forms the shoe outsole or insole, and the second material layer forms the shoe midsole.</li><li>18. Shoe according to one of the preceding embodiments 15 or 16, wherein the first material layer and/or the second material layer form at least one reinforcing element of the shoe upper.</li><li>19. Apparel, in particular a sports apparel, according to one of the preceding embodiments 1-14, wherein the first material layer and/or the second material layer forms at least one reinforcing element of the apparel.</li><li>20. Method of manufacturing a shoe or apparel according to one of embodiments 1 to 19, comprising the steps: <ol id="ol0004" compact="compact"><li>a. manufacturing a first material layer with a first plurality of protrusions;</li><li>b. manufacturing a flexible layer with a plurality of apertures;</li><li>c. positioning the flexible layer onto the first material layer, such that each protrusion of the first plurality of protrusions of the first material layer extends through at least one aperture of the plurality of apertures of the flexible layer;</li><li>d. manufacturing a second material layer;</li><li>e. connecting each protrusion of the first plurality of protrusions of the first material layer to the second material layer.</li></ol></li><li>21. Method of manufacturing a shoe or apparel according to the preceding embodiment, wherein the first material layer and/or the second material layer are manufactured as a single piece.</li><li>22. Method of manufacturing a shoe or apparel according to one of embodiments 20 or 21, wherein at least step e) comprises an additive manufacturing process step, preferably wherein steps a), d) and e) comprise an additive manufacturing process step.</li></ol>