U.S. patent application number 16/778741 was filed with the patent office on 2020-05-28 for article of footwear with extruded components.
The applicant listed for this patent is REEBOK INTERNATIONAL LIMITED. Invention is credited to Brian CHRISTENSEN, Paul DAVIS, Dennis GABORIAULT, Henry HARDIGAN, Ricardo VESTUTI.
Application Number | 20200163415 16/778741 |
Document ID | / |
Family ID | 62846067 |
Filed Date | 2020-05-28 |
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United States Patent
Application |
20200163415 |
Kind Code |
A1 |
CHRISTENSEN; Brian ; et
al. |
May 28, 2020 |
ARTICLE OF FOOTWEAR WITH EXTRUDED COMPONENTS
Abstract
An upper for an article of footwear includes a first upper
panel, a second upper panel, and an extruded component. The
extruded component is disposed along a border between the first
upper panel and the second upper panel. The extruded component
joins the first upper panel to the second upper panel.
Inventors: |
CHRISTENSEN; Brian;
(Centerville, MA) ; DAVIS; Paul; (Blackstone,
MA) ; VESTUTI; Ricardo; (Providence, RI) ;
HARDIGAN; Henry; (Pawtucket, RI) ; GABORIAULT;
Dennis; (Millbury, MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
REEBOK INTERNATIONAL LIMITED |
London |
|
GB |
|
|
Family ID: |
62846067 |
Appl. No.: |
16/778741 |
Filed: |
January 31, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16047821 |
Jul 27, 2018 |
10568387 |
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16778741 |
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15644463 |
Jul 7, 2017 |
10485302 |
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16047821 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A43B 23/0275 20130101;
B29C 48/15 20190201; B29C 65/50 20130101; B29C 65/62 20130101; A43B
1/04 20130101; A43B 23/0265 20130101; B29C 48/156 20190201; A43B
13/188 20130101; A43C 11/00 20130101; A43B 23/025 20130101; A43B
23/0255 20130101; A43B 23/027 20130101; A43B 1/0072 20130101; A43B
13/186 20130101; B33Y 80/00 20141201; A43B 23/0295 20130101; A43B
13/127 20130101; A43B 23/0215 20130101; B29C 48/151 20190201; B29C
48/155 20190201; A43B 23/088 20130101 |
International
Class: |
A43B 23/02 20060101
A43B023/02; B29C 48/155 20060101 B29C048/155; B29C 48/151 20060101
B29C048/151; A43B 23/08 20060101 A43B023/08; A43B 13/18 20060101
A43B013/18; A43B 13/12 20060101 A43B013/12; A43B 1/04 20060101
A43B001/04; B33Y 80/00 20060101 B33Y080/00; B29C 65/50 20060101
B29C065/50; B29C 48/15 20060101 B29C048/15; B29C 48/156 20060101
B29C048/156; B29C 65/62 20060101 B29C065/62 |
Claims
1. An article of footwear comprising: an upper; and an extruded
component having a first segment, a second segment, an inner
surface facing the upper, and an outer surface, wherein the inner
surface is bonded to the upper at the first segment and is not
bonded to the upper at the second segment.
2. The article of footwear of claim 1, further comprising a third
segment of the extruded component that is bonded to the upper,
wherein the second segment is between the first and third
segments.
3. The article of footwear of claim 2, wherein the second segment
is disposed over a void in the upper.
4. The article of footwear of claim 2, further comprising a tongue
region, wherein the second segment is disposed over the tongue
region.
5. The article of footwear of claim 2, wherein the first segment is
disposed on a medial side of the upper and the third segment is
disposed on a lateral side of the upper.
6. The article of footwear of claim 2, wherein a portion of the
upper disposed underneath the second segment is configured to move
independently of the second segment.
7. The article of footwear of claim 1, wherein the upper comprises
a textile fabric.
8. The article of footwear of claim 1, wherein the upper comprises
a knitted fabric.
9. An article of footwear comprising: a sole; an upper coupled to
the sole, wherein a portion of the upper comprises a non-stick
material; and an extruded component having a bonded segment and a
non-bonded segment, wherein the non-bonded segment is disposed over
the non-stick material.
10. The article of footwear of claim 9, wherein the bonded segment
comprises two portions and the non-bonded segment is disposed
between the two portions of the bonded segment.
11. The article of footwear of claim 9, wherein the upper comprises
one of a knit, woven, or non-woven material.
12. The article of footwear of claim 9, wherein the non-stick
material comprises a coating.
13. The article of footwear of claim 9, wherein the portion of the
upper comprising the non-stick material is configured to move
independently of the non-bonded segment.
14. An article of footwear comprising: a sole; an upper coupled to
the sole; and an extruded component having a bonded segment and a
non-bonded segment, the non-bonded segment forming an upper support
element configured to provide support to a wearer of the article of
footwear in a midfoot region of the article of footwear.
15. The article of footwear of claim 14, wherein the bonded segment
of the extruded component is bonded to a portion of the upper.
16. The article of footwear of claim 14, wherein the bonded segment
of the extruded component is bonded to a portion of the sole.
17. The article of footwear of claim 14, wherein the upper support
element comprises a non-extruded component.
18. The article of footwear of claim 17, wherein the non-extruded
component comprises loops configured to receive laces.
19. The article of footwear of claim 17, wherein the non-extruded
component is embedded within the extruded component.
20. The article of footwear of claim 14, further comprising a
second extruded component having a bonded segment and a non-bonded
segment, the second extruded component disposed on an opposite side
of the article of footwear from the extruded component.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional of U.S. patent application
Ser. No. 16/047,821, filed Jul. 27, 2018, the disclosure of which
is incorporated herein in its entirety by reference thereto. U.S.
patent application Ser. No. 16/047,821 is a continuation of U.S.
patent application Ser. No. 15/644,463, filed Jul. 7, 2017 and
entitled, "Article of Footwear with Extruded Components," the
disclosure of which is incorporated herein in its entirety by
reference thereto.
BACKGROUND
Field
[0002] Embodiments of the present invention relate generally to
articles of footwear; and more specifically to articles of footwear
with extruded (e.g., dispensed) components.
Background
[0003] Individuals can be concerned with the amount of cushioning
an article of footwear provides, as well as the aesthetic appeal of
the article of footwear. This is true for articles of footwear worn
for non-performance activities, such as a leisurely stroll, and for
performance activities, such as running, because throughout the
course of an average day, the feet and legs of an individual are
subjected to substantial impact forces. When an article of footwear
contacts a surface, considerable forces may act on the article of
footwear and, correspondingly, the wearer's foot.
[0004] The human foot is a complex and remarkable piece of
machinery, capable of withstanding and dissipating many impact
forces. The natural padding of fat at the heel and forefoot, as
well as the flexibility of the arch, help to cushion the foot.
Although the human foot possesses natural cushioning and rebounding
characteristics, the foot alone is incapable of effectively
overcoming many of the forces encountered during every day
activity. Unless an individual is wearing footwear that provides
proper cushioning, support, and flexibility, the soreness and
fatigue associated with every day activity is more acute, and its
onset accelerated. The discomfort for the wearer that results may
diminish the incentive for further activity. Also, inadequate
cushioning, support, or flexibility in an article of footwear can
lead to injuries such as blisters; muscle, tendon, and ligament
damage; and bone stress fractures. Improper footwear can also lead
to other ailments, including back pain.
BRIEF SUMMARY
[0005] Articles of footwear with extruded (e.g., dispensed)
components are disclosed. The components may be formed via an
automated dispensing process that is done robotically. In some
embodiments, an upper for an article of footwear includes a first
upper panel, a second upper panel, and an extruded component. In
some embodiments, the extruded component is disposed along a border
between the first upper panel and the second upper panel. In some
embodiments, the extruded component joins the first upper panel to
the second upper panel.
[0006] In some embodiments, the extruded component is polyurethane
(or another suitable polymeric material). In some embodiments, a
material of the first upper panel is different than a material of
the second upper panel. In some embodiments, the extruded component
forms a portion of a closure system for the article of footwear. In
some embodiments, the upper also includes a seam joining the first
upper panel and the second upper panel.
[0007] In some embodiments, the extruded component is disposed on
an exterior surface of the first upper panel and the second upper
panel. In some embodiments, the extruded component forms an
exterior surface of the upper.
[0008] In some embodiments, the upper also includes a third upper
panel and an additional extruded component. In some embodiments,
the additional extruded component is disposed along a border
between the first upper panel and the third upper panel. In some
embodiments, the additional extruded component joins the first
upper panel to the third upper panel.
[0009] In some embodiments, an article of footwear includes a sole,
an upper having a plurality of panels, and an upper extruded
component joining two adjacent panels of the plurality of panels
together. In some embodiments, the two adjacent panels are joined
together only by the upper extruded component.
[0010] In some embodiments, the upper extruded component joins each
of the plurality of panels to adjacent panels. In some embodiments,
each of the plurality of panels are joined together only by the
upper extruded component.
[0011] In some embodiments, the sole includes a sole extruded
component. In some embodiments, the sole extruded component is a
ground-contacting surface of the article of footwear. In some
embodiments, the sole extruded component extends from a heel area
of the article of footwear to a toe area of the article of
footwear. In some embodiments, the sole extruded component may be
discontinuous (e.g., separate heel and forefoot extruded
components). In some embodiments, the sole extruded component may
be positioned only in a portion of the article of footwear (e.g.,
heel area only, midfoot area only, forefoot area only, or a
combination thereof). In some embodiments, the sole extruded
component extends above the sole to form a closure system for the
article of footwear.
[0012] In some embodiments, the plurality of panels includes at
least ten panels. In some embodiments, at least one panel of the
plurality of panels is a heel counter.
[0013] In some embodiments, a method of making an upper includes
shaping a first panel to form part of the upper, shaping a second
panel to form another part of the upper, placing the first panel
adjacent to the second panel, and extruding a component along a
border between the first panel and the second panel to join the
first panel and the second panel together.
[0014] In some embodiments, placing the first panel adjacent to the
second panel includes abutting the first panel against the second
panel. In some embodiments, the method also includes shaping
additional panels to form parts of the upper and extruding the
component along borders between the additional panels, the first
panel, and the second panel to join each of the panels to form the
entire upper. In some embodiments, the first panel completely
surrounds the second panel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The accompanying drawings, which are incorporated herein and
form a part of the specification, illustrate the present invention
and, together with the description, further serve to explain the
principles of the invention and to enable a person skilled in the
pertinent art to make and use the invention.
[0016] FIG. 1 shows a perspective view of an article of footwear
according to some embodiments.
[0017] FIG. 2 shows a front view of an article of footwear
according to some embodiments.
[0018] FIG. 3 shows a back view of an article of footwear according
to some embodiments.
[0019] FIG. 4 shows a medial side view of an article of footwear
according to some embodiments.
[0020] FIG. 5 shows a lateral side view of an article of footwear
according to some embodiments.
[0021] FIG. 6 shows a top view of an article of footwear according
to some embodiments.
[0022] FIG. 7 shows a bottom view of an article of footwear
according to some embodiments.
[0023] FIG. 8 shows a top view of an upper layout for an article of
footwear according to some embodiments.
[0024] FIG. 9 shows a bottom view of an upper layout for an article
of footwear according to some embodiments.
[0025] FIG. 10 shows a top view of an upper layout for an article
of footwear according to some embodiments.
[0026] FIG. 11 shows a bottom view of an upper layout for an
article of footwear according to some embodiments.
[0027] FIG. 12 shows a bottom view of a sole for an article of
footwear according to some embodiments.
[0028] FIG. 13 shows a top view of a sole for an article of
footwear according to some embodiments.
[0029] FIG. 14 shows a side view of a sole for an article of
footwear according to some embodiments.
[0030] FIGS. 15A-15I show portions of an upper with an extruded
component according to some embodiments.
[0031] FIG. 16 shows an article of footwear having an upper support
element with an extruded component according to some
embodiments.
[0032] FIG. 17 shows an upper support element for an article of
footwear made with an extruded component according to some
embodiments.
[0033] FIG. 18 shows an upper support element for an article of
footwear made with an extruded component according to some
embodiments.
[0034] FIG. 19 shows an upper support element for an article of
footwear made with an extruded component according to some
embodiments.
[0035] FIG. 20 shows an upper support element for an article of
footwear made with an extruded component according to some
embodiments.
[0036] FIG. 21 shows an upper support element for an article of
footwear made with an extruded component according to some
embodiments.
[0037] FIG. 22 shows an upper support element for an article of
footwear made with an extruded component according to some
embodiments.
[0038] FIG. 23 shows an upper support element for an article of
footwear made with an extruded component according to some
embodiments.
[0039] FIG. 24 shows a portion of a sole during the process of
creating the sole for an article of footwear according to some
embodiments.
[0040] FIG. 25 shows a portion of a sole during the process of
creating the sole for an article of footwear according to some
embodiments.
[0041] FIG. 26 shows a portion of a sole during the process of
creating the sole for an article of footwear according to some
embodiments.
[0042] FIG. 27 shows a portion of a sole during the process of
creating the sole for an article of footwear according to some
embodiments.
[0043] FIG. 28 shows a sole for an article of footwear according to
some embodiments.
[0044] FIG. 29 shows an upper support element and an upper layout
for an article of footwear according to some embodiments.
[0045] FIG. 30 shows an upper support element and an upper layout
for an article of footwear according to some embodiments.
[0046] FIG. 31 shows an upper support element and an upper layout
for an article of footwear according to some embodiments.
[0047] FIG. 32 shows an upper support element and an upper layout
for an article of footwear according to some embodiments.
[0048] FIG. 33 shows an article of footwear with an extruded
component according to some embodiments.
[0049] FIG. 34 shows an upper support element for an article of
footwear made with an extruded component according to some
embodiments.
DETAILED DESCRIPTION
[0050] The present invention will now be described in detail with
reference to embodiments thereof as illustrated in the accompanying
drawings, in which like reference numerals are used to indicate
identical or functionally similar elements. References to "one
embodiment", "an embodiment", "an example embodiment", etc.,
indicate that the embodiment described may include a particular
feature, structure, or characteristic, but every embodiment may not
necessarily include the particular feature, structure, or
characteristic. Moreover, such phrases are not necessarily
referring to the same embodiment. Further, when a particular
feature, structure, or characteristic is described in connection
with an embodiment, it is submitted that it is within the knowledge
of one skilled in the art to affect such feature, structure, or
characteristic in connection with other embodiments whether or not
explicitly described.
[0051] The term "invention" or "present invention" as used herein
is a non-limiting term and is not intended to refer to any single
embodiment of the particular invention but encompasses all possible
embodiments as described in the application.
[0052] The following examples are illustrative, but not limiting,
of the present invention. Other suitable modifications and
adaptations of the variety of conditions and parameters normally
encountered in the field, and which would be apparent to those
skilled in the art, are within the spirit and scope of the
invention.
[0053] Embodiments of the present invention provide articles of
footwear having one or more extruded components created by an
automated dispensing process. It is understood that while the term
"extruded" is generally used herein to refer to certain materials,
these materials may also be "dispensed," for example, dispensed
from a mechanical device. Thus, the term "extruded component"
includes components that are extruded and components that are
dispensed.
[0054] In some embodiments, an upper and/or a sole of the article
of footwear may have one or more extruded components. In some
embodiments, an upper and/or a sole, or portions thereof, can be
formed from one or more extruded components. In some embodiments,
the extruded component can be a single, continuous piece of solid
material. An extruded footwear component can have advantages over
traditionally-formed components, such as those made by casting,
pouring, injection molding, screen-printing, or thermo-plastically
forming. For example, an extruded component can be customized
without having to machine a new, expensive mold. The use of
extruded components can also allow for the use of shapes and
geometries that are difficult to achieve using conventional upper
or bottom molding techniques. Moreover, the data and knowledge to
make an extruded component can be quickly deployed to any location
that houses equipment and material suitable for processing.
[0055] Various physical properties of the extruded component can be
manipulated, adjusted, altered, and/or modified. For example, in
some embodiments, the width, length, shape, wall thickness, color,
density, elasticity, material, viscosity, hardness, etc. of the
extruded component can vary along the extruded component or between
a first and second extruded component. As an example, an extruded
component on an upper may be less viscous than an extruded
component on a sole, which can help the extruded component on the
upper lay flat. As another example, an extruded upper component may
be rigid in a first portion, flexible in a second portion that is
continuous with the first portion, and rigid in a third portion
that is continuous with the first portion. The extruded upper
component may similarly vary in other characteristics, such as
color.
[0056] In some embodiments, the extruded component can be made of
rubber, foam (e.g., dispensed polyurethane foam), silicone, plastic
including thermoplastic (e.g., polyurethane (such as TPU), nylon,
or polypropylene), or any other suitable material. In some
embodiments, the extruded component can be made of a composite
material. In some embodiments, the cross-section of the extruded
component can be substantially circular, oval, rectangular,
triangular, square, or any other suitable shape or design (e.g.,
star-shaped). In some embodiments, the cross-section of the
extruded component can be relatively flat (i.e., low profile).
Moreover, the cross-section of the extruded component may be
adjusted dynamically and may vary throughout the automated
dispensing process.
[0057] In some embodiments, the extruded component can be extruded
directly onto the article of footwear, such as directly onto the
sole (e.g., insole, midsole, and/or outsole) or the upper. For
example, the extruded component can be extruded or dispensed
directly onto a formed upper on a last (e.g., a flat knit upper, a
circular knit upper, a formed three-dimensional knit, a sock, a
fully-finished traditionally-lasted upper, etc.). The upper may be
made of a textile fabric, leather, synthetic, or film product. In
some embodiments, the extruding or dispensing is done automatically
(i.e., robotically). In some embodiments, a scanner may scan the
upper and then robotically dispense the extruded component onto the
upper based on the scan.
[0058] In some embodiments, the extruded component can be used to
partially or completely join a plurality of panels together to form
the upper. In some embodiments, the extruded component can be
extruded along the border between two panels. In some embodiments,
the extruded component may bond (e.g., by thermal fusion, chemical
adhesion, or mechanical locking) to a portion of the article of
footwear (e.g., one or more panels). In some embodiments, a portion
of the extruded component may bond to the article of footwear,
while another portion of the extruded component does not bond to
the article of footwear.
[0059] In some embodiments, the extruded component may form an
upper support element for the article of footwear. In some
embodiments, the extruded component may be used as part of a
closure system for the article of footwear. For example, the
extruded component may support laces or other securement straps for
securing the article of footwear to the wearer.
[0060] In some embodiments, the article of footwear may include or
utilize any of the extruded components or other features disclosed
in U.S. application Ser. No. 14/455,650, filed Aug. 8, 2014, and/or
U.S. application Ser. No. 14/945,077, filed Nov. 18, 2015, the
disclosures of which are incorporated herein in their entireties by
reference thereto.
[0061] In some embodiments, extruded components may be extruded
directly onto other portions of an article of footwear, such as
article of footwear 100 shown in FIGS. 1-7. In some embodiments,
article of footwear 100 may include a sole 110 and an upper 120. In
some embodiments, sole 110 and/or upper 120 include an extruded
component. The component may be extruded onto a surface so as to
provide an extruded component that extends above the surface at a
certain width and height profile. In some embodiments, the height,
width, or geometry or physical appearance/characteristic of the
extruded components may be dynamically changed as the components
are extruded onto article of footwear 100, such as onto upper 120.
In some embodiments, the geometry or physical
appearance/characteristics of the extruded components may be
changed by dynamically changing the height of the nozzle (relative
to the dispensing surface or substrate) from which the material,
used to form the component, is extruded. In some embodiments, the
geometry or physical appearance/characteristics of the extruded
components may be changed by dynamically changing the speed at
which the nozzle is moving as the material is extruded and the
component is formed. In some embodiments, the geometry or physical
appearance/characteristics of the extruded components may be
changed by dynamically changing the flow rate of the material that
is extruded. Other parameters may be changed to dynamically change
the height, width, or other characteristic of the extruded
components. In some embodiments, the density or viscosity of the
extruded components may be changed. For example, a low density
extruded component may be used to form a collar of the upper
120.
[0062] In some embodiments, upper 120 has one or more panels 130
and one or more upper extruded components 140 that define all or a
portion of the area of the upper. In some embodiments, panels 130
comprise individual textile pieces. In some embodiments, panels 130
may be made of leather, synthetic leather, plastic (e.g.,
thermoplastic film), mesh, textile, knit-goods, woven-goods,
non-woven, or other suitable materials. In some embodiments, panels
130 may be made of a knitted or woven fabric. In some embodiments,
panels 130 may be made of a non-knitted or non-woven fabric. In
some embodiments, upper 120 is a knit upper. In some embodiments,
upper 120 is a circular knit upper. For example, a portion or the
entirety of upper 120 may be circular knit. In some embodiments,
upper 120 is a 360 degree circular knit upper. In some embodiments,
upper 120 is a flat knit upper. For example, a portion or the
entirety of upper 120 may be flat knit.
[0063] In some embodiments, upper 120 comprises at least five
panels 130. In some embodiments, upper 120 comprises at least ten
panels 130. In some embodiments, panels 130 may differ from one
another in size, shape, material, and/or other characteristics. In
some embodiments, the characteristics vary based on desired
functions of article of footwear 100 at particular locations. For
example, in some embodiments, upper 120 comprises one or more
panels 132 configured to provide additional support, such as in a
heel region of upper 120. In some embodiments, panels 132 comprise
a heel counter (see FIG. 3). In some embodiments, upper comprises
one or more panels 134 made of a first material and one or more
panels 136 made of a second material. In some embodiments, panels
134 are made of a knitted fabric and panels 136 are made of a
non-knitted fabric.
[0064] In some embodiments, upper extruded components 140 are
extruded directly onto upper 120 (e.g., panels 130 of upper 120) to
form a portion of upper 120. In some embodiments, upper extruded
components 140 may have a lower viscosity than other extruded
components (e.g., extruded components in sole 110). Accordingly,
upper extruded components 140 may be relatively flat on upper 120
(see, e.g., FIG. 2). In some embodiments, upper extruded components
140 are disposed on an exterior portion of article of footwear 100.
In some embodiments, upper extruded components 140 form an exterior
portion of article of footwear 100.
[0065] In some embodiments, upper extruded components 140 provide
aesthetic and functional features of article of footwear 100. In
some embodiments, upper extruded components 140 may form a pattern
on upper 120. In some embodiments, upper extruded components 140
may be a single, continuous element. In some embodiments, upper
extruded components 140 may include a plurality of continuous
elements. In some embodiments, upper extruded components 140
include one or more extruded components 142 that are disposed along
a border (i.e., transition) between two or more panels 130 or an
area of overlap between two or more panels 130, one or more
extruded components 144 that are disposed across (but not along a
border between) one or more panels 130, and one or more extruded
components 146 that completely surround a panel 130 along the
border of panel 130. In some embodiments, a single upper extruded
component 140 may form both an extruded component 142 and an
extruded component 144. In some embodiments, a single upper
extruded component 140 may form both an extruded component 142 and
an extruded component 146. In some embodiments, a single upper
extruded component 140 may form both an extruded component 144 and
an extruded component 146.
[0066] In some embodiments, upper extruded components 140 form part
of a closure system for article of footwear. For example, as shown
in FIG. 1, laces 150 extend through upper 120 between portions of
upper extruded component 144. This may strengthen the hole that
receives laces 150. In some embodiments, upper extruded components
140 may provide a loop to receive laces 150. In some embodiments,
extruded components may support other components configured to
receive laces 150.
[0067] In some embodiments, upper extruded components 140 (e.g.,
extruded component 142, extruded component 144, or extruded
component 146) join two or more panels 130 together. In some
embodiments, upper extruded components 140 are the only means for
joining panels 130 together (i.e., panels 130 are not sewn, joined
with an adhesive, joined with low-melt film, laser-welded,
ultrasonically welded, radio-frequency welded, or otherwise joined
together except by upper extruded components 140). In some
embodiments, panels 130 are joined together by upper extruded
components 140 as well as being sewn, joined with an adhesive,
laser-welded, ultrasonically welded, or radio-frequency welded.
[0068] In some embodiments, two or more panels 130 are joined
together or coupled at a seam. In some embodiments, the seam may
include one or more of upper extruded component 140, adhesive,
stitching, or another suitable redundant joining method. In some
embodiments, the seam is a stitchless seam. In some embodiments,
the seam is a stitchless seam with an overlay. In some embodiments,
the seam is a butt seam. In some embodiments, the seam is a hidden
seam (e.g., closed seam). In some embodiments, the seam is covered
with seam tape. For example, the seam may include upper extruded
component 140 on an outer surface of upper 120 and seam tape on an
inner surface of upper 120. In some embodiments, the seam comprises
an area of overlap between the two panels 130.
[0069] For example, a layout for an upper 120 is shown in FIGS. 8
and 9. The various panels 130 making up upper 120 (including panels
132, panels 134, and panels 136) are joined together by upper
extruded components 140. Some of upper extruded components 140
extend along the border between panels 130 (i.e., extruded
components 142). Some of upper extruded components 140 extend
across multiple panels 130, but not along a border between panels
130 (i.e., extruded components 144). Some of upper extruded
components 140 extend to completely surround a panel 130 (i.e.,
extruded components 146). As shown on the inner side of upper 120
(see FIG. 9), no additional element or means (other than upper
extruded components 140) joins panels 130 together.
[0070] The placement of upper extruded components 140 is not
limited to a particular design or configuration. Instead, upper
extruded components 140 may be dispensed in a desired location to
provide a desired function or aesthetic. An additional example of
upper 120 is provided in FIGS. 10 and 11. In some embodiments, as
shown in FIGS. 10 and 11, all upper extruded components 140 are
extruded components 142 (i.e., all upper extruded components 140
extend along a border between panels 130). As shown on the inner
side of upper 120 (see FIG. 11), no additional element or means
(other than upper extruded components 140) joins panels 130
together.
[0071] In some embodiments, upper 120 is made by shaping a
plurality of panels 130 to form parts of the upper. In some
embodiments, a first panel 130 may be shaped to form part of upper
120. For example, the first panel 130 may be cut to a particular
shape. In some embodiments, a second panel 130 may also be shaped
to form another part of upper 120, for example, by cutting. In some
embodiments, the first and second panels 130 may be placed adjacent
to each other. For example, the first panel 130 may be abutted
against the second panel 130 to form a border. In some embodiments,
a component 140 is extruded along a border between the first and
second panels 130. As extruded component 140 hardens, extruded
component 140 bonds with first and second panels 130 and thus joins
first and second panels 130 together. In some embodiments,
component 140 is extruded onto panels 130 in a flat configuration.
In some embodiments, component 140 is extruded onto panels 130 in a
three dimensional configuration (e.g., onto a contoured surface).
For example, component 140 may be extruded onto panels 130 when
panels 130 are on a shoe last, a foot form, or any other
three-dimensional form suitable for holding panels 130. While only
two panels 130 are discussed here, additional panels 130 may be
shaped to form other parts of upper 120 and components 140 may be
extruded along each of the borders between panels 130 to join
panels 130 together to form the entire upper 120. In some
embodiments, one panel 130 may completely surround another panel
130.
[0072] In some embodiments, as shown, for example, in FIGS. 1-7,
sole 110 comprises various layers of extruded components. In some
embodiments, sole 110 can provide the desired ride and feel
characteristics to the wearer. In some embodiments, sole 110 can
minimize the weight of article of footwear 100; control the
flexion, resilience, and support of article of footwear 100; and
provide customized desired cushioning and shape for an article of
footwear 100. In some embodiments, sole 110 comprises an extruded
component 112. In some embodiments, extruded component 112 is
disposed at the junction between sole 110 and upper 120. In some
embodiments, extruded component 112 forms an outer edge of sole 110
and/or upper 120. In some embodiments, extruded component 112 is
one continuous component that surrounds article of footwear
100.
[0073] In some embodiments, extruded component 112 provides a base
component or layer around which the rest of sole 110 is made (see
FIGS. 24-28). For example, in some embodiments, additional layers
of extruded component(s) may be deposited adjacent to extruded
component 112 to form a portion of sole 110, such as a midsole. For
example, one or more layers 114 of extruded component may be
deposited adjacent to extruded component 112. In some embodiments,
layers 114 provide a midsole of sole 110. In some embodiments,
layers 114 are formed from one continuous extruded component. In
some embodiments, each layer 114 is formed from a separate
continuous extruded component. In some embodiments, as shown in
FIGS. 4 and 5, the number of layers 114 varies along a length of
the article of footwear 100. In some embodiments, the extruded
component of layers 114 may be extruded in a pattern, such as a
loop-forming pattern back and forth across article of footwear 100
(e.g., in a longitudinal direction, a transverse direction, or an
angled direction between a longitudinal direction and a transverse
direction). In some embodiments, the extruded component of layers
114 extends from a heel area of article of footwear 100 to a toe
area of the article of footwear 100.
[0074] In some embodiments, the extruded component of layers 114 is
discontinuous such that there are separate heel and forefoot
extruded components. In some embodiments, the extruded component of
layers 114 is positioned only in a portion of sole 110 (e.g., heel
area only, midfoot area only, forefoot area only, or a combination
thereof). In some embodiments, other portions of sole 110 may be
made of foam. For example, article of footwear 100 may include the
extruded component of layers 114 only in the heel of sole 110 with
foam in the forefoot of sole 110. As another example, article of
footwear 100 may include the extruded component of layers 114 only
in the forefoot of sole 110 with foam in the heel of sole 110. In
some embodiments, there may be more layers 114 in the heel of sole
110 than in the forefoot of sole 110 to create a heel lift. In some
embodiments, a heel lift may be created with the same number of
layers 114 in the heel of sole 110 and in the forefoot of sole 110,
but with the nozzle running faster in the forefoot and slower in
the heel.
[0075] In some embodiments, one or more layers 116 of extruded
component are deposited adjacent to layers 114 (i.e., underneath
layers 114). In some embodiments, layers 116 provide an outsole of
sole 110. In some embodiments, layers 116 are formed from one
continuous extruded component. In some embodiments, each layer 116
is formed from a separate continuous extruded component. In some
embodiments, the extruded component of layers 116 may be extruded
in a pattern, such as an undulating pattern back and forth across
article of footwear 100 (e.g., in a longitudinal direction, a
transverse direction, or an angled direction between a longitudinal
direction and a transverse direction). For example, as shown in
FIG. 7, sole 110 includes a layer 116 of an extruded component that
extends back and forth in a transverse direction across article of
footwear 100 in an undulating pattern and a layer 116 of an
extruded component that extends back and forth in an angled
direction (between the longitudinal and transverse directions)
across article of footwear 100 in an undulating pattern. In some
embodiments, layers 116 differ from layers 114 in at least one
characteristic (e.g., color, density, shape, size, material
composition, etc.). In some embodiments, layers 116 comprise a
ground-contacting surface of article of footwear 100.
[0076] In some embodiments, sole 110 is made entirely of extruded
components. For example, layers 114, layer 116 and extruded
component 112 may make up the entirety of sole 110. In some
embodiments, other materials or layers may be included in sole 110.
For example, as shown in FIGS. 12-14, a sole 210 for an article of
footwear can include one or more extruded components formed in a
controlled geometric pattern along with layers of non-extruded
material. In some embodiments, sole 210 can include one or more
layers. In some embodiments, one or more of the layers may comprise
an extruded member. In some embodiments, one or more of the layers
may comprise a material that is not extruded. For example, in some
embodiments, sole 210 includes layers 212 that comprise a material
that is not extruded and layers 214 and/or layers 216 that comprise
an extruded material. In some embodiments, layers 214 may have
similar characteristics as layers 114. In some embodiments, layers
216 may have similar characteristics as layers 116. In some
embodiments, the extruded components of layers 214 and 216 may be
aligned with each other such that they follow the same pattern. In
some embodiments, sole 210 comprises cushioning elements 218, as
shown in FIG. 12. In some embodiments, cushioning elements 218
comprises an extruded component. For example, cushioning elements
218 may be extruded into loops formed by layer 216. In some
embodiments, layer 216 and/or cushioning element 218 comprise a
ground-contacting surface of the article of footwear.
[0077] In some embodiments, sole 210 comprises alternating layers
(i.e., layers that comprise an extruded member (layers 214 and/or
layers 216) alternating with layers that do not comprise an
extruded member (layer 212)). For example, as shown in FIG. 14,
sole 210 comprises layer 214, layer 212, layer 214, layer 212,
layer 214, and layer 216, in that order. Thus, layers 212 may be
disposed between layers of extruded members (i.e., layers 214).
[0078] For example, in some embodiments, a first layer 214 may be
extruded in a controlled geometric pattern. In some embodiments, a
layer 212 may then be placed adjacent to first layer 214. In some
embodiments, a second layer 214 may then be extruded over layer 212
and first layer 214. As the second layer 214 hardens, layer 212 is
secured between two extruded components. In some embodiments, this
arrangement allows for components to be embedded within a midsole
of an article of footwear. In some embodiments, layers 212 comprise
a mesh material. In some embodiments, layers 212 comprise a
nonwoven layer. In some embodiments, layer 212 may be a film, a
textile, a molded component, or other suitable material. In some
embodiments, layers 212 may extend beyond sole 210. For example,
layers 212 may extend up and attach to or form part of an upper. In
some embodiments, other components (other than layer 212) may be
disposed between layers 214 or between two or more extruded
components.
[0079] In some embodiments, as shown, for example, in FIGS.
15A-15I, extruded components 240 may be deposited in a variety of
designs. In some embodiments, extruded component 240 may be
deposited in a back and forth undulating pattern to secure upper
parts 232 to a portion 230 of an upper. In some embodiments,
extruded component 240 secures parts 232 to reduce stretching or
moving of parts 232 around on the upper. In some embodiments, part
232 comprises a tip of the upper, as shown in FIG. 15A. In some
embodiments, part 232 comprises a counter of the upper, as shown in
FIG. 15B. In some embodiments, as shown in FIG. 15C, a
non-continuous extruded component 242 may join panels 234 and 236
together. For example, a plurality of deposits of non-continuous
extruded component 242 along a border between panels 234 and 236
may join panels 234 and 236 together. In some embodiments, as shown
in FIGS. 15D and 15E, extruded component 240 may provide a pattern
on a portion 230 of an upper. In some embodiments, as shown in FIG.
15F, extruded component 240 may provide a pattern and join panels
234 and 236 together. In some embodiments, as shown in FIG. 15G,
non-continuous extruded component 242 may secure part 232 onto a
portion 230 of an upper without being deposited along a border of
part 232, for example, if part 232 comprises a mesh material.
Alternatively, there may be a cut-out or a void in part 232 for the
material of non-continuous extruded component 242 (e.g., extruded
dots) to flow into and bond to portion 230 of an upper. In some
embodiments, as shown in FIG. 15H, some parts 232 may be joined to
portion 230 of the upper by an extruded component 240 deposited
along a border of part 232, while other parts 232 may be joined to
portion 230 of the upper by an extruded component deposited back
and forth across part 232. In some embodiments, as shown in FIG.
15I, the border between panels 234 and 236 may not be straight. For
example, the border between panels 234 and 236 may curve back and
forth. In some embodiments, extruded component 240 may curve back
and forth along the border between panels 234 and 236.
[0080] In some embodiments, a segment of an extruded component may
bond or stick to an article of footwear and another segment of the
extruded component may not bond or stick to the article of
footwear. In some embodiments, having a bonded segment and a
non-bonded segment of the extruded component allows a designated
part of the article of footwear (e.g., the substrate) to stretch
and move independently from the extruded component (and/or where
the extruded component bonds to the substrate). In some
embodiments, the non-bonded segment of the extruded component may
extend over a hole or void in the upper (and/or substrate). In some
embodiments, the non-bonded segment of the extruded component may
extend over a tongue of the upper. For example, the extruded
component may be bonded to an article of footwear on both a medial
side and a lateral side (e.g., at the feather line, at the
quarters, etc.) and include a non-bonded segment that extends over
a tongue of the upper. In some embodiments, the non-bonded segment
of the extruded component may extend over a portion of the upper to
provide stress relief.
[0081] In some embodiments, to form the non-bonded segment of the
extruded component, the component is extruded over a non-stick
material (see FIG. 32). A non-stick material is any material that
does not bond with the extruded component as it hardens. In some
embodiments, the non-stick material may be removed after the
extruded component has hardened, thus leaving a non-bonded segment
of the extruded component. In some embodiments, the non-stick
material may be a temporary insert made from
polytetrafluoroethylene (PTFE), or other suitable non-stick
material. In some embodiments, the non-stick material may be screen
printed or sprayed over a portion of the article of footwear, such
as a portion of a panel. In some embodiments, a last on which the
component is extruded may be made of or coated with the non-stick
material. In some embodiments, the article of footwear may have an
upper that is completely knit (e.g., flat knit, circular knit,
etc.) with areas of the knit upper comprising yarns that are
inherently non-stick (e.g., PTFE yarns, polyolefin yarns,
ultra-high-molecular-weight polyethylene (UHMWPE) yarn). In some
embodiments, the upper may include woven, non-woven, or knit
sections that are entirely made from non-stick yarns that are
seamed together (i.e., stitched) to other upper panels that are
made from traditional yarns (i.e., polyester, nylon, etc.) that may
or may not be coated with the non-stick material.
[0082] In some embodiments, an entire extruded component 254 may be
made as a non-bonded segment (i.e., the extruded component is
dispensed only over a non-stick material to form a stand-alone
component), as shown, for example, in FIG. 34. In some embodiments,
the extruded component 254 may then be attached to an article of
footwear. For example, the extruded component 254 may be attached
to an article of footwear as an upper support element 250. In some
embodiments, an extruded component that is a stand-alone component
may be attached to an article of footwear as a heel counter.
[0083] In some embodiments, as shown, for example, in FIG. 16, a
non-bonded segment of an extruded component 254 may form an upper
support element 250 of article of footwear 100. In some
embodiments, upper support element 250 may provide support to the
wearer in the midfoot region of article of footwear 100. In some
embodiments, upper support element 250 comprises a non-extruded
component 252. In some embodiments, non-extruded component 252
comprises loops to receive laces. In some embodiments, as shown in
FIG. 17, upper support element 250 may comprise an additional layer
256. In some embodiments, extruded component 254 is bonded to
additional layer 256. In some embodiments, additional layer 256
comprises a mesh material.
[0084] In some embodiments, upper support element 250 is attached
to article of footwear 100. In some embodiments, as shown in FIG.
18, upper support element 250 is attached to article of footwear
100 at attachment portion 105 of article of footwear 100. In some
embodiments, attachment portion 105 comprises part of the upper of
article of footwear 100. In some embodiments, attachment portion
105 comprises part of the sole of article of footwear 100. In some
embodiments, attachment portion 105 is any other part of article of
footwear 100 (e.g., between the sole and the upper). In some
embodiments, attachment portion 105 may be disposed between the
sole and the upper at the feather line of the article of footwear.
In some embodiments, attachment portion 105 is tucked under
portions of the upper and/or sole. For example, attachment portion
105 may be tucked under the midsole. In some embodiments,
attachment portion 105 is bonded to an extruded component of the
sole.
[0085] In some embodiments, attachment portion 105 is stitched to
article of footwear 100. In some embodiments, attachment portion
105 is adhered to article of footwear 100 with an adhesive. For
example, as shown in FIG. 29, upper support element 250 is bonded
to attachment portion 105 via extruded component 254 and attachment
portion 105 is then attached to the rest of an upper 120 (e.g., via
stitching, joined with an adhesive, laser-welded, ultrasonically
welded, radio-frequency welded, low-melt film or any other suitable
method for joining). In some embodiments, attachment portion 105 is
an integral part of article of footwear 100 and upper support
element 250 is attached to article of footwear 100 via extruded
component 254 (i.e., extruded component 254 bonds with attachment
portion 105 as extruded component 254 hardens). For example, as
shown in FIGS. 30 and 32, attachment portion 105 may be a part of
upper 120. In some embodiments, extruded component 254 bonds
directly to upper 120. In some embodiments, extruded component 254
does not include a non-bonded segment (see FIG. 30). In some
embodiments, extruded component 254 includes a non-bonded segment
(see FIG. 32). For example, a removable non-stick component 255 may
be inserted under portions of extruded component 254. In some
embodiments, as shown in FIG. 31, attachment portion 105 comprises
the randing 106 of article of footwear. Extruded component 254 may
bond directly with randing 106. Other means of attaching upper
support element 250 to article of footwear 100 may also be
used.
[0086] In some embodiments, a portion of non-extruded component 252
may be embedded within extruded component 254. Non-extruded
component 252 may take a variety of forms. In some embodiments,
non-extruded component 252 may comprise a piece of fabric that
extends from extruded component 254 and includes a plurality of
loops to receive laces, as shown, for example, in FIGS. 16, 18, and
20.
[0087] In some embodiments, non-extruded component 252 may
comprises a strip of fabric that extends across the top of extruded
component 254 and includes a plurality of loops to receive laces,
as shown in FIG. 17.
[0088] In some embodiments, a gap 253 separates part of
non-extruded component 252 from extruded component 254. In some
embodiments, non-extruded component 252 comprises a plurality of
strips of material that extend from the bottom of extruded
component 254 to beyond the top of extruded component 254, as shown
in FIG. 19. In some embodiments, each strip of material comprises a
loop to receive laces
[0089] In some embodiments, non-extruded component 252 comprises a
yarn, thread, or string that extends across the top of extruded
component 254, as shown in FIGS. 21 and 22. Several portions of the
yarn, thread, or string may be bonded with extruded component 254
while several other portions of the yarn, thread, or string are not
bonded and form loops to receive laces.
[0090] In some embodiments, non-extruded component 252 comprises a
plurality of yarns, threads, or strings that extend from the bottom
of extruded component 254 to beyond the top of extruded component
254, as shown in FIG. 23. In some embodiments, the plurality of
yarns, threads, or strings also extend beyond the bottom of
extruded component 254. In some embodiments, a portion 258 of
yarns, threads, or strings is configured to extend underneath upper
(e.g., between upper and sole, or within sole).
[0091] For example, as shown in FIGS. 24 and 25, a sole may be
formed by vacuum forming a film 300, such as a polyurethane film,
and extruding a component 310 into a groove formed in the vacuum
formed film 300. In some embodiments, component 310 may be similar
to extruded component 112. In some embodiments, one or more
non-extruded components 252 may be placed over extruded component
310 and vacuum formed film 300, as shown in FIGS. 26 and 27. In
some embodiments, portions 258 of non-extruded components 252 are
disposed on an inside of the area formed by extruded component
310.
[0092] In some embodiments, as shown in FIG. 28, layers of extruded
component 320 may then be extruded over non-extruded component 252
and extruded component 310, thus securing non-extruded component
252 within the sole. Vacuum formed film 300 may be removed (see
FIG. 28) after extruded components 310 and/or 320 have set. In some
embodiments, instead of placing non-extruded component 252 over
extruded component 310, non-extruded component 252 may be placed
between layers of extruded component 320. In some embodiments, a
sole may be formed without a vacuum formed film (e.g., via plasma
coated rapid prototype tooling).
[0093] In some embodiments, as shown, for example, in FIG. 33, an
article of footwear 400 may comprise a sole 410 and an upper 420.
In some embodiments, sole 410 is made of extruded components. In
some embodiments, article of footwear 400 may comprise an upper
extruded component 430. In some embodiments, upper extruded
component 430 may extend from a side of sole 410. In some
embodiments, upper extruded component 430 extends above sole 410.
In some embodiments, upper extruded component 430 may form a
closure system for article of footwear 400. For example, upper
extruded component 430 may extend on the sides of upper 420 and
have loops to receive laces. In some embodiments, upper extruded
component 430 may extend above sole 410 onto upper 420 in a toe
region and a heel region of article of footwear 400. In some
embodiments, upper extruded component 430 may be bonded to article
of footwear 400 at sole 410 and not bonded to article of footwear
400 at upper 420. Thus, in some embodiments, upper 420 can move
independent of upper extruded component 430 and upper extruded
component 430 can move independent of upper 420. In addition, as
shown in FIG. 33, extruded components for sole 410 and upper
extruded component 430 may be extruded or dispensed to a single
substrate.
[0094] Various embodiments described herein allow for joining of
individual panels together via an extruded component and allow for
the use of shapes and geometries that may be difficult to achieve
with conventional molding techniques. Various embodiments described
herein provide the use of extruded components to customize articles
of footwear. Various embodiments described herein provide extruded
components that have segments that are bonded to the article of
footwear (e.g., bonded to the sole or upper) and segments that are
not bonded. Further variations of the embodiments described above
may also be provided.
[0095] The foregoing description of the specific embodiments will
so fully reveal the general nature of the invention that others
can, by applying knowledge within the skill of the art, readily
modify and/or adapt for various applications such specific
embodiments, without undue experimentation, without departing from
the general concept of the present invention. Therefore, such
adaptations and modifications are intended to be within the meaning
and range of equivalents of the disclosed embodiments, based on the
teaching and guidance presented herein. It is to be understood that
the phraseology or terminology herein is for the purpose of
description and not of limitation, such that the terminology or
phraseology of the present specification is to be interpreted by
the skilled artisan in light of the teachings and guidance.
[0096] The breadth and scope of the present invention should not be
limited by any of the above-described exemplary embodiments, but
should be defined only in accordance with the following claims and
their equivalents.
* * * * *