Patent Description:
The manufacturing of footwear is usually done in a factory, with runs of large quantities of identical footwear. For example, uppers are secured to sole structures in factories by stitching, with adhesives, or by thermal processes such as thermal bonding. If a manufacturer offers customers the ability to request customized footwear, the individual custom orders must be tracked at the factory. This process can be time consuming in comparison to the manufacturing of stock (non-customized) footwear. Additionally, the time from receipt of the order to customer receipt of the customized footwear may be weeks longer than if a non-customized pair of footwear is ordered. Document <CIT> describes a shoe having a rigid or semi-rigid sole and an upper integrated to the sole. A removable vamp is mounted on the sole and includes a forepart. The vamp includes fixing units cooperating with complementary fixing units integrated to the sole and with complementary fixing units integrated to inner quarter and an outer quarter of the upper. The inner and outer quarters completely extend to a plantar arch of the sole. A dog-point or covering element is positioned at a distance relative to upper edge of the sole. Document <CIT> describes a shoe consisting of a lower part or base and a heel which base is surmounted by an upper part or upper one of the parts forming the base or upper being respectively interchangeable with relative to each other by means of retractable connecting means arranged additionally on the periphery of the base and of the rod. Document <CIT> describes an athletic shoe that includes a resilient sole portion and an upper portion having an ankle enclosing section and a toe enclosing section. The toe enclosing section is hinged to the inner edge of the resilient sole and swings upwardly for introduction of the wearer's foot. The toe enclosing section is detachably secured to the outer edge of the sole portion. Document <CIT> describes a shock-absorbing system for a shoe comprising an upper shell having a forefoot portion, a midfoot portion and a rear-foot portion; a sole unit having an insole, a midsole and an outsole, the midsole or outsole being formed with a depression; a cap member received in the depression formed in the sole unit while defining an inner space of a desired cross-section, the cap member having a plurality of cushioning arms which are spaced apart from each other and have an arch-shaped configuration; and a fluid-filled bladder member nested onto the plurality of cushioning arms of the cap member. Document <CIT> describes a footwear system that is customizable and offers a plurality of interchangeable base portions, upper portions, and connector elements in various styles, colors and designs, thus allowing an assortment of easily interchangeable and distinct styles of footwear in a single system. The footwear system specifically comprises an interchangeable base portion having a plurality of spaced openings and hollow receptacles formed in the base portion, an interchangeable upper portion adapted for removable attachment to the base portion where the upper portion has a plurality of spaced openings on each side end, and a plurality of interchangeable connector elements for connecting the upper portion to the base portion, where the connector elements may have decorative elements.

A modular article of footwear according to claim <NUM> and a method of manufacturing an article of footwear according to claim <NUM> are disclosed herein. Particular embodiments of the claimed invention are further disclosed in the dependent claims.

As discussed herein, the article of footwear can be customized by selection of the module and/or by secondary processes applied to the module, such as by printing or otherwise applying a graphical image on the upper component of the module prior to securing the module to the sole structure. The modules can be pre-made, leaving only securement to the sole structure and any secondary customization to be carried out after receiving a customization request for a customer. The pre-made modules are configured to be securable to the sole structure with manufacturing methods that are relatively fast and require a minimal amount of tooling and machinery. In some cases, the customization and assembly can occur at a retail outlet while a customer waits.

In an aspect of the disclosure, the peripheral side surface of the sole structure has at least one first locating feature in the recess. The flange of the module has at least one second locating feature at the inner surface. The at least one first locating feature interfits with the at least one second locating feature. The locating features are configured in shape, location, and number to ensure that an assembler can easily, accurately, and quickly fit the flange to the sole structure. The at least one second locating feature numbers the same as the at least one first locating feature, and is complementary to the first locating feature. Stated differently, the first locating feature(s) and the second locating feature(s) are cooperatively configured with complementary shapes to interfit.

For example, the at least one first locating feature may be one of a protrusion of, or a recess in, the peripheral side surface of the sole structure. In one such embodiment, the at least one first locating feature is one of a ridge and a slot, the at least one second locating feature is the other of the ridge and the slot, and the ridge fits within the slot. In an embodiment, the slot extends in the peripheral side surface along a rear periphery of the sole structure from a medial side of the sole structure to a lateral side of the sole structure, the second locating feature is the ridge, and the ridge protrudes at the inner surface of the flange.

In an aspect of the disclosure, the sole structure and the flange may mechanically secure to one another, so that the module can be easily secured to the sole structure during the customization process. For example, the sole structure has one of a male connector and a female connector, and the flange has the other of the male connector and the female connector. The locating features may serve as the mechanical connectors, or the mechanical connectors may be additional features, such as the ridge and slot discussed herein.

Instead of or in addition to mechanical connectors, an adhesive may be disposed on either or both of the inner surface of the flange and the peripheral side surface of the sole structure to secure the flange to the sole structure. In some embodiments, the adhesive may be a hot melt adhesive, in which case the adhesive has a lower melting temperature than the material of the flange. Still further, instead of or in addition to adhesive, a thermal process may be used to secure the flange to the sole structure. For example, the upper component may include a first material, and the flange may include a second material that thermally bonds (i.e., fuses) to the sole structure under sufficient heating. For example, both the flange and the sole structure may be a polymer foam, such as a thermoplastic polymer foam or a thermoset polymer foam.

In various embodiments, the sole structure may not have any upper components secured thereto prior to the start of the customization process. Alternatively, the sole structure itself may be included in a module with an upper component that is secured to the sole structure prior to customization, in which case the sole structure with upper component secured thereto serves as a base module, and one or more other modules to be secured thereto can be selected according to a customization request. In either case, more than one module may be secured to the sole structure during the customization process, such as but not limited to two, three, four, or five modules, each module including a flange and an upper component. For example, in one embodiment, a module may include an upper component and a flange securable to the sole structure where the upper component serves as a heel region of an upper. In the same or a different embodiment, a module may include an upper component and a flange securable to the sole structure where the upper component serves as a forefoot region of the upper.

In some embodiments, the at least one recess is a single recess. For example, the sole structure and the upper component may each include a forefoot region, a midfoot region, and a heel region, the at least one recess may be a single recess extending around the peripheral side surface throughout the forefoot region, the midfoot region, and the heel region of the sole structure, and the flange may be a single flange extending around the forefoot region, the midfoot region, and the heel region of the upper component. The flange may be continuous, or in some embodiments, the upper component may have a split that helps enable the upper component to achieve a relatively flat state desirable for some customization processes. The upper component can then be seamed together at the split after customization to help achieve a three-dimensional shape that defines a foot-receiving cavity. For example, the upper component may have a split heel region, and the flange may have a first end at a medial side of the split heel region and a second end at a lateral side of the split heel region.

In an embodiment, more than one module is secured to the sole structure. For example, the upper component is a first upper component and the flange is a first flange. The article of footwear further comprises a second upper component, and a second flange secured to the second upper component and projecting therefrom. An inner surface of the second flange and the peripheral side surface of the sole structure are configured to fit against one another with the second flange in the at least one recess, the second upper component further defining the foot-receiving cavity, and the second flange secured to the peripheral side surface. In such an embodiment, when the second flange is secured to the peripheral side surface of the sole structure in the at least one recess, the second upper component is adjacent to the first upper component, and the article of footwear may have stitching that secures the second upper component to the first upper component.

In some embodiments, the at least one recess includes a first recess and a second recess separated from the first recess by a non-recessed portion of the peripheral side surface of the sole structure. In such an embodiment, the inner surface of the first flange fits against and is securable to the peripheral side surface of the sole structure with the first flange in the first recess, and the inner surface of the second flange fits against and is securable to the peripheral side surface of the sole structure with the second flange in the second recess. The first flange is separated from the second flange by the non-recessed portion of the peripheral side surface.

In another embodiment, the sole structure is included in a first module having an additional upper component secured to the sole structure and partially defining the foot-receiving cavity over the foot-facing surface. The first module is manufactured prior to the customization process. The additional upper component may be spaced apart from the at least one recess to which a second module (including the upper component and the flange) secure. In such an embodiment, when the flange of the second module is secured to the peripheral side surface of the sole structure in the recess, the additional upper component is adjacent to the upper component, and the article of footwear may include stitching that secures the second upper component to the first upper component.

In an embodiment, an outer surface of the flange may be flush with an adjacent portion of the peripheral side surface when the inner surface of the flange and the peripheral side surface of the sole structure are fit against and secured to one another with the flange in the recess.

Still further, the peripheral side surface of the sole structure may have a curvature at the recess, such as but not limited to a curvature at the rear of or at the front of the sole structure from a medial side to a lateral side of the sole structure. The upper component and the flange secured thereto may be sufficiently flexible to adopt a first state when the flange is disjoined from the sole structure, and a second state when the flange is secured to the sole structure in the recess, so that the inner surface of the flange has the curvature of the peripheral side surface in the second state.

The module with the flange and the upper component may be relatively flat in the first state in comparison to the second state. This may be advantageous for some customization processes that are more optimally performed with the module relatively flat. For example, various printing techniques that may be used for customization can be performed with the module in the first state. Some printing apparatuses more accurately print when the printer head may be maintained relatively close to the surface to be printed. In one example embodiment, a predetermined region of a surface of the upper component has a maximum variance in elevation of less than or equal to <NUM> millimeters in the first state. Such a variance in elevation may enable a customized graphical image to be applied on the upper component with an inkjet printer having a relatively stationary printer head that prints most optimally when the surface to be printed is disposed within a <NUM> millimeter range from the ink nozzle. Accordingly, in the example embodiment, the predetermined region of the surface of the upper component has a graphical image thereon and the graphical image is comprised of ink.

Additionally, the sole structure may be customized in accordance with a request for a specified stiffness or stability characteristic. For example, the sole structure may have a cavity at the peripheral side surface. The modular article of footwear may include an insert shaped and sized to fit within the cavity. The insert may have a different compressive stiffness than the sole structure. Accordingly, when the insert is placed in the cavity, the sole structure with the insert therein provides the specified stiffness or stability characteristic. References herein to a "stiffness" of a component refer to the compressive stiffness of the component.

An article of footwear comprises an upper component, and a flange secured to the upper component and projecting therefrom. The upper component is a first material and the flange is a polymer foam. For example, the flange may be a thermoplastic polymer foam material or a thermoset polymer foam material. The material of the flange may be the same as the material of a midsole of a sole structure to which it is to be secured. In some embodiments, the upper component includes a forefoot region, a midfoot region, and a heel region, and the flange extends along the forefoot region, the midfoot region, and the heel region of the upper component. In some embodiments, the upper component has a split heel region, and the flange has a first end at a medial side of the split heel region and a second end at a lateral side of the split heel region. In other embodiments, the upper component comprises only a heel region, only a midfoot region, or only a forefoot region, or not more than two selected from among a heel region, a midfoot region, and a forefoot region.

A method of manufacturing a customized article of footwear comprises receiving a request for an upper with a specified characteristic, and assembling a modular article of footwear in accordance with the request by securing a module to a sole structure. The sole structure has a foot-facing surface, a ground-engaging surface, and a peripheral side surface extending between the foot-facing surface and the ground-engaging surface, the peripheral side surface has at least one recess. The module includes an upper component having the specified characteristic, and a flange secured to the upper component and projecting therefrom. Securing the module to the sole structure comprises fitting an inner surface of the flange against the peripheral side surface of the sole structure with the flange in the at least one recess and with the upper component partially defining a foot-receiving cavity over the foot-facing surface, and securing the inner surface of the flange to the peripheral side surface of the sole structure.

The specified characteristic requested may be one of an aesthetic characteristic, a performance characteristic, a dimensional characteristic, a material, a physical property, or a footwear style. Examples of an aesthetic characteristic include a graphical image, such as a number, a picture, a name, or other text, or simply a choice of color of the upper component or a portion thereof.

Examples of performance characteristics may include upper components categorized by the manufacturer as stiff, flexible, supportive, breathable, for training, for leisure etc., and may be related to specified characteristics which are more specific physical properties, such as a stiffness within a range of numerical stiffnesses, elasticity within a range of elasticities, etc..

Examples of dimensional characteristics may include thickness of the upper, which may be determined by the amount of padding that can be added to satisfy a specified request. For example, the thickness of the upper can be selected to enable the same size sole structure to be used for different orders within a half-size of one another. A module with a relatively thick upper can be used if the customer requests footwear of a first size, while a relatively thin upper can be used if the customer requests footwear of a second size larger than the first size, as the flange that interfaces with the sole structure will be identical with either module. This enables a smaller inventory of sole structures to be kept on hand by a seller and/or manufacturer. Additionally, the dimensions of the upper can be tailored, such as by adding padding, to satisfy a specified request in order to be optimal for a customer with a foot abnormality. Examples of materials may include leather, textiles, polymers, cottons, composites, etc., with different weaves, braids or knits. Examples of footwear styles may include high top, low top, mule, etc..

In an embodiment, the upper component has a split heel region, the flange has a first end at a medial side of the split heel region and a second end at a lateral side of the split heel region, and the specified characteristic is a graphical image. In such an embodiment, the method further comprises printing the graphical image on a surface of the upper component prior to the securing the inner surface of the flange to the peripheral side surface of the sole structure. After said printing and prior to fitting the inner surface of the flange against the peripheral side surface and securing the inner surface of the flange to the peripheral side surface, the method includes securing the lateral side of the split heel region to the medial side of the split heel region.

In another embodiment, the at least one recess includes a first recess and a second recess separated from the first recess by a non-recessed portion of the peripheral side surface of the sole structure. In such an embodiment, fitting the inner surface of the flange against the peripheral side surface of the sole structure is with the flange in the first recess, and fitting an inner surface of the additional flange against the peripheral side surface of the sole structure is with the additional flange in the second recess and with the flange separated from the additional flange by the non-recessed portion of the peripheral side surface.

Within the scope of the claimed invention, as defined by the claims, fitting the inner surface of the flange to the peripheral side surface of the sole structure may include interfitting at least one first locating feature provided on the sole structure with at least one second locating feature provided on the flange. For example, the peripheral side surface of the sole structure may have at least one first locating feature in the at least one recess, and the flange may have at least one second locating feature at the inner surface.

In an example embodiment in which the at least one first locating feature includes a slot extending along the peripheral side surface from a medial side of the sole structure to a lateral side of the sole structure, and the at least one second locating feature includes a ridge protruding at the inner surface of the flange, the method may further comprise aligning the ridge with the slot prior to the interfitting the slot with the ridge.

In an example embodiment in which the peripheral side surface has at least one first locating feature in the at least one recess, and the flange has at least one second locating feature at the inner surface, fitting the inner surface of the flange to the peripheral side surface of the sole structure may include interfitting the at least one first locating feature with the at least one second locating feature.

Under the method, the manufacturer or retailer will have on hand an inventory with various sets of modules in order to be ready to satisfy any of a number of different possible customization requests. The method may further comprise selecting the module from an inventory of modules, wherein the inventory includes at least a first set of modules and a second set of modules, and wherein each of the modules of the first set has an upper component that has the specified characteristic. For example, each of the modules of the second set may have an upper component without the specified characteristic. Each of the modules of the second set may have an upper component with a characteristic different than the specified characteristic. In either case, carrying out the first set is identified as satisfying the customer's request.

In an embodiment in which the specified characteristic is a graphical image, the method may further comprise printing the graphical image on a surface of the upper component prior to the securing the inner surface of the flange to the peripheral side surface of the sole structure. In an embodiment, the printing is ink-jet printing, and the method further comprises, prior to printing the graphical image on the surface of the upper component, placing the module in a first state in which a predetermined region of a surface of the upper component has a maximum variance in elevation of less than or equal to <NUM> millimeters in the first state. Printing the graphical image on the surface of the upper component is done with the module in the first state. In other embodiments, the graphical image may be provided by processes other than ink-jet printing, such as but not limited to three-dimensional printing, painting, stamping, heat transfer, etc..

In an embodiment, securing the inner surface of the flange to the peripheral side surface of the sole structure includes adhering the inner surface of the flange to the peripheral side surface of the sole structure. In the same or a different embodiment, securing the inner surface of the flange to the peripheral side surface of the sole structure includes thermally bonding the inner surface of the flange to the peripheral side surface of the sole structure.

The method also enables customization requests that are specific to only one article of footwear of a pair of footwear, such as a right shoe or a left shoe. For example, in an embodiment, the article of footwear is a first article of footwear of a pair of footwear that includes the first article of footwear and a second article of footwear. The specified characteristic is a first specified characteristic. One of the first article of footwear and the second article of footwear has a right foot orientation and the other of the first article of footwear and the second article of footwear has a left foot orientation. The method further comprises receiving a request for the second article of footwear having a second upper with a second specified characteristic different than the first specified characteristic. The method further comprises assembling the second article of footwear in accordance with the request for the second article of footwear by securing an inner surface of an additional flange of an additional module to a sole structure of the second article of footwear. Similar to the first article of footwear, the sole structure of the second article of footwear has a foot-facing surface, a ground-engaging surface, and a peripheral side surface extending between the foot-facing surface and the ground-engaging surface. The peripheral side surface of the second article of footwear has at least one recess. The additional module has an additional upper component secured to the additional flange of the additional module, and the additional upper component has the second specified characteristic.

In an embodiment in which the sole structure is included in a first module having an additional upper component secured to the sole structure and partially defining the foot-receiving cavity over the foot-facing surface, with the additional upper component spaced apart from the at least one recess, and where the upper component and the flange are a second module, the method may further comprise stitching the upper component to the additional upper component after securing the flange of the second module to the peripheral side surface of the sole structure.

In an embodiment in which the upper component is a first upper component, the flange is a first flange, the specified characteristic is a first specified characteristic, and the request for the upper further includes a second specified characteristic, assembling the modular article of footwear in accordance with the request may further include securing a second module to the sole structure. The second module includes an additional upper component, and an additional flange secured to the additional upper component and projecting therefrom. Securing the second module to the sole structure may comprise fitting an inner surface of the additional flange against the peripheral side surface of the sole structure with the additional flange in the at least one recess and with the additional upper component further defining the foot-receiving cavity.

Additionally, the method may include customizing the sole structure in response to a request for a specified stiffness or stability characteristic. For example, the method may include receiving a request for a sole structure with a specified stiffness or stability characteristic, and inserting an insert into a cavity in the peripheral side surface of the sole structure. The insert has a compressive stiffness different than the sole structure, and the sole structure with the insert therein provides the specified stiffness or stability characteristic.

Referring to the drawings, where like reference numbers refer to like components, <FIG> shows a customized modular article of footwear <NUM> in a fully-manufactured state. The article of footwear <NUM> includes a sole structure <NUM> and a modular upper <NUM>, <NUM> including a first upper component <NUM> and additional upper component <NUM>. In the embodiment shown, the sole structure <NUM> includes a full-length unitary midsole <NUM> having a forefoot region <NUM>, a midfoot region <NUM>, and a heel region <NUM>. The forefoot region <NUM>, midfoot region <NUM>, and heel region <NUM> also correspond with and can be used to refer to a forefoot region, a midfoot region, and a heel region, respectively, of the article of footwear <NUM>. The sole structure <NUM> also includes an insole <NUM>, best shown in <FIG>. A strobel <NUM> may be secured to a lower periphery of the upper component <NUM>. The insole <NUM> is a drop-in insole that rests on the midsole <NUM> or on a strobel <NUM> (if a strobel is provided), but is not secured to the strobel <NUM> or to the midsole <NUM> so that it is removable. In other embodiments, the insole <NUM> can be secured to the strobel <NUM> or to the midsole <NUM> by adhesive or otherwise.

As best shown in <FIG>, the sole structure <NUM> has a foot-facing surface <NUM>, a ground-engaging surface <NUM>, and a peripheral side surface <NUM> extending between the foot-facing surface <NUM> and the ground-engaging surface <NUM>. Multiple recesses <NUM> are shown in the foot-facing surface <NUM> to increase compliance of the sole structure <NUM>. The peripheral side surface <NUM> in this embodiment is a single, continuous recess <NUM> that extends along the medial side <NUM> of the sole structure <NUM>, as shown in <FIG>, around the rear periphery <NUM>, and along a lateral side <NUM> of the sole structure <NUM>. Accordingly, the recess <NUM> has a medial end <NUM>, a lateral end <NUM>, and a lower periphery <NUM> bounded by a lip <NUM> of the midsole <NUM>. The articles of footwear herein are depicted as leisure shoes or athletic shoes, but the present teachings also include an article of footwear that is a dress shoe, a work shoe, a sandal, a slipper, a boot, or any other category of footwear.

The sole structure <NUM> is included in a first module <NUM> shown in <FIG>. The first module <NUM> includes the upper component <NUM> secured to the sole structure <NUM> and partially defining a foot receiving cavity <NUM> over the foot- facing surface <NUM>. The upper component <NUM> is secured to the sole structure <NUM> along a lower periphery <NUM> at the forefoot region <NUM>, at the midfoot region <NUM>, and at the heel region <NUM>, and has a mule shape.

The article of footwear <NUM> also includes a second module <NUM> best shown in <FIG> and <FIG>. The second module <NUM> includes the upper component <NUM> and a flange <NUM> secured to the upper component <NUM> and projecting therefrom. The upper component <NUM> may be stitched, thermally bonded, adhered, or otherwise secured to the flange <NUM>. The second module <NUM> is shown in a pre-customization state in <FIG> and <FIG> in which it is discrete and separate from the first module <NUM>. More specifically, the second module <NUM> is left unsecured from the first module <NUM> until a customization request is made, as the customization request may result in selection of the module <NUM> and/or additional processing of the module <NUM>, referred to as one or more secondary processes. In addition to or even if no secondary processes are to be carried out to meet the customization request, this also enables the option of selecting a specific second module <NUM> from an inventory of available second modules, where the selected second module has a different characteristic than some of the other second modules in the inventory, such as a specific aesthetic characteristic, a specific performance characteristic, a specific dimensional characteristic, a specific material, a specific physical property, and/or a specific footwear style.

A second module <NUM> is configured to be secured to the first module <NUM> in a relatively quick manner without requiring extensive machinery so that, once a specific characteristic is requested, the customized article of footwear can be completed and provided relatively quickly. Accordingly, the first module <NUM> and the second module <NUM> could be secured to one another at a manufacturing facility or at a retail location following a customization request by a customer. More specifically, an inner surface <NUM> of the flange <NUM> (see <FIG>) fits against and is securable to the peripheral side surface <NUM> of the sole structure <NUM> (see <FIG>) with the flange <NUM> in the at least one recess <NUM>. When the flange <NUM> is secured to the sole structure <NUM>, the upper component <NUM> further defines the foot-receiving cavity <NUM> over the foot-facing surface <NUM>. In other words, the upper component <NUM> defines a forefoot and midfoot region of the foot receiving cavity <NUM> and the upper component <NUM> defines a heel region of the foot receiving cavity <NUM> and provides an ankle opening <NUM>.

In order to aid in quick and accurate assembly, the peripheral side surface <NUM> of the sole structure <NUM> has at least one first locating feature <NUM> in the recess <NUM>. In the embodiment of <FIG>, there are three of the first locating features <NUM> in the recess <NUM>, referred to as locating features 68A, 68B, and 68C (see <FIG> and <FIG>). First locating feature 68A is on the medial side <NUM> of the midsole <NUM> in the recess <NUM> near the medial end <NUM>. First locating feature 68B is at a center of the rear periphery <NUM> of the midsole <NUM> in the recess <NUM>. First locating feature 68C is on the lateral side <NUM> of the midsole <NUM> in the recess <NUM> near the lateral end <NUM>. There may be additional first locating features <NUM> in the recess <NUM>, or only one of the first locating features <NUM> may be provided. However, by providing a first locating feature <NUM> on each of the medial side, on the lateral side, and at the rear periphery, easy and accurate assembly of the second module <NUM> to the first module <NUM> is maximized.

The flange <NUM> of the second module <NUM> has at least one second locating feature <NUM> at the inner surface <NUM>. The first locating feature(s) <NUM> interfits with the second locating feature(s) <NUM> when the first locating feature(s) <NUM> is aligned with the second locating feature(s) <NUM>, and the inner surface <NUM> of the flange <NUM> is fit to the peripheral side surface <NUM> of the sole structure <NUM>. In the embodiment of <FIG>, there are three of the second locating features <NUM> on the inner surface <NUM> of the flange <NUM>, referred to as locating features 70A, 70B, and 70C. Second locating feature 70A interfits with first locating feature 68A, second locating feature 70B interfits with first locating feature 68B, and second locating feature 70C interfits with first locating feature 68C. There may be additional second locating features <NUM> on the inner surface <NUM>, or only one of the second locating features <NUM> may be provided. Accordingly, the number of second locating features <NUM> is the same as the number of first locating features <NUM>, each first locating feature <NUM> interfitting with a corresponding second locating feature <NUM>.

The locating features <NUM>, <NUM> are configured in shape, location, and number to ensure an assembler can easily, accurately, and quickly fit the flange <NUM> to the sole structure <NUM>, with the flange <NUM> in the recess <NUM>. The locating features <NUM>, <NUM> ensure that the upper component <NUM> is correctly positioned to partially define the foot-receiving cavity <NUM> when the second module <NUM> is secured to the first module <NUM>. The at least one second locating feature <NUM> is complementary to the at least one first locating feature <NUM>. Stated differently, the first locating feature(s) <NUM> and the second locating feature(s) <NUM> are cooperatively configured with complementary shapes to interfit. For example, the at least one first locating feature <NUM> may be one of a protrusion of, or a recess in, the peripheral side surface <NUM> of the midsole <NUM>. In the embodiment shown, the first locating features <NUM> are recesses in the peripheral side surface <NUM>. In fact, the first locating features <NUM> are further recessed portions of the recess <NUM>. The second locating features <NUM> are protrusions at the inner surface <NUM> of the flange <NUM>. The size of the recesses formed by the first locating features <NUM> is sufficient to receive the second locating features <NUM>. In the embodiment shown, the features <NUM>, <NUM> locate the flange <NUM> at the correct position in the recess <NUM> for subsequent permanent securing of the flange <NUM> to the midsole <NUM> in the recess <NUM>. As shown in <FIG>, when the flange <NUM> is correctly positioned in the recess <NUM> using the locating features <NUM>, <NUM>, an outer surface <NUM> of the flange <NUM> is flush with an adjacent portion <NUM> of the peripheral side surface <NUM> at both the medial side <NUM> and the lateral side <NUM> when the inner surface <NUM> of the flange <NUM> and the peripheral side surface <NUM> of the sole structure <NUM> are fit against and secured to one another with the flange <NUM> in the recess <NUM>. Stated differently, a thickness T of the flange <NUM> (see <FIG>) is the same as the depth D of the recess <NUM> (see <FIG>) at portions of the recess <NUM> not at the locating features <NUM>, so that the outer surface <NUM> is flush with the peripheral side surface <NUM> at the adjacent portion <NUM> (see <FIG>). Additionally, a medial end <NUM> of the flange <NUM> is at the medial end <NUM> of the recess <NUM>, and a lateral end <NUM> of the flange <NUM> is at the lateral end <NUM> of the recess <NUM>.

The flange <NUM> can be secured to the midsole <NUM> in a variety of different ways. For example, an adhesive layer can be applied to the surface <NUM> that cures to bond the flange <NUM> to the midsole <NUM>. Alternatively, the flange <NUM> can be thermally bonded to the midsole <NUM>. For example, the flange <NUM> can be a material that can be heated to fuse to the midsole <NUM>. The midsole <NUM> can be a similar material to the flange <NUM>. For example, both the flange <NUM> and the midsole <NUM> may be a polymer foam, such as but not limited to a thermoplastic polymer foam or a thermoset polymer foam. By way of non-limiting example, the foam may be a polyurethane (PU) foam (also referred to as a PU-based foam) or an ethylene-vinyl acetate (EVA) foam (also referred to as an EVA-based foam), and in some embodiments may include heat-expanded and molded EVA foam pellets. The upper component <NUM> may be a first material, including a composite of a number of different materials, such as textiles and foam, and the flange <NUM> may be a second material different than the first material.

The upper component <NUM> may be a first material, including a composite of a number of different materials, such as textiles and foam, and the flange <NUM> may be a second material different than the first material.

Alternatively, the locating features <NUM>, <NUM> may sufficiently mechanically secure the flange <NUM> to the midsole <NUM>. For example, if the recesses of the first locating features <NUM> and the protrusions of the second locating features <NUM> are sufficiently sized to provide an interference fit, the flange <NUM> may snap fit to the midsole <NUM> via the interfitting locating features <NUM>, <NUM> (i.e., with the first locating features <NUM> as female connectors) and the second locating features <NUM> as male connectors, without heating or adhesive required.

As is evident in <FIG>, the additional upper component <NUM> is spaced apart from the at least one recess <NUM> to which the flange <NUM> of the second module <NUM> secures. Stated differently, the upper component <NUM> does not overlap or enter into the recess <NUM>. Accordingly, when the flange <NUM> of the second module <NUM> is secured to the peripheral side surface <NUM> of the sole structure <NUM> in the recess <NUM>, the additional upper component <NUM> is adjacent to the upper component <NUM>. In the embodiment shown, the upper component <NUM> overlaps the mule portion of the upper component <NUM> in the heel region <NUM>, and slightly overlaps the upper component <NUM> at the medial side <NUM> and at the lateral side <NUM> in the midfoot region <NUM>. The perimeter of the upper component <NUM> is represented with hidden lines in <FIG> where it is overlapped by the upper component <NUM>. The upper component <NUM> is outward of the upper component <NUM> where it overlaps upper component <NUM>, so that the upper component <NUM> defines the outer surface of the footwear <NUM> in the heel region.

The footwear <NUM> may include stitching <NUM> that secures the upper component <NUM> to the upper component <NUM>. Stitching <NUM> is shown at the medial side <NUM> in <FIG>, and may also be used at the lateral side <NUM> in the same manner. With reference to <FIG>, loops <NUM> are shown sewed to the medial edge <NUM> and the lateral edge <NUM> of the upper component <NUM>. The loops <NUM> are used for handling the upper component <NUM> during the method of manufacturing, but are cut off of the upper component <NUM> prior to stitching the upper component <NUM> to upper component <NUM>. The upper component <NUM> has eyelets <NUM> or other lace-receiving or fastening features that are disposed at the medial side <NUM> and the lateral side <NUM> when the module <NUM> is secured to the module <NUM>.

As best shown in <FIG> and <FIG>, the peripheral side surface <NUM> of the sole structure <NUM> has a curvature at the recess <NUM>, such as but not limited to a curvature at the rear periphery <NUM> of the sole structure <NUM> which curves generally in a U-shape from the medial side <NUM> to the lateral side <NUM>. The materials of the upper component <NUM> and the flange <NUM> are chosen so that they are sufficiently flexible to adopt a first state (shown in <FIG> and <FIG>) when the flange <NUM> is disjoined from the sole structure <NUM>, and a second state (shown in <FIG>) when the flange <NUM> is secured to the sole structure <NUM> in the recess <NUM>. The inner surface <NUM> of the flange <NUM> has the curvature of the peripheral side surface <NUM> in the second state. The second module <NUM> with the flange <NUM> and the upper component <NUM> are relatively flat in the first state in comparison to the second state. This may be advantageous for some customization processes that are more optimally performed with the second module <NUM> relatively flat. For example, various printing techniques that may be used for customization can be performed with the module <NUM> in the first state. <FIG> shows a printed image <NUM> on the upper component <NUM> that is a specified characteristic requested by a customer. Stated differently, the printed image <NUM> is a requested customization of the upper. For purposes of example, the printed image <NUM> is the number "<NUM>" printed on the medial side <NUM>. Although not shown, the printed image <NUM> may also be printed on the lateral side <NUM> in addition to or instead of the medial side, or may be on the inner surface of the upper component <NUM> instead of the outer surface. In other embodiments, the printed image could be a picture, a shape, or text, such as initials, a proper name, a nickname, a team name, or a slogan.

Some printing apparatuses or printing techniques are more accurate when the printer head is maintained relatively close to the surface to be printed. In one example embodiment, a predetermined region <NUM> (i.e., the region within the phantom circle in <FIG>) of a surface <NUM> of the upper component <NUM> has a maximum variance in elevation H of less than or equal to <NUM> millimeters in the first state. The variance in elevation H is represented in <FIG>. Such a variance in elevation H enables a customized graphical image such as printed image <NUM> to be applied on the upper component <NUM> at the predetermined region <NUM> with an ink jet printer <NUM> shown in <FIG>. The printer <NUM> has a printer head <NUM> that prints most optimally when the surface to be printed is disposed within a <NUM> millimeter range from the ink nozzle <NUM> (with multiple nozzles <NUM> in the printer head <NUM>). Ink <NUM> is shown being applied in <FIG>. Accordingly, in the example embodiment, the predetermined region <NUM> of the surface <NUM> of the upper component <NUM> has a graphical image <NUM> thereon and the graphical image is comprised of ink. Alternatively, other types of printers may be used to apply a graphical image, or the graphical image may be applied by heat transfer, sewn onto the upper component <NUM>, or woven or otherwise provided in the material of the upper component <NUM>.

<FIG> show alternative sole structures 12A, 12B that can be customized in accordance with a request for a specified stiffness or stability characteristic. The sole structures 12A and 12B are like sole structure <NUM> in all aspects except that they are provided with a cavity at the peripheral side surface <NUM> in either or both of the medial side <NUM> and the lateral side <NUM>. More specifically, sole structure 12A has a cavity 56A at the lateral side <NUM>, and a cavity 56B at the medial side <NUM>, both of the cavities 56A, 56B disposed generally in the heel region <NUM>. The cavities 56A, 56B may be generally wedge-shaped, tapering in height in an inward direction from the peripheral side surface <NUM>. As indicated in <FIG>, a lateral insert 58A is sized and shaped to fit within the lateral cavity 56A generally so that the lateral cavity 56A is completely filled by the lateral insert 58A, and an outer surface 59A of the lateral insert 58A is flush with the peripheral side surface <NUM>. The insert 58A may be a material that has a different compressive stiffness than the material of the sole structure 12A. Accordingly, when the insert 58A is placed in the cavity, the sole structure 12A with the insert 58A therein provides the specified stiffness or stability characteristic. For example, the insert 58A may be stiffer than the material of the sole structure <NUM>.

The lateral insert 58A may be permanently secured to the sole structure 12A within the cavity 56A such as with adhesive. Alternatively, the lateral insert 58A may be interference fit to the sole structure 12A within the cavity 56A so that it is selectively removable from the cavity 56A without damage to the sole structure 12A. This would enable an alternative insert with a different stiffness characteristic to be used at a different time if a wearer desires a different stiffness or stability characteristic. For example, multiple sets of inserts may be provided, and a wearer could select a first lateral insert 58A for some activities, and a second lateral insert 58A for other activities, with the second lateral insert 58A being stiffer than the first lateral insert 58A.

Similar to the lateral insert 58A, the medial insert 58B is sized and shaped to fit within the medial cavity 56B generally so that the medial cavity 56B is completely filled by the medial insert 58B, and an outer surface 59B of the medial insert 58B is flush with the peripheral side surface <NUM>. The insert 58B may have a different compressive stiffness than the sole structure 12A. Accordingly, when the insert 58B is placed in the cavity, the sole structure 12A with the insert 58B therein provides the specified stiffness or stability characteristic. For example, the insert 58B may be a material with a greater compressive stiffness than the material of the sole structure <NUM>. Like the lateral insert 58A, the medial insert 58B may be permanently secured in the cavity 56B such as with adhesive, or may be removably press-fit in the cavity 56B. Optionally, the lateral insert 58A and the medial insert 58B may have different stiffnesses than one another. For example, the medial insert 58B may be stiffer than the lateral insert to satisfy a stability characteristic, such as enhanced medial support to prevent overpronation.

To enable alternate sets of inserts to be used with the sole structure 12A, the sole structure 12A with inserts 58A, 58B is best provided with an upper component that is removably securable to the sole structure 12A ((rather than adhered), such as with a mechanical connection between the flange of the upper component and the sole structure, as described herein. Once the inserts 58A, 58B are placed in the cavities 56A, 56B, the flange of the upper component will cover the opening of the cavity 56A, 56B at the peripheral side surface <NUM>, further securing the inserts 58A, 58B in the cavities 56A, 56B. Although two cavities and two inserts are shown in <FIG>, the sole structure 12A may have only one cavity or more than two cavities for receiving an equal number of inserts, and the cavities may be located elsewhere than the heel region <NUM>, such as in the forefoot region <NUM> or the midfoot region <NUM>.

<FIG> show another alternative embodiment of a sole structure 12B that has two cavities 56C at the lateral side <NUM>, and two cavities 56D at the medial side <NUM>. Only one of the cavities 56D is visible in the cross-section of <FIG>, but the medial side <NUM> has another identical cavity 56D positioned forward of the cavity 56D shown, similar to the relative positions of cavities 56A. Although two cavities are at each of the medial and lateral sides in the embodiment shown, in other embodiments, only one of the sides <NUM>, <NUM> may have a cavity, or both of the sides <NUM>, <NUM> may have multiple cavities. The cavities 56C, 56D are disposed generally in the heel region <NUM>, but may instead be disposed in another region of the sole structure 12B.

The cavities 56C, 56D are generally cylindrical in shape, extending in an inward direction from the peripheral side surface <NUM>. As indicated in <FIG>, each lateral insert 58C is sized and shaped to fit within the lateral cavity 56C generally so that the lateral cavity 56C is completely filled by the lateral insert 58C, and an outer surface 59C of the lateral insert 58C is flush with the peripheral side surface <NUM>. The inserts 58C may be a material that has a different compressive stiffness than the material of the sole structure 12A. Accordingly, when the inserts 58C are placed in the cavities 56C, the sole structure 12A with the inserts 58C therein provides the specified stiffness or stability characteristic. For example, the inserts 58C may be stiffer than the material of the sole structure <NUM>.

Similar to the lateral inserts 58C, each medial insert 58D is sized and shaped to fit within the medial cavity 56D generally so that the medial cavity 56D is completely filled by the medial insert 58D, and an outer surface 59D of the medial insert 58D is flush with the peripheral side surface <NUM>. The inserts 58D may have a different compressive stiffness than the sole structure 12A. Accordingly, when the inserts 58D are placed in the cavities 56D, the sole structure 12A with the inserts 58D therein provides the specified stiffness or stability characteristic. For example, the inserts 58D may be stiffer than the material of the sole structure <NUM>. Like the lateral inserts 58C, the medial inserts 58D may be permanently secured in the cavities 56D with adhesive, or may be removably press-fit in the cavities 56D. Optionally, the lateral inserts 58C and the medial inserts 58D may have different stiffnesses than one another.

To enable alternate sets of inserts to be used with the sole structure 12B, the sole structure 12B with inserts 58C, 58D is best provided with an upper component that is removably securable to the sole structure 12B (rather than thermally bonded or adhered), such as with a mechanical connection between the flange of the upper component and the sole structure, as described herein. Once the inserts 58C, 58D are placed in the cavities 56C, 56D, the flange of the upper component will cover the opening of the cavity 56C, 56D at the peripheral side surface <NUM>, further securing the inserts 58C, 58D in the cavities 56C, 56D. Although two cavities and two inserts are shown in <FIG>, the sole structure 12B may have only one cavity or more than two cavities for receiving an equal number of inserts, and the cavities may be located in other regions than the heel region <NUM>.

<FIG> shows an alternative embodiment of a sole structure <NUM> including a midsole <NUM> that can be used in place of midsole <NUM> in the module <NUM> of <FIG>, or can be used in place of midsole <NUM> of <FIG>. The midsole <NUM> is part of a first module <NUM> that has many of the same features of midsole <NUM>, as indicated by like reference numbers. Instead of first locating features 68A and 68C, the midsole <NUM> includes a first locating feature <NUM> that is a slot. The slot <NUM> extends in the peripheral side surface <NUM> along the rear periphery <NUM> of the sole structure <NUM> and along the medial side <NUM> of the sole structure <NUM> and the lateral side <NUM> of the sole structure <NUM>. The locating feature 68B as described in <FIG> is also included and intersects the slot <NUM> at the rear periphery <NUM>.

<FIG> shows a second module <NUM> that has many of the same features as second module <NUM>, as indicted by like reference numbers. Instead of second locating features 70A and 70C, the flange <NUM> includes a second locating feature that is a ridge <NUM> that protrudes at the inner surface <NUM> of the flange <NUM>. The locating feature 70B as described in <FIG> is also included and intersects the ridge <NUM>. The sole structure <NUM> and the flange <NUM> may mechanically secure to one another when the ridge <NUM> is aligned with and placed into the slot <NUM>. The ridge <NUM> can be aligned with the slot <NUM> by aligning the locating feature 70B with locating feature 68B, so that the module <NUM> can be easily secured to the sole structure <NUM> during the customization process. For example, the ridge <NUM> is a male connector, and the slot <NUM> is a female connector. <FIG> shows an article of footwear <NUM> including the modules <NUM> and <NUM>. The upper components <NUM>, <NUM> each partially define a foot-receiving cavity <NUM> when secured to the sole structure <NUM> in an article of footwear <NUM>. <FIG> depicts the ridge <NUM> in the slot <NUM> when the second module <NUM> is secured to the first module <NUM>, in a cross-sectional view taken at lines <NUM>-<NUM> in <FIG>.

<FIG> shows that, instead of or in addition to mechanical connectors, an adhesive <NUM> may be disposed on either or both of the inner surface <NUM> of the flange <NUM> and the peripheral side surface <NUM> of the sole structure <NUM> to secure the flange <NUM> to the sole structure <NUM>. In some embodiments, the adhesive <NUM> may be a hot melt adhesive.

<FIG> shows an embodiment of a sole structure <NUM>. The sole structure <NUM> has many of the same features as sole structure <NUM>, and these are referred to with like reference numbers. First locating features 68A, 68B, and 68C are described with respect to <FIG> and <FIG>, as well as additional first locating features 68D, 68E and 68F are provided as recesses in the peripheral side surface <NUM> at the recess <NUM>. The recess <NUM> extends around the entire peripheral side surface <NUM>, including in the forefoot region <NUM>, rather than stopping at ends <NUM>, <NUM> at the midfoot region <NUM> as in <FIG> and <FIG>. A slot <NUM> similar to slot <NUM> extends around the entire peripheral side surface <NUM> and serves as a first locating feature that is a female connector. Although six locating features are shown on the sole structure <NUM>, in other embodiments, fewer locating features, such as one, two, three, four, or five locating features may be used. The one or more flanges secured to the sole structure <NUM> have an equal number of locating features corresponding to those on the sole structure <NUM>.

The sole structure <NUM> has no upper components secured to it prior to the start of the customization process. In other words, even the upper component <NUM> is not secured to the sole structure <NUM>. More than one module may be separate from the sole structure <NUM> prior to a request for a specified characteristic (i.e., a customization request), and secured to the sole structure <NUM> during the customization process. Each such module includes a flange and an upper component. For example, the module <NUM> of <FIG> and the module <NUM> of <FIG> can both be customized and secured to the midsole <NUM> during the customization process. The module <NUM> includes upper component <NUM> as a first upper component, and the flange <NUM> as a first flange. The flange <NUM> has second locating features 70A, 70B and 70C, which are protrusions at the inner surface <NUM> of the flange <NUM>. The flange <NUM> also has the ridge <NUM> as a male connector protruding at the inner surface <NUM>. The flange <NUM> fits in the recess <NUM> with the locating features 70A, 70B, 70C aligned with the locating features 68A, 68B, 68C, respectively, and with the ridge <NUM> in the slot <NUM> to mechanically secure the module <NUM> to the sole structure <NUM>.

The second module <NUM> comprises the second upper component <NUM>, and a second flange <NUM> secured to the second upper component <NUM> and projecting therefrom. An inner surface <NUM> of the second flange <NUM> has locating features 270D, 270E, and 270F, as well as a protruding ridge <NUM> that serves as a male connector feature. An inner surface <NUM> of the second flange <NUM> fits against the peripheral side surface <NUM> of the sole structure <NUM> with the second flange <NUM> in the recess <NUM>, the locating features 270D, 270E, and 270F aligned with the locating features 68D, 68E, and 68F, respectively, and the ridge <NUM> serving as a male connector feature that fits into the female connector feature (i.e., slot <NUM>) to mechanically secure the module <NUM> to the sole structure <NUM>. The upper components <NUM>, <NUM> each partially define a foot-receiving cavity <NUM> when secured to the sole structure <NUM> in an article of footwear <NUM> as shown in <FIG>. Upper component <NUM> serves as a forefoot region of a modular upper <NUM>, <NUM>, and upper component <NUM> serves as a heel region of a modular upper <NUM>, <NUM>. In such an embodiment, when the second flange <NUM> is secured to the peripheral side surface <NUM> of the sole structure <NUM> in the recess <NUM>, the second upper component <NUM> is adjacent to the first upper component <NUM>, and the article of footwear may have stitching that secures the second upper component <NUM> to the first upper component <NUM> which may be identical to stitching <NUM> of <FIG>.

<FIG> shows an alternative embodiment of a second module <NUM> for use with the sole structure <NUM> of <FIG> or another similar sole structure having a single recess <NUM>. The second module <NUM> includes an upper component <NUM> that includes a forefoot region <NUM>, a midfoot region <NUM>, and a heel region <NUM> corresponding with the forefoot region <NUM>, the midfoot region <NUM>, and the heel region <NUM> of the sole structure <NUM>. The second module <NUM> includes a single flange <NUM> extending around the periphery of the upper component <NUM> at the forefoot region, the midfoot region, and the heel region of the upper component <NUM>. The upper component <NUM> is a first material, and the flange <NUM> is a second material such as polymer foam. For example, the flange <NUM> may be a thermoplastic polymer foam or a thermoset polymer foam. The polymer foam of the flange may be the same polymer foam as the material of the sole structure to which the flange is to be attached. In the embodiment shown, the flange <NUM> is a single, continuous flange. The flange <NUM> establishes the lower periphery of the second module <NUM>, and has a ridge <NUM> extending around the entire flange <NUM> with second locating features 70A-70F as described herein.

The upper component <NUM> is a single, unitary, one-piece upper component, and is shown in a flattened state in <FIG> gathered or bunched inward of the flange <NUM>. The second module <NUM> is maintained in a relatively flattened state by a jig <NUM> shown in phantom in preparation for customization by printing or otherwise, as described with respect to <FIG>. The jig <NUM> is shown at the forefoot region <NUM> in the example embodiment as the forefoot region <NUM> is to undergo a secondary customization process such as printing a graphical image <NUM> on the upper component <NUM> at the forefoot region <NUM>. However, the jig <NUM> may have a different configuration and/or may be secured to other portions of the second module <NUM> such as for customization of the heel region, the lateral side, or otherwise. Following customization, the second module <NUM> is removed from the jig <NUM>, and may be returned to an unflattened state. The ridge <NUM> is aligned with the slot <NUM> of the sole structure <NUM>, with the additional second locating features 70A-70F aligned with the corresponding additional first locating features 68A, 68F. The inner surface <NUM> of the flange <NUM> is fit against and secured to the peripheral side surface <NUM> of the sole structure <NUM> by any of the methods described herein.

<FIG> shows an alternative embodiment of a second module <NUM> for use with the sole structure <NUM> of <FIG> or another similar sole structure having a single recess <NUM>. The second module <NUM> includes a single, one-piece, unitary upper component <NUM> that includes a forefoot region <NUM>, a midfoot region <NUM>, and a heel region <NUM> corresponding with the forefoot region <NUM>, the midfoot region <NUM>, and the heel region <NUM> of the sole structure <NUM>. The second module <NUM> includes a single flange <NUM> extending along the periphery of the upper component <NUM> at the forefoot region, the midfoot region, and the heel region of the upper component <NUM>. In a pre-assembly state in which the second module <NUM> is ready for a secondary customization process, the upper component <NUM> has a split in the heel region <NUM>, separating the heel region <NUM> into a medial side heel region 422A and a lateral side heel region 422B. The split heel region helps the upper component <NUM> maintain a relatively flat state optimal for some secondary processes as described herein, such as printing a graphical image <NUM> at the forefoot region.

The upper component <NUM> is a first material, and the flange <NUM> is a second material such as polymer foam. For example, the flange <NUM> may be a thermoplastic polymer foam or a thermoset polymer foam. The polymer foam of the flange may be the same polymer foam as the material of the sole structure to which the flange is to be attached. The flange <NUM> has a first end <NUM> at the medial side split heel region 422A, and a second end <NUM> at a lateral side split heel region 422B. A jig (not shown) similar to jig <NUM> of <FIG> may be used to hold the second module <NUM> in its pre-assembly state of <FIG> during customization by secondary processing steps. The flange <NUM> establishes the lower periphery of the second module <NUM>, and has a ridge <NUM> extending around the entire flange <NUM> with second locating features 70A-70F as described herein. Locating feature 70B may have two halves 70B1 and 70B2 at the respective first and second ends <NUM>, <NUM> of the flange <NUM>.

Following customization, the second module <NUM> is removed from any jig used to secure it during customization. A lateral edge <NUM> of the upper component <NUM> at a lateral side of the split heel region 422B is then secured to a medial edge <NUM> of the upper component in a medial side of the split heel region 422A, and the second module <NUM> is then no longer in a flattened state. Optionally, a strobel is secured along the lower edge of the upper component <NUM> inward of the flange <NUM>. Following these steps, the ridge <NUM> is aligned with the slot <NUM> of the sole structure <NUM>, with the second locating features 70A-70F aligned with the corresponding first locating features 68A, 68F. The two halves 70BA and 70BB are adjacent one another in the second locating feature 68B when the inner surface <NUM> of the flange <NUM> is fit against and secured to the peripheral side surface <NUM> of the sole structure <NUM> by any of the methods described herein.

<FIG> shows another embodiment of a sole structure <NUM> for use in a modular article of footwear <NUM> of <FIG>. The sole structure <NUM> has a first recess 30A and a second recess 30B. The second recess 30B is separated from the first recess 30A by a non-recessed portion 569A of the peripheral side surface <NUM> on the medial side <NUM> of the sole structure <NUM>, and by a non-recessed portion 569B of the peripheral side surface <NUM> of the sole structure <NUM> on the lateral side <NUM> of the sole structure. In other embodiments, the positions of the first and second recesses and the non-recessed portions can be switched, for example, with the non-recessed portions 569A, 569B instead at the front and rear of the sole structure <NUM>, respectively, and the first recess 30A and second recess 30B at the lateral side <NUM> and the medial side <NUM>, respectively. The first recess 30A includes a first locating feature 568A that is a slot, and also includes an additional first locating feature 68F. The second recess 30B includes a first locating feature 568B that is a slot, an also includes an additional first locating feature 68B.

<FIG> shows the sole structure <NUM> as assembled with upper components 516A, 516B secured at the non-recessed portions 569A, 569B, respectively. The upper components 516A, 516B include eyelets <NUM>, and are the portions of the upper potentially subject to the greatest stress when the upper is tightened at the eyelets. By securing the upper components 516A, 516B to the sole structure <NUM> in an initial pre-customization state, the components 516A, 516B may be secured to the sole structure <NUM> by any means best able withstand such stress. For example, the upper components 516A, 516B could each include a flange similar to flange <NUM> discussed herein, with the flanges thermally bonded to the non-recessed portions 569A, 569B, stitched to the sole structure <NUM> at the non-recessed portions 569A, 569B, or otherwise. A complete range of securement options and methods are available, as the methods for securement of the upper components 516A, 516B need not necessarily be conducive to secondary processes easily carried out at retail locations.

<FIG> shows a first module <NUM> that has a first upper component 516C with a first flange 564C secured thereto. The first upper component 516C is generally only a forefoot region in this embodiment. The first upper component 516C is a first material, and the first flange 564C is a second material such as polymer foam. For example, the first flange 564C may be a thermoplastic polymer foam or a thermoset polymer foam. The polymer foam of the flange may be the same polymer foam as the material of the sole structure to which the flange is to be attached. An inner surface 566C of the flange 564C has second locating features including a ridge 570C and a protruding locating feature 270F described herein. The first module <NUM> is shown with a customized graphical image <NUM>, which may be provided in response to a customer request.

<FIG> shows a second module <NUM> that includes an upper component <NUM> with a flange 564D secured thereto. The upper component <NUM> is referred to as a second upper component, and the flange 564D is referred to as a second flange. The second upper component <NUM> is generally only a heel region in this embodiment. The second upper component <NUM> is a first material, and the second flange 564D is a second material such as polymer foam. For example, the second flange 564D may be a thermoplastic polymer foam or a thermoset polymer foam. The polymer foam of the flange may be the same polymer foam as the material of the sole structure to which the flange is to be attached. An inner surface 566D of the flange 564D has second locating features including a ridge 570D and a protruding locating feature 270B described herein. The second module <NUM> may be customized, such as with a graphical image, with added cushioning for fit, or otherwise.

Either or both of the modules <NUM>, <NUM> may be customized in accordance with a customer request for a specified characteristic using secondary processing. Once customization procedures are complete, the inner surface 566C of the first flange 564C is fit against and secured to the peripheral side surface <NUM> of the sole structure <NUM> with the first flange 564C in the first recess 30A, and the inner surface 566D of the second flange 564D fit against and secured to the peripheral side surface <NUM> of the sole structure <NUM> in the second recess 30B. Securing the flanges 564C, 564D to the sole structure <NUM> includes first aligning and securing the ridges 570C, 570D with the slots 568A, 568B, and the second locating features 270F, 270B with the first locating features 68F, 68B. For example, the flanges 564C, 564D may be secured to the sole structure <NUM> in these positions by thermal processing. As assembled, the first flange 564C is separated from the second flange 564D by the non-recessed portions 569A, 569B of the peripheral side surface <NUM>. Optionally, prior to or after the thermal processing to secure the flanges 564C, 564D to the sole structure <NUM>, one or both of the upper components <NUM>, 516C can be secured to the upper components 516A, 516B, such as by stitching, adhesive, or otherwise. <FIG> illustrates the overlap of the upper component 516A with the upper component <NUM>, showing the medial edge <NUM> of upper component <NUM> disposed inward of upper component 516A. Upper component 516A also overlaps upper component 516C, with the medial edge <NUM> of upper component 516C shown disposed inward of upper component 516A. Similar overlap exists with the upper components <NUM> and 516B, and with the upper components 516C and 516B on the lateral side. In these overlapped regions, the upper components may be secured to one another to further secure the modules <NUM> and <NUM> to the module <NUM>.

<FIG> shows a flowchart representing a method <NUM> of manufacturing a customized article of footwear. The method <NUM> is applicable to the articles of footwear <NUM>, <NUM>, <NUM>, <NUM>, <NUM> that include the sole structures <NUM>, 12A, 12B, <NUM>, <NUM>, <NUM>, and modules <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> described herein. Under the method <NUM>, a footwear manufacturer or retailer will have on hand an inventory of various sets of modules in order to be ready to satisfy a number of different possible customer requests for customized uppers. The specified characteristic requested may be one of an aesthetic characteristic, a performance characteristic, a dimensional characteristic, a material, a physical property, or a footwear style. Examples of an aesthetic characteristic include a graphical image, such as a number, a picture, a name, or other text, or simply a choice of color of the upper component or a portion thereof. Some modules in the inventory may have undergone processing steps such that the requested specified characteristic is already present at the time the request is received. For example, some aesthetic characteristics, including some images may be pre-printed or otherwise provided on an upper component included in a module that is kept at hand in inventory, ready for securement to other modules in assembling an article of footwear meeting the customer's request. Some modules having different performance characteristics may be kept at hand in inventory, ready for securement to other modules in assembling an article of footwear meeting the customer's request. The performance characteristics may be categorized by the retailer, for example, as supportive, lightweight, providing tactile feedback, etc. Examples of performance characteristics may include upper components categorized by the manufacturer as stiff, flexible, supportive, breathable, for training, for leisure etc., and may be related to specified characteristics which are more specific physical properties, such as a stiffness within a range of numerical stiffnesses, elasticity within a range of elasticities, etc..

The modules with specific performance characteristics may also have different materials and/or physical properties that satisfy requests for these characteristics. For example, a request may be for a textile upper, a leather upper, or an upper of a different material, and modules with these types of upper components can be kept in an inventory and selected to satisfy a customer's request. A request may be for an upper that has a medial side with a greater stiffness than a lateral side, in order to inhibit pronation. Modules with upper components of different stiffnesses, including stiffnesses that are different on the medial side or the lateral side can be kept in an inventory and selected to satisfy a customer's request. The request may be for a right foot article of footwear having an upper component with a greater stiffness in the heel region than a left foot article of footwear to support a weaker right ankle, for example. The request may be for upper components creating a custom-sized foot-receiving cavity in order to provide custom support for a customer's specific foot anomaly. This can be satisfied, for example, by providing a greater amount of foam padding in certain areas of the upper components. The amount of padding can also be varied to satisfy a request for a specific foot size. For example, a module with an upper component with less padding can be used to satisfy a half size larger foot size request, and a module with an upper component with more padding can be used for a half size smaller foot size request, both using the same sole structure. Modules with upper components having different amounts of padding can be kept in an inventory and selected to satisfy these or other customer requests. Examples of dimensional characteristics may include thickness of the upper, which may be determined by the amount of padding that can be added to satisfy a specified request. For example, the thickness of the upper can be selected to enable the same size sole structure to be used for orders within a half-size of one another. A module with a relatively thick upper can be used if the customer requests footwear of a first size, while a relatively thin upper can be used if the customer requests footwear of a second size larger than the first size, as the flange that interfaces with the sole structure will be identical with either module. This enables a smaller inventory of sole structures to be kept on hand by a seller and/or manufacturer. The dimensions of the upper can be tailored to satisfy a specified request in order to be optimal for a customer with a foot abnormality.

An upper component of a first footwear style, such as a high top style can be kept in an inventory and selected to satisfy a customer's request for a high top, while a module having an upper component with a second footwear style, such as a low-top, can be kept in an inventory and selected to satisfy a customer's request for a low top. Examples of materials may include leather, textiles, polymers, cottons, composites, etc., with different weaves, braids or knits. Examples of footwear styles may include high top, low top, mule, etc..

The footwear module <NUM> of <FIG> is manufactured to the state shown in <FIG>, and is then placed in an inventory awaiting a customer request before final assembly in an article of footwear. More specifically, the flange <NUM> is secured to the upper component <NUM> by optionally, marking gauge points on the outer surface of the upper component <NUM>, adding primer and cement or other adhesive on the surface areas of the upper component <NUM> and/or the flange <NUM> to be joined, attaching the flange <NUM> to the upper component <NUM>, and then pressing the flange <NUM> and the upper component <NUM> to one another while the cement cures.

In another example, the footwear module <NUM> of <FIG> is manufactured to the state shown in <FIG> then placed in an inventory awaiting a customer request before subsequent final assembly in an article of footwear. For example, a strobel may first be cut and sewn, and then secured to the upper component <NUM> around a last. At this point, a temporary upper heel portion may be secured to the upper component <NUM> to occupy a position where upper component <NUM> will later be secured, in order to more properly shape the upper component <NUM> prior to securement to the sole structure <NUM>. Gauge points are marked on the upper component <NUM>, and primer and cement or other adhesive is applied on the surface areas of the upper and strobel to be joined to the sole structure <NUM>. The upper component <NUM> and strobel are secured to the sole structure <NUM> and the assembly is allowed to cure. The last is then removed from the upper component <NUM>, and the temporary heel is removed.

In another aspect of the method <NUM>, the sole structure 12A and/or 12B of <FIG> may be placed in an inventory, along with a selection of corresponding inserts 58A, 58B, 58C, 58D of various stiffnesses. The inserts are available to be placed into a cavity on the medial side and/or the lateral side of the sole structure 12A or 12B as described herein to modify the sole structure in correspondence with a specified stiffness or stability characteristic. For example, if a request for a stiffer (e.g., more firm, less easily compressible, etc.) heel region <NUM> at the medial side <NUM> is requested, inserts of greater stiffness than the material of the sole structure 12A or 12B can be placed in the cavity or cavities at the medial side <NUM>, as described herein. If a request for relatively high lateral stability is requested (i.e., a request for a sole structure stiffer on the lateral side <NUM> than on the medial side <NUM>), inserts of greater stiffness than the material of the sole structure 12A or 12B can be placed at least in the cavity or cavities at the lateral side <NUM>.

<FIG> shows an example inventory <NUM> of various modules that include upper components having different characteristics that may satisfy a customer's request for a specified characteristic, or that are sufficient to enable secondary processing that will provide the specified characteristic. For example, the inventory <NUM> includes a set <NUM> of modules 50A that include an upper component <NUM> secured to a flange <NUM>, with the upper component <NUM> already having the graphical image 80A thereon. The inventory <NUM> also includes a set <NUM> of modules 50B that may be alike in every aspect as modules 50A except that the graphical image 80A is not on the upper component <NUM>. The module 50B may not have a graphical image, allowing the module 50B to be used where a graphical image 80A is not requested, or if a different graphical image is requested than graphical image 80A provide on the modules 50A, it will be provided on the upper component <NUM> of the module 50B as secondary process, following the request. Still further, the modules 50B may have a different graphical image already provided on the upper component <NUM> when stored in the inventory.

The inventory <NUM> includes a set <NUM> of modules 50C that include an upper component <NUM> secured to a flange <NUM>, with the upper component <NUM> being a high top style, while the upper components <NUM> of the sets <NUM>, <NUM> are a low top style. The inventory <NUM> includes a set <NUM> of modules 50D that include an upper component <NUM> secured to a flange <NUM>, with the upper component <NUM> having additional padding <NUM> to provide a different dimensional characteristic as discussed herein. The inventory <NUM> includes a set <NUM> of modules 50E that include an upper component <NUM> secured to a flange <NUM>, with the upper component <NUM> being a smaller size than the upper components <NUM> of the modules 50A, 50B. The inventory <NUM> includes a set <NUM> of modules 50F that include an upper component <NUM> secured to a flange <NUM>, with a stiffening plate <NUM> embedded in a medial side of the upper component <NUM>, providing a higher stiffness on the medial side of the upper component <NUM> than on the lateral side.

The sets <NUM>-<NUM> of modules shown and described in the inventory <NUM> are representative examples of different modules. However, the inventory <NUM> may include modules with other specified characteristics that will satisfy various customer requests, or that are suitable for secondary processing to satisfy a specified request. For example, the inventory <NUM> may also include the sole structures 12A, 12B and inserts 58A-58D of <FIG>.

Referring to <FIG>, the method <NUM> begins when a request for an upper with a specified characteristic is received in block <NUM>. The request may be received in a number of different ways. Additionally, the request may be received by a retailer or by a manufacturer. The request may be an electronic order placed on a manufacturer's or retailer's website, mobile or online application (i.e., "app"), social media page, or by email. Alternatively, the request may be received in block <NUM> by telephone, by mail, or in person.

Once the request is received in block <NUM>, the method <NUM> proceeds to block <NUM>, assembling a modular article of footwear in accordance with the request by securing a module to a sole structure. The sole structure has a foot-facing surface <NUM>, a ground-engaging surface <NUM>, and a peripheral side surface <NUM> extending between the foot-facing surface <NUM> and the ground-engaging surface <NUM>, as described with respect the sole structures <NUM>, <NUM>, <NUM>, and <NUM> herein. The peripheral side surface <NUM> has at least one recess <NUM> as described herein. In some cases, the sole structure may be a module separate from any upper components, as is the sole structure <NUM> of <FIG>. In other embodiments, the sole structure is included in a module that has an upper component secured to the sole structure, as shown and described with respect to modules <NUM>, <NUM> and <NUM>.

Assembling the modular article of footwear in block <NUM> includes providing a custom module with an upper component having the specified characteristic in block <NUM>. In block <NUM>, the custom module with an upper component having the specified characteristic may be selected from an inventory of modules in block <NUM>, wherein the inventory includes at least a first set of modules and a second set of modules, and wherein each of the modules of the first set has an upper component that has the specified characteristic. For example, each of the modules of the second set may have an upper component without the specified characteristic. Each of the modules of the second set may have an upper component with a characteristic different than the specified characteristic. In either case, selecting the module from the first set is identified as satisfying the customer's request.

For example, if the specified characteristic is the graphical image 80A shown on the modules 50A, or the high top type module 50C, or a dimensional characteristic satisfied by the added padding <NUM> of modules 50D, or the size of the modules 50E, or a stiffness characteristic provided by the modules 50F, one of these modules pre-manufactured to possess the specified characteristic is selected in block <NUM> as a module of the first set with respect to the specific customization.

Alternatively or in addition, a module selected from the inventory <NUM> may need to be customized with secondary processes in order to possess the specified characteristic. For example, the specified characteristic may be a graphical image different from graphical image 80A and different from other pre-processed graphical images on modules on hand in inventory <NUM>. In that case, block <NUM> may include block <NUM>, printing of the graphical image on a surface of the upper component prior to securing the inner surface of the flange <NUM> to the peripheral side surface <NUM> of the sole structure. In an embodiment, the printing is ink-jet printing, and the method <NUM> further comprises block <NUM>, prior to the printing the graphical image on the surface of the upper component, placing the module in a first state in which a predetermined region of a surface of the upper component has a maximum variance in elevation of less than or equal to <NUM> millimeters in the first state, as described with respect to <FIG>. <FIG> shows another example of block <NUM> in which the surface of module <NUM> to be printed on is placed in a relatively flat state and secured with a jig <NUM> for customization. The printing of the graphical image on the surface of the upper component is with the module in the first state. Blocks <NUM> and <NUM> are optional, and are suitable for some example embodiments. In other embodiments, the graphical image may be provided by ink-jet printing, but with a printer that can optimally print without a maximum elevation of <NUM> or less being required. In still other embodiments, the graphical image may be provided by processes other than ink-jet printing, such as but not limited to three-dimensional printing, painting, stamping, heat transfer, etc., in which case block <NUM> would include these additional processes.

In an example embodiment in which the sole structure to be assembled in the customized article of footwear has one or more first locating features, and the flange <NUM> included on the custom module to be secured to the sole structure has one or more second locating features that interfit with the first locating features, the method <NUM> may include block <NUM>, aligning the first locating feature of the sole structure (e.g., locating feature <NUM>) with the second locating feature of the flange <NUM> (e.g., locating feature <NUM>). For example, the aligning may occur with any of modules <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> as described herein. In an example embodiment in which the at least one first locating feature includes a slot <NUM>, <NUM>, 568A, or 568B extending along the peripheral side surface of the sole structure to, and the at least one second locating feature includes a ridge <NUM>, <NUM>, <NUM>, <NUM>, 570C, 570D protruding at the inner surface of the flange <NUM>, the method may further comprise aligning the ridge with the slot prior to the interfitting the slot with the ridge. In an embodiment, block <NUM> may further include receiving a request for a sole structure with a specified stiffness or stability characteristic, in which case, prior to block <NUM>, the method <NUM> may include block <NUM>, placing an insert in a cavity in the peripheral side surface of the sole structure, as shown and described with respect to <FIG>, wherein the insert (e.g., insert 58A, 58B, 58C, 58D) has a compressive stiffness different than the sole structure (e.g., 12A or 12B), and the sole structure with the insert therein provides the specified stiffness or stability characteristic. In another embodiment, the sole structure does not have any inserts inserted into a cavity in the sole structure, or does not have any cavities in the sole structure to receive an insert, and the method <NUM> instead proceeds from block <NUM> directly to block <NUM>.

The method <NUM> may include block <NUM>, fitting an inner surface <NUM> of the flange <NUM> against the peripheral side surface <NUM> of the sole structure with the flange in the at least one recess <NUM> and with the upper component <NUM> partially defining a foot-receiving cavity <NUM> over the foot-facing surface <NUM> (or with similar upper components as those shown in <FIG>). For example, with respect to sole structure <NUM>, flange 564C is in first recess 30A and flange 564D is in second recess 30B. Within the scope of the claimed invention, as defined by the claims, fitting the inner surface of the flange <NUM> to the peripheral side surface <NUM> of the sole structure may include block <NUM>, interfitting the locating features of the flange <NUM> to the sole structure <NUM>, <NUM>, or <NUM>, or similar locating features of flanges <NUM>, <NUM>, 564C, or 564D to the respective sole structures <NUM>, <NUM>, as once the locating features are aligned, they are configured to interfit.

Next, in block <NUM>, the flange <NUM> is secured to the peripheral side surface <NUM> of sole structure <NUM>, or the flanges <NUM>, <NUM>, 564C, or 564D are secured to the respective sole structures <NUM>, <NUM>. Dependent upon the structure and materials of the flange and the sole structure, block <NUM> can be carried out in different ways. For example, in an embodiment, block <NUM> may include block <NUM>, adhering the flange <NUM> to the peripheral side surface <NUM>. The flange <NUM> can be adhered to the sole structure <NUM> with adhesive <NUM> as described with respect to <FIG>. In another embodiment, the flange <NUM> and the sole structure are configured to mechanically connect to one another, such as described with respect to locating features <NUM>, <NUM> that may have an interference fit, or slot <NUM> and ridge <NUM>, in which case block <NUM> includes block <NUM>, mechanically connecting the flange <NUM> to the peripheral side surface <NUM>. In the same or a different embodiment, securing the inner surface of the flange <NUM> to the peripheral side surface <NUM> of the sole structure in block <NUM> can include block <NUM>, thermally bonding the inner surface of the flange to the peripheral side surface of the sole structure, as described herein.

In some embodiments, the method <NUM> may include block <NUM>, stitching the upper component to the additional upper component after the securing the flange of the second module to the peripheral side surface of the sole structure. For example, stitching <NUM> is provided as shown and described with respect to each of the articles of footwear <NUM>, <NUM>, <NUM>, <NUM>, and <NUM>.

The method <NUM> enables customization requests specific to one article of footwear of a pair of footwear, such as a right shoe or a left shoe, so that the right shoe and the left shoe will be different after customization of one or both under the method <NUM>. For example, in an embodiment, the method <NUM> as described is first performed for an article of footwear that is a first article of footwear of a pair of footwear that includes the first article of footwear and a second article of footwear. The specified characteristic is a first specified characteristic. One of the first article of footwear and the second article of footwear has a right foot orientation and the other of the first article of footwear and the second article of footwear has a left foot orientation. The method <NUM> is then performed again for the second article of footwear, and the request received in block <NUM> is for an upper with a second specified characteristic different than the first specified characteristic.

Accordingly, the second article of footwear is assembled under the method <NUM> in accordance with the request for the second article of footwear by securing an inner surface of an additional flange of an additional module to a sole structure of the second article of footwear, such as additional module <NUM>. Similar to the first article of footwear, the sole structure of the second article of footwear has a foot-facing surface, a ground-engaging surface, and a peripheral side surface extending between the foot-facing surface and the ground-engaging surface. The peripheral side surface of the second article of footwear has at least one recess. The additional module has an additional upper component secured to the additional flange of the additional module, and the additional upper component has the second specified characteristic.

In another embodiment in which the customization request for the left article of footwear is different than for the right article of footwear, assembling the modular article of footwear in accordance with the request may further include securing a second module to the sole structure, such as a second module <NUM> or <NUM>. The second module includes an additional upper component <NUM>, and an additional flange <NUM> secured to the additional upper component and projecting therefrom. Securing the second module to the sole structure may comprise fitting an inner surface of the additional flange against the peripheral side surface of the sole structure with the additional flange in the at least one recess and with the additional upper component further defining the foot-receiving cavity.

The term "any of' is understood to include any possible combination of referenced claims of the appended claims, including "any one of' the referenced claims.

Those having ordinary skill in the art will recognize that terms such as "above", "below", "upward", "downward", "top", "bottom", etc., may be used descriptively relative to the figures, as defined by the claims.

The term "longitudinal" refers to a direction extending a length of a component. For example, a longitudinal direction of a shoe extends between a forefoot region and a heel region of the shoe. The term "forward" or "anterior" is used to refer to the general direction from a heel region toward a forefoot region, and the term "rearward" or "posterior" is used to refer to the opposite direction, i.e., the direction from the forefoot region toward the heel region. In some cases, a component may be identified with a longitudinal axis as well as a forward and rearward longitudinal direction along that axis. The longitudinal direction or axis may also be referred to as an anterior-posterior direction or axis.

The term "transverse" refers to a direction extending a width of a component. For example, a transverse direction of a shoe extends between a lateral side and a medial side of the shoe. The transverse direction or axis may also be referred to as a lateral direction or axis or a mediolateral direction or axis.

The term "vertical" refers to a direction generally perpendicular to both the lateral and longitudinal directions. For example, in cases where a sole is planted flat on a ground surface, the vertical direction may extend from the ground surface upward. It will be understood that each of these directional adjectives may be applied to individual components of a sole. The term "upward" or "upwards" refers to the vertical direction pointing towards a top of the component, which may include an instep, a fastening region and/or a throat of an upper. The term "downward" or "downwards" refers to the vertical direction pointing opposite the upwards direction, toward the bottom of a component and may generally point towards the bottom of a sole structure of an article of footwear.

Claim 1:
A modular article of footwear (<NUM>, <NUM>, <NUM>, <NUM>) comprising:
a sole structure (<NUM>, 12A, 12B, <NUM>, <NUM>, <NUM>) having a foot-facing surface (<NUM>), a ground-engaging surface (<NUM>), and a peripheral side surface (<NUM>) extending between the foot-facing surface (<NUM>) and the ground-engaging surface (<NUM>);
wherein the peripheral side surface (<NUM>) has at least one recess (30A, 30B, <NUM>);
an upper component (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, 516A, 516C, <NUM>, <NUM>);
a flange (<NUM>, <NUM>, <NUM>, 564C, 564D, <NUM>) secured to the upper component and projecting therefrom; and
wherein an inner surface (<NUM>, <NUM>, <NUM>, 566C, 566D, <NUM>) of the flange (<NUM>, <NUM>, <NUM>, 564C, 564D, <NUM>) fits against and is securable to the peripheral side surface (<NUM>) of the sole structure (<NUM>, 12A, 12B, <NUM>, <NUM>, <NUM>) with the flange in the at least one recess (30A, 30B, <NUM>), and the upper component (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, 516A, 516C, <NUM>, <NUM>) at least partially defining a foot-receiving cavity (56A, 56B, 56C, 56D) over the foot-facing surface (<NUM>),
wherein the upper component (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, 516A, 516C, <NUM>, <NUM>) is a first material; and
the flange (<NUM>, <NUM>, <NUM>, 564C, 564D, <NUM>) is a second material,
wherein the peripheral side surface (<NUM>) of the sole structure is the second material, or further comprising:
an adhesive (<NUM>) disposed on either or both of the inner surface of the flange (<NUM>, <NUM>, <NUM>, 564C, 564D, <NUM>) and the peripheral side surface (<NUM>) of the sole structure.