Material for shoe upper

Abstract

Described are materials for a shoe upper, in particular for soccer shoes, with a particularly low weight. The material includes an inner polyurethane layer, an outer polyurethane layer, and a textile reinforcing layer. The textile reinforcing layer is arranged between the inner polyurethane layer and the outer polyurethane layer. The inner polyurethane layer and the outer polyurethane layer comprise thermoset polyurethane. The textile reinforcing layer comprises apertures through which the inner polyurethane layer and the outer polyurethane layer are connected to each other.

1 .- 22 . (canceled) 
     
     
         23 . A method for manufacturing a material for a shoe upper, the method comprising:
 (a) arranging a textile reinforcing layer between an inner polyurethane layer and an outer polyurethane layer; and   (b) pressing the textile reinforcing layer, the inner polyurethane layer and the outer polyurethane layer under heat such that the inner polyurethane layer and outer polyurethane layer bond together through a plurality of apertures of the textile reinforcing layer,   wherein at least one of the inner polyurethane layer and the outer polyurethane layer comprises at least three polyurethane sublayers.   
     
     
         24 . The method of  claim 23 , wherein the textile reinforcing layer comprises a non-thermoplastic material, and wherein the inner polyurethane layer and the outer polyurethane layer comprise thermoset polyurethane. 
     
     
         25 . The method of  claim 23 , further comprising:
 (c) manufacturing at least one of the inner polyurethane layer or the outer polyurethane layer by applying the at least three polyurethane sublayers onto a substrate.   
     
     
         26 . The method of  claim 25 , wherein arranging the textile layer between the inner polyurethane layer and the outer polyurethane layer comprises arranging the textile layer such that one sublayer of the at least three polyurethane sublayers having a lower melting point is arranged closer to the textile reinforcing layer than the other sublayers of the at least three polyurethane sublayers having a higher melting point. 
     
     
         27 . The method of  claim 23 , wherein arranging the textile reinforcing layer comprises using ultrasonic positioning to arrange the textile reinforcing layer between the inner polyurethane layer and the outer polyurethane layer. 
     
     
         28 . The method of  claim 23 , wherein step (b) is performed for approximately 30-60 seconds. 
     
     
         29 . The method of  claim 23 , wherein step (b) is performed with an upper mold temperature of about 110-160° C. 
     
     
         30 . The method of  claim 23 , wherein step (b) is performed with a lower mold temperature of about 50-100° C. 
     
     
         31 . The method of  claim 23 , wherein step (b) is performed with a pressure of approximately 50-100 kg/cm 2 . 
     
     
         32 . A method for manufacturing a material for a shoe upper, the method comprising:
 (a) pouring a first polyurethane layer in liquid form onto a release layer;   (b) applying a textile reinforcing layer comprising apertures onto the first polyurethane layer; and   (c) pouring a second polyurethane layer in liquid form onto the textile reinforcing layer, such that the first polyurethane layer and the second polyurethane layer bond together through a plurality of the apertures of the textile reinforcing layer,   wherein at least one of the first polyurethane layer and the second polyurethane layer comprises at least three polyurethane sublayers.   
     
     
         33 . The method of  claim 32 , wherein heat is applied after at least one of step (a) and step (c). 
     
     
         34 . The method of  claim 32 , further comprising:
 (d) pressing the first polyurethane layer, the textile reinforcing layer, and the second polyurethane layer after step (c).   
     
     
         35 . The method of  claim 32 , wherein the method is a continuous process, and the release layer and the textile reinforcing layer are supplied from respective rolls. 
     
     
         36 . A method for manufacturing a shoe upper comprising:
 (a) manufacturing a composite material 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, wherein the inner polyurethane layer and outer polyurethane layer bond together through a plurality of apertures of the textile reinforcing layer;   (b) arranging a toe cap, a vamp overlay, and the composite material;   (c) pressing the toe cap, the vamp overlay, and the composite material under heat to form an upper component;   (d) welding decorative components to a surface of the upper component; and   (e) removing excess material from the upper component.   
     
     
         37 . The method of  claim 36 , wherein step (c) is performed for approximately 60 seconds. 
     
     
         38 . The method of  claim 36 , wherein step (c) is performed with an upper mold temperature of about 120-170° C. 
     
     
         39 . The method of  claim 36 , wherein step (c) is performed with a lower mold temperature of about 50-100° C. 
     
     
         40 . The method of  claim 36 , wherein step (c) is performed with a pressure of approximately 50-60 kg/cm 2 . 
     
     
         41 . The method of  claim 36 , further comprising applying hot melt film or primer between the components to increase bond strength prior to pressing. 
     
     
         42 . The method of  claim 36 , further comprising adding at least one of a stripe and an eyestay onto the upper component. 
     
     
         43 . A method for manufacturing a material for a shoe upper, the method comprising:
 (a) arranging a textile reinforcing layer between an inner polyurethane layer and an outer polyurethane layer; and   (b) pressing the textile reinforcing layer, the inner polyurethane layer and the outer polyurethane layer under heat such that the inner polyurethane layer and outer polyurethane layer connect through a plurality of apertures of the textile reinforcing layer,   wherein at least one of the inner polyurethane layer and the outer polyurethane layer comprises at least three polyurethane sublayers.