Cycling footwear structure with a composite sole and a method to realise such structure

Abstract

Cycling footwear structure including a composite sole formed by at least one base sole and by at least one substantially annular shaped stiffening element, equipped with a front part, and with a back part and that extends progressively upwards until it wraps around at least one portion of the heel of a user and a method for making it.

1 . Cycling footwear structure comprising a composite sole comprising at least one base sole, wherein it comprises at least one substantially annular shaped stiffening element, equipped with a front part and with a back part and that extends progressively upwards until it wraps around at least a portion of the heel of a user. 
     
     
         2 . Cycling footwear structure according to  claim 1 , wherein said base sole is equipped with at least one recess arranged substantially along at least part of the perimeter of said base sole, in which said at least one stiffening element is at least partially positioned. 
     
     
         3 . Cycling footwear structure according to  claim 1 , wherein said at least one stiffening element comprises at least one insert. 
     
     
         4 . Cycling footwear structure according to  claim 1 , wherein said at least one stiffening element extends progressively upwards until it wraps around at least the upper part and/or the middle part of the heel of a user. 
     
     
         5 . Cycling footwear structure according to  claim 1 , wherein said at least one stiffening element has sections (A′, B′, C′ and D′) of thickness and geometry that can be varied in a predetermined manner. 
     
     
         6 . Cycling footwear structure according to  claim 5 , wherein said section (A′) is substantially two-dimensional, with the two dimensions being substantially equal to one another, and matches said at least one recess of said base sole. 
     
     
         7 . Cycling footwear structure according to  claim 5 , wherein said section (D′) is substantially one-dimensional, with a main dimension, of lower thickness than said section (A′) and with a substantially membrane-type configuration. 
     
     
         8 . Cycling footwear structure according to  claim 5 , wherein said sections (B′, C′ and D′), positioned progressively towards said back part of the at least one stiffening element, have a substantially elongated configuration with lower thickness than said section (A′). 
     
     
         9 . Cycling footwear structure according to any  claim 3 , wherein said at least one insert is positioned in said back part of said at least one stiffening element. 
     
     
         10 . Cycling footwear structure according to  claim 3 , wherein said at least one insert comprises a flexible material that has different stiffness characteristics from the material that makes up said at least one stiffening element and said base sole. 
     
     
         11 . Cycling footwear structure according to  claim 3 , wherein said at least one insert comprises a substantially rigid material comprising a plastic material reinforced with fibres (Fiber Reinforced Plastic, FRP), including a polyamide and/or polyurethane and/or, in general, thermoplastic material reinforced with carbon fibres and/or glass fibres and/or aramid fibres and/or the same fibres bonded to an epoxy and/or, in general, thermosetting matrix and/or, more generally, a tough composite material with high modulus of elasticity. 
     
     
         12 . Cycling footwear structure according to  claim 1 , wherein said at least one stiffening element comprises a base plastic material of a thermoplastic or thermosetting type that can optionally comprise fibres, such as kevlar fibres and/or polyester and/or rubber and/or carbon fibres and/or glass fibres. 
     
     
         13 . Cycling footwear structure according to  claim 1 , wherein said base sole comprises an epoxy resin with which carbon fibres are combined. 
     
     
         14 . Method for making a cycling footwear structure comprising a composite sole comprising at least one base sole and at least one substantially annular shaped stiffening element, equipped with a front part and with a back part, wherein it comprises the following steps:
 providing a mould,   manually or automatically inserting the material making up said at least one stiffening element,   forming said at least one stiffening element by compression or by injection.   
     
     
         15 . Method for making a cycling footwear structure according to  claim 14 , comprising the following steps:
 providing a mould,   manually or automatically inserting the material making up said base sole,   forming said base sole by compression, optionally equipped with at least one recess arranged substantially along at least part of the perimeter of said base sole.   
     
     
         16 . Method for making a cycling footwear structure according to  claim 14 , comprising the following steps:
 providing a mould, optionally equipped with a special seat,   manually or automatically positioning at least one insert,   coupling said at least one stiffening element with said at least one insert positioned in the back part of said at least one stiffening element.   
     
     
         17 . Method for making a cycling footwear structure according to  claim 14 , comprising a step of treating said at least one stiffening element and/or said at least one insert and/or said at least one base sole with compatibilizing agents. 
     
     
         18 . Method for making a cycling footwear structure according to  claim 14 , wherein said at least one stiffening element, said at least one base sole and said at least one insert are obtained in a single mould. 
     
     
         19 . Method for making a cycling footwear structure according to  claim 14 , wherein said at least one stiffening element, said at least one base sole and said at least one insert are coupled manually and/or through special machinery and/or by co-moulding and/or by gluing of at least two of said elements together. 
     
     
         20 . Method for making a cycling footwear structure according to  claim 14 , wherein said at least one stiffening element, said at least one base sole and said at least one insert have a predetermined stiffness/flexibility that can undergo variations both by modifying the composition of the various materials and by varying their thickness and geometry. 
     
     
         21 . Method for making a cycling footwear structure according to  claim 14 , wherein said method comprises the step of trimming and finishing the composite sole carried out mechanically. 
     
     
         22 . Method for making a cycling footwear structure according to  claim 14 , wherein said at least one insert is made according to the following steps:
 providing a starting material consisting of a dry fabric based on carbon and/or glass and/or aramid fibres,   coupling said dry fabric based on fibres with a thermoplastic or thermosetting resin,   obtaining a dry fabric based on fibres impregnated with said thermoplastic or thermosetting resin,   obtaining said at least one insert by cutting or blanking.   
     
     
         23 . Method for making a cycling footwear structure according to  claim 22 , wherein said at least one insert is formed by compression or thermoforming and at least matches at least one portion of the heel of a user.