Method for producing a shell part of a sports shoe and a shell part produced according to this method

Abstract

The invention relates to a shell part of sports shoe and a method for producing such a shell part based on joining together several components made preferably of different materials in one or more injection molding processes. The method comprises: the production of at least one three-dimensional stable shoe reinforcing part, the application of a filler material on the inner side of the shoe reinforcing part; the positioning of the shoe reinforcing part on a last; and the at least partial overmolding of the shoe reinforcing part with plastic. The method enables the simple and easily controllable production of a shell part with very high rigidity or stability at least in specific areas and at the same time also ensures the workability or adjustability of the shell part during the production and afterwards.

1 . A method for producing a shell part of a sports shoe based on joining together several components of the shell part preferably made of different materials in one or more injection molding processes, comprising producing at least one three-dimensional, stable shoe reinforcing part, applying a filler material onto at least 50% of an inner side of the shoe reinforcing part, so that an inner side of the filler material facing away from the shoe reinforcing part follows largely the form of a last, whereby the shoe reinforcing part equipped with the filler material is positioned on the last, and is at least partially overmolded with plastic. 
     
     
         2 . The method as claimed in  claim 1 , wherein the step of at least partial overmolding with plastic of the shoe reinforcing part is performed at an edge section or an outer side of the shoe reinforcing part, so that a one-piece shell part of the sports shoe is formed. 
     
     
         3 . The method as claimed in  claim 1 , whereby the three-dimensional, stable shoe reinforcing part is made of a material with a modulus of elasticity of 40 GPa to 240 GPa, the material selected from a group consisting of metal, steel, fibrous composite material, carbon-fiber reinforced plastic, glass-fiber reinforced plastic, carbon and glass-fiber reinforced plastic, aramid fiber composite material and basalt fiber composite material. 
     
     
         4 . The method as claimed in  claim 1 , comprising producing a three-dimensional, stable shoe reinforcing part with a thickness of 0.6 mm to 1.5 mm. 
     
     
         5 . The method as claimed in  claim 1 , comprising producing a three-dimensional, stable shoe reinforcing part having at least one round openings between the inner side and the outer side. 
     
     
         6 . The method as claimed in  claim 1 , comprising producing a three-dimensional, stable shoe reinforcing part with one or more connecting elements arranged in its edge section and overmolding said connecting elements with a plastic, so that a stable connection is formed between the shoe reinforcing part and the plastic. 
     
     
         7 . The method according to  claim 6 , comprising producing a three-dimensional, stable shoe reinforcing part with one or more connecting elements arranged in its edge section, wherein the connecting elements comprise openings between an inner side and an outer side, and overmolding said connecting elements with plastic, wherein the openings are also filled with the plastic. 
     
     
         8 . The method as claimed in  claim 6 , comprising overmolding the connecting elements with plastic, so that both the outer side and the inner side of the connecting elements are completely surrounded by the plastic. 
     
     
         9 . The method as claimed in  claim 1 , comprising positioning a plurality of shoe reinforcing parts equipped with a filler material on a last and at least partially overmolding said shoe reinforcing parts with plastic. 
     
     
         10 . The method as claimed in  claim 1 , comprising positioning a shoe reinforcing part equipped with a filler material on a last in the heel area, in the toe area and/or in the sole area of the sports shoe, so that in the respective area the rigidity and bending resistance of the shell part are increased. 
     
     
         11 . The method as claimed in  claim 1 , comprising applying a filler material which can be worked comparatively easily compared to the shoe reinforcing part onto at least one part of the inner side of the shoe reinforcing part, wherein as the filler material a plastic foam is used, in particular foamed polystyrene, polyurethane foam or polypropylene foam. 
     
     
         12 . The method as claimed in  claim 1 , comprising applying a filler material which can be worked comparatively easily compared to the shoe reinforcing part onto at least one part of the inner side of the shoe reinforcing part, wherein the thickness of the filler material is 1 mm to 12 mm. 
     
     
         13 . The method as claimed in  claim 1 , comprising applying a filler material which can be worked comparatively easily compared to the shoe reinforcing part onto at least one part of the inner side of the shoe reinforcing part, which filler material can be milled, cut, rasped, ground and/or shaped after heating. 
     
     
         14 . The method as claimed in  claim 1 , comprising customizing the three-dimensional shape of the inner side of the filler material facing away from the shoe reinforcing part, the material properties, in particular the hardness, of the filler material, and/or the haptic of the filler material according to the requirements or wishes of a user of the sports shoe. 
     
     
         15 . The method as claimed in  claim 1 , comprising adjustment of the three-dimensional shape and/or the haptic of the filler material after production of the shell part and according to the special or individual requirements of a user of the sports shoe, in particular by milling, cutting, rasping, grinding and/or shaping after heating. 
     
     
         16 . A shell part of a sports shoe, in particular a front foot shell of a ski shoe, comprising several components made preferably of different materials, which can be added in one or more injection molding processes to the shell part wherein at least one three-dimensional, stable shoe reinforcing part is formed with a filler material arranged on at least 50% of an inner side of the shoe reinforcing part, the filler material can be worked comparatively easily compared to the shoe reinforcing part, a three-dimensional inner side of said filler material facing away from the shoe reinforcing part forms an inner surface of the shell part, and wherein an injection molded plastic part is formed, which at least partially surrounds the shoe reinforcing part, in order to form a one-piece shell part of the sports shoe. 
     
     
         17 . The shell part of a sports shoe according to  claim 16 , wherein at least an edge section of the shoe reinforcing part is surrounded at least partially by the plastic part, so that a one-piece shell part of the sports shoe is formed. 
     
     
         18 . The shell part of a sports shoe as claimed in  claim 16 , wherein the three-dimensional, stable shoe reinforcing part comprises a material having a modulus of elasticity of 40 GPa to 240 GPa, the material selected from a group consisting of metal, steel, fibrous composite material, and carbon-fiber reinforced plastic, glass-fiber reinforced plastic, carbon and glass-fiber reinforced plastic, aramid fiber composite material, and basalt fiber composite material. 
     
     
         19 . The shell part of a sports shoe as claimed in  claim 16 , wherein the three-dimensional, stable shoe reinforcing part has a thickness of 0.6 mm to 1.5 mm. 
     
     
         20 . The shell part of a sports shoe as claimed in  claim 16 , wherein the three-dimensional, stable shoe reinforcing part comprises a plurality of round openings between the inner side and an outer side. 
     
     
         21 . The shell part of a sports shoe as claimed in  claim 16 , wherein the three-dimensional, stable shoe reinforcing part comprises in its edge section one or more connecting elements, and the plastic part surrounds said connecting elements, so that a stable connection is formed between the shoe reinforcing part and the plastic part. 
     
     
         22 . The shell part of a sports shoe as claimed in  claim 21 , wherein the connecting elements arranged in the edge section of the three-dimensional, stable shoe reinforcing part comprise openings between an inner side and an outer side, and the plastic part surrounds the connecting elements such that also said openings are filled with the plastic part. 
     
     
         23 . The shell part of a sports shoe as claimed in  claim 21 , wherein the connecting elements arranged in the edge section of the shoe reinforcing part are surrounded by the plastic part both on the outer side and on the inner side. 
     
     
         24 . The shell part of a sports shoe as claimed in  claim 16 , wherein within the components of the shell part several shoe reinforcing parts equipped with a filler material are formed and are surrounded at least partially by the plastic part. 
     
     
         25 . The shell part of a sports shoe as claimed in  claim 16 , wherein a shoe reinforcing part equipped with a filler material is formed respectively in the heel area, in the toe area and/or in the sole area of the sports shoe, so that in the respective area the rigidity and bending resistance of the shell part is increased. 
     
     
         26 . The shell part of a sports shoe as claimed in  claim 16 , wherein the filler material comprises a plastic foam selected from the group consisting of foamed polystyrene, polyurethane foam and polypropylene foam. 
     
     
         27 . The shell part of a sports shoe as claimed in  claim 16 , wherein the filler material has a thickness of 1 mm to 12 mm. 
     
     
         28 . The shell part of a sports shoe as claimed in  claim 16 , wherein the filler material can be worked comparatively easily compared to the shoe reinforcing part, in particular the filler material can be milled, cut, rasped, ground and/or shaped after heating. 
     
     
         29 . The shell part of a sports shoe as claimed in  claim 16 , wherein the three-dimensional shape of the filler material, in particular the shape of the inner side of the filler material facing away from the shoe reinforcing part, the material properties, in particular the hardness, of the filler material, and/or the haptic of the filler material is customizable according to the requirements or wishes of a user of the sports shoe. 
     
     
         30 . The shell part of a sports shoe as claimed in  claim 16 , wherein the three-dimensional shape and/or haptic of the filler material is adjustable after production of the shell part and according to the special or individual requirements of a user of the sports shoe, in particular by milling, cutting, rasping, grinding and/or shaping after heating. 
     
     
         31 - 32 . (canceled)