Patent Description:
Articles of footwear may provide functional benefits, including protecting the wearer's feet from the environment, such as surfaces and debris. Additionally, footwear may provide cushioning to the wearer's feet based on the application of the footwear (e.g., running or walking) and the wearer's anatomy. Manufacturing footwear may be expensive though, and design freedom may be limited. For example, shoe soles are traditionally made in a closed mold and require expensive tooling. Customizing a shoe sole may require a new, expensive mold. Moreover, such closed molds are limited in geometries that can be achieved and the materials that can be used. As one example, direct-soling technology has the limitations of expensive tooling, closed molds, limited geometries, material, etc. Newer techniques, such as dispensed (or extruded) components without a mold, can reduce (or eliminate) mold cost and provide more design freedom. Extruded components for articles of footwear are described in <CIT>. However, dispensing a shoe sole may lead to other challenges.

For example, known dispensing techniques can still require an additional step of adhering the dispensed components using adhesives, along with other labor and machinery to complete the pressing and assembly processes to form the shoe. In addition, it can be challenging to achieve a desired width for a shoe bottom, as well as a desired thickness, using dispensing techniques. As another example, controlling the dispensed material (e.g., the boundaries of the dispensed component) and achieving consistency can also be challenging. Accordingly, a need exists to improve dispensed articles of footwear components while realizing the wearer's functional needs.

In some embodiments, the dispensed components may be dispensed directly on the upper. In some embodiments, the dispensed components may be disposed on at least one of a forefoot region, a midfoot region, and a rearfoot region of the sole. In some embodiments, a dispensed component disposed on the forefoot region may include a first radius. A dispensed component disposed on the midfoot region may include a second radius different from the first radius. In some embodiments, at least one of the spiral dispensed components may extend in a lateral direction beyond a medial side of the upper. In some embodiments, at least one of the spiral dispensed components may extend onto a medial side of the upper. In some embodiments, at least one of the spiral dispensed components may extend in a lateral direction beyond a lateral side of the upper. In some embodiments, at least one of the spiral dispensed components may extend onto a lateral side of the upper.

The sole may include a dispensed component disposed on the upper. The sole may also include a sidewall. A boundary component may be disposed at a top line of the side wall.

In some embodiments, the upper may include a knit upper. The boundary component may be a raised knitted structure of the upper. In some embodiments, the upper may include a knit upper. The boundary component may be a raised knitted structure of the upper. In some embodiments, the boundary component may include a portion of the upper stitched together to form a trim. In some embodiments, the boundary component may include a frame coupled to and surrounding the upper. In some embodiments, the frame may include one or more lateral members that extend in a lateral direction underneath the upper from a medial side to a lateral side of the upper. In some embodiments, the frame may include a gutter configured to catch the dispensed component.

A method of making an article of footwear is also disclosed in claim <NUM>.

In some embodiments, the spiral geometry of each of the first dispensed component and the second dispensed component forming a hollow portion surrounded by the layers stacked on top of each other may include dispensing the material in the hollow portion of the first dispensed component and the second dispensed component. In some embodiments, the spiral path may include an elliptical shape. In some embodiments, the method may further include placing a removable fixture around the upper prior to dispensing the material. The removable fixture may catch the dispensed material to form an outer boundary of the first dispensed component and the second dispensed component. In some embodiments, controlling the dosing rate and the velocity for the dispensing nozzle may include adjusting the dosing rate or the velocity for the dispensing nozzle while dispensing the material.

The accompanying drawings, which are incorporated herein and form a part of the specification, illustrate the present invention and, together with the description, further serve to explain the principles of the invention and to enable a person skilled in the pertinent art to make and use the invention.

The present invention will now be described in detail with reference to embodiments thereof as illustrated in the accompanying drawings. References to "one embodiment," "an embodiment," "an example embodiment," etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic.

The term "invention" or "present invention" as used herein is a non-limiting term and is not intended to refer to any single embodiment of the particular invention but encompasses all possible embodiments as described in the application.

The following examples are illustrative, but not limiting, of the present invention.

The systems and methods described herein provide articles of footwear having a sole structure comprising one or more dispensed components created by an automated dispensing process. In some embodiments, the dispensed component may be made of rubber, foam (e.g., dispensed polyurethane foam), silicone, plastic including thermoplastic (e.g., polyurethane (such as TPU), nylon, or polypropylene), or any other suitable material. In some embodiments, the dispensed component may be made of a composite material. It is understood that while the term "dispensed" is generally used herein to refer to certain materials, these materials may also be "extruded. " Thus, the term "dispensed component" includes components that are dispensed and components that are extruded. These dispensed components may be dispensed from a mechanical device. In some embodiments, the dispensed components include one or more spiral dispensed components (e.g., dispensed components having a spiral geometry (either hollow or non-hollow). The spiral dispensed components may be formed by dispensing material from a dispensing nozzle moving in a spiral path.

Existing sole structures may be manufactured without use of an automated dispensing process. Such existing manufacturing processes are expensive and limit design freedom. For example, material may be poured or injected into a closed mold or cast. Once the material is ready (e.g., cured, cooled, reacted, etc.), the material may be removed. The material, retaining the shape of the mold or cast, may be used in an article of footwear. However, producing molds to achieve particular customizations is expensive. Further, the mold may not be easily altered to achieve other customizations. Thus, design freedom is impeded and new, expensive molds must be produced to create different designs and structures. Direct-soling technology similarly requires expensive tooling, closed molds, and use of certain materials.

As an alternative to molding techniques, direct dispensing techniques have been developed. A dispensed footwear component may have advantages over traditionally-formed components, such as those made by casting, pouring, injection molding, screenprinting, or thermo-plastically forming. For example, a dispensed component may be customized without having to machine a new, expensive mold. Additionally, components may be quickly created by dispensing without having to conduct the time-consuming process of creating a new mold. Indeed, a new mold may require multiple steps involving design, production, and surface treatment. The use of dispensed components may also provide the design freedom that traditional manufacturing lacks. The dispensing freedom may allow for localized, targeted dispensing to create and modify comfort support for various parts of the foot. Additionally, the dispensing process allows for the use of shapes and geometries that are difficult to achieve using conventional upper or bottom molding techniques. For example, a dispensed component may be shaped based on its output from a dispensing nozzle, which may be manipulated in terms of movement direction, rate, and time, and may utilize different output geometries (e.g., output dispensing nozzle size and shape may be varied). Moreover, the data and knowledge to make a dispensed component may be quickly deployed to any location that houses equipment and material suitable for processing.

Still, there are new challenges to address with these direct dispensing techniques. For example, a greater footwear bottom size may be difficult to achieve with direct dispensing. Increased width and height is desirable to provide protection and cushioning for a wearer's feet. However, dispensing a liquid material onto an upper to form a sole makes it difficult to achieve the desired height and width. Further, dispensing a liquid material may compromise design control, for example, creating inconsistency along a midsole top line, as the dispensed component is dispensed and before it cures. Finally, dispensed components may require additional processing to adhere to the upper, such as with adhesives, labor, or machinery. Thus, creating articles of footwear with direct dispensing may still require additional pressing and assembly processes that add time, cost, and material or effort.

The present disclosure addresses these challenges. In some embodiments, an article of footwear is provided that includes an upper (such as a knitted upper) and a sole that is formed with one or more dispensed components. In some embodiments, one or more dispensed components may form the entire sole of the article of footwear. Forming the sole with a dispensed component may provide flexibility and speed in development and manufacturing of the sole, while still meeting the functional purposes of the sole. The dispensed components may be dispensed directly onto the upper to create a sole and may adhere to the upper without requiring secondary adhesives, labor, heat, stock-fitting, pressing, cement, film, or machinery. Thus, the sole and upper may be combined to create an article of footwear in a more efficient manner.

In some embodiments, the dispensed components have a spiral geometry. The spiral geometry may result from the dispensing nozzle following a spiral path during dispensing. The spiral geometry is non-hollow (i.e., due to the liquid nature of the dispensed material and/or the tightness of the spiral, there is no hollow portion in the center of the spiral). Spiral dispensed components may be dispensed with the advantages provided by dispensed component formation. As described herein, the spiral geometry may incrementally build a sole thickness. In some embodiments, a first layer of the spiral geometry is dispensed directly onto an upper. In some embodiments, the spiral dispensed component is continuously dispensed to form additional layers, with each of the layers stacked on top of each other. Each subsequent layer may step up incrementally on each preceding layer to create a spiral dispensed component. In some embodiments, spiral dispensed components may extend vertically from the upper. Increasing the number of layers and/or a thickness of each layer may create height. Accordingly, an ideal thickness may be achieved both overall and locally using the spiral techniques. Additionally, dispensing the spiral geometry in an elliptical shape may increase the width of the layers. Thus, an overall width and height of a sole formed with spiral dispensed components may be increased to enhance cushioning effects and achieve a larger footwear bottom. In some embodiments, the size, shape, placement, and number of spiral dispensed components along the upper may be varied to influence protection and cushioning.

Dispensed components may be dispensed directly onto an inverted upper held on a shoe last. Thus, dispensed material may drip onto the sides of the upper, creating an uncontrolled and inconsistent top line of the midsole sidewall. Various techniques may be used to control the sidewall of the midsole, particularly the top line. In some embodiments, a boundary component may be disposed at a top line to prevent dripping and control and restrain the midsole sidewall. In some embodiments, the boundary component may include a raised structure or stitched trim integrated into the upper. Additionally or alternatively, a removable, non-stick fixture may extend along the upper to support and control dispensing. In some embodiments, portions of the upper may include a textured area to receive and retain the dispensed component. In some embodiments, the textured area may include raised structures and/or recesses. The texture and localized geometry may enhance dispensing control, which may facilitate dispensing consistency and achieving a particular geometry. Additionally, dispensed component adherence may also be improved such that secondary tools for assembling the article of footwear are not needed. The textured surface may also increase dispensing control, which may significantly affect stability of the overall sole structure, allowing for stacking of layers to increase height. Accordingly, securing a first layer may provide support to each subsequent layer.

In some embodiments, the article of footwear may include or utilize any of the extruded/dispensed components or other features disclosed in <CIT>,<CIT>,
<CIT>, <CIT>, and/or <CIT>.

Dispensing methods and dispensed systems based on the foregoing discussion will now be described with reference to the figures. In some embodiments, dispensed components may be utilized in an article of footwear <NUM>, as shown, for example, in <FIG>. In some embodiments, article of footwear <NUM> comprises an upper <NUM> and a sole <NUM>. Upper <NUM> may be made of a variety of materials (e.g., a textile fabric, woven or knit goods, leather, synthetic, a film product, etc.). In some embodiments, upper <NUM> may be a knitted upper. For example, upper <NUM> may be a circular knit material <NUM>. In some embodiments, upper <NUM> may be made of a combination of these materials. In some embodiments, upper <NUM> and sole <NUM> are coupled together. In some embodiments, sole <NUM> comprises one or more dispensed components <NUM>.

In some embodiments, article of footwear <NUM> may be made by directly dispensing material onto an upper <NUM>. For example, a completed upper <NUM> may be placed on a shoe last form (e.g., last <NUM> (see <FIG>, <FIG>, <FIG>). In some embodiments, the upper <NUM> comprises a 3D knit upper, such as a 3D knit sock. Upper <NUM> may be slipped over the shoe last form and then inverted in place beneath a dispensing nozzle <NUM> (<FIG>) so that the bottom of upper <NUM> is facing up.

At least a portion of sole <NUM> may be made with dispensed component <NUM>. In some embodiments, sole <NUM> may be formed with one or more dispensed components <NUM>. In some embodiments, one or more dispensed components <NUM> may form the entire sole <NUM> of article of footwear <NUM>. Dispensed component <NUM> may provide a sole <NUM> that supports functional benefits, such as providing enhanced protection and cushioning for a wearer's feet. In some embodiments, dispensed components <NUM> may be dispensed directly onto upper <NUM> to create sole <NUM>. Accordingly, sole <NUM> may be easily and quickly manufactured. In some embodiments, dispensed components <NUM> may adhere to the upper without requiring adhesives, additional labor, heat, stock-fitting, pressing, cement, film, or machinery to press and assemble article of footwear <NUM>. In some embodiments, the article of footwear <NUM> comprises a knitted upper <NUM> and a sole <NUM> consisting of dispensed components <NUM>. In some embodiments, the article of footwear <NUM> only includes the knitted upper <NUM> and the sole <NUM> consisting of dispensed components <NUM>. Thus, there may not be any other coupling structure between the upper <NUM> and the sole <NUM> (e.g., adhesive, stitching material).

In some embodiments, dispensed components <NUM> may be dispensed onto a surface to provide a dispensed component that extends beyond the surface at a certain width and height profile. In some embodiments, the height, width, or geometry or physical appearance/characteristic of the dispensed components may be dynamically changed as dispensed components <NUM> are dispensed onto article of footwear <NUM>, such as onto upper <NUM>. In some embodiments, the geometry or physical appearance/characteristics of the dispensed components may be changed by dynamically changing the height of the dispensing nozzle in any direction (relative to the dispensing surface or substrate) from which the material, used to form the component, is dispensed. In some embodiments, the geometry or physical appearance/characteristics of the dispensed components may be changed by dynamically changing the speed, in any direction, at which the dispensing nozzle is moving as the material is dispensed and the component is formed. In some embodiments, the geometry or physical appearance/characteristics of the dispensed components may be changed by dynamically changing the flow rate of the material that is dispensed. Other parameters may be changed to dynamically change the height, width, or other characteristic of the dispensed components. In some embodiments, the density or viscosity of the dispensed components may be changed.

In some embodiments, dispensed component <NUM> may be a single, continuous component formed by a single dispense. In some embodiments, dispensed component <NUM> is disposed on upper <NUM> in a non-solid form (e.g., liquid). The dispensed components <NUM> may be in a variety of shapes and configurations. For example, dispensed components <NUM> may include stacked elongate members that continuously extend back and forth medio-laterally, pod-like forms (such as the spiral dispensed components discussed below), or a combination of these. For example, <FIG> shows an elongate dispensed component <NUM> that extends back and forth medio-laterally disposed on a bottom of a plurality of pod-like dispensed components <NUM>. Other geometries may also be used.

As discussed above, direct dispensing with spiral geometries may increase the size (e.g., height and width) of a footwear bottom to enhance protection and cushioning for the wearer's feet. With reference to <FIG>, in some embodiments, dispensed component <NUM> has a spiral geometry to form a spiral dispensed component <NUM>. Spiral dispensed components <NUM> may create height and width to build a larger footwear bottom. In some embodiments, a spiral dispensed component <NUM> includes a first layer <NUM> comprising a starting point <NUM> and an outer end <NUM>. Outer end <NUM> is the edge of the layer that is not covered by a subsequent layer. In some embodiments, spiral dispensed component <NUM> includes a subsequent layer <NUM> comprising an outer end <NUM> and an end point <NUM>. In some embodiments, spiral dispensed component <NUM> includes a central portion <NUM>.

With reference to <FIG>, in some embodiments, first layer <NUM> of a spiral dispensed component <NUM> is dispensed directly onto upper <NUM>. In some embodiments, first layer <NUM> of a spiral dispensed component <NUM> is dispensed directly onto a bottom surface <NUM> of upper <NUM>. In some embodiments, spiral dispensed component <NUM> is dispensed onto a rearfoot region <NUM>, a midfoot region <NUM>, or a forefoot region <NUM> of upper <NUM>. In some embodiments, starting point <NUM> of first layer <NUM> is where spiral dispensed component <NUM> is first dispensed. In some embodiments, first layer <NUM> is continuously dispensed. In some embodiments, first layer <NUM> begins and ends at starting point <NUM>. In some embodiments, spiral dispensed component <NUM> is continuously dispensed to form a step up region <NUM> at starting point <NUM>. In some embodiments, subsequent layer <NUM> is dispensed onto first layer <NUM> so that subsequent layer <NUM> is disposed directly on top of first layer <NUM>. In some embodiments, subsequent layer <NUM> is continuously dispensed. In some embodiments, subsequent layer <NUM> begins at step up region <NUM>. In some embodiments, subsequent layer <NUM> is continuous with step up region <NUM> and first layer <NUM>.

In some embodiments, spiral dispensed component <NUM> comprises a plurality of subsequent layers <NUM>. In some embodiments, each subsequent layer <NUM> (e.g., a second layer, a third layer, a fourth layer, etc.) may step up incrementally on each preceding layer (e.g., first layer <NUM> or first layer <NUM> and a preceding subsequent layer <NUM>) to create a spiral dispensed component <NUM>. In some embodiments, each subsequent layer <NUM> is dispensed onto another subsequent layer <NUM> so that each subsequent layer is disposed directly on top of the other subsequent layer <NUM>. In this way, subsequent layers <NUM> may stack onto each other to build a higher sole thickness. In some embodiments, each subsequent layer <NUM> is stacked in a direction generally parallel to a preceding subsequent layer <NUM> along vertical axis <NUM>. <FIG> also shows longitudinal axis <NUM> and lateral axis <NUM>. In some embodiments, vertical axis <NUM>, longitudinal axis <NUM>, and lateral axis <NUM> are perpendicular axes.

The spiral geometry of spiral dispensed component <NUM> may be non-hollow. For example, as shown in <FIG>, dispensed material extends across the central portion <NUM> of the exposed layer of the spiral dispensed component <NUM> to entirely fill in the space within outer end <NUM>. The other layers (first layer <NUM> and subsequent layers <NUM>) similarly have a central portion <NUM> that is entirely filled in within outer end <NUM>. This may result from the liquid nature of the dispensed material running together as it is dispensed in a spiral, particularly where the spiral motion of the dispensing nozzle is a tight spiral.

In some embodiments, the spiral geometry of spiral dispensed component <NUM> may be hollow. In other words, the dispensed material does not entirely run together, even if the spiral is tight, such that there is a hollow portion within central portion <NUM> defined by the spiral (or coiled) shape of the dispensed material. In some embodiments, the hollow portion in the center of the spiral may be filled with dispensed material after dispensing the spiral geometry, as discussed below and shown in <FIG>.

The spiral geometry of spiral dispensed component <NUM> may result from a dispensing nozzle following a spiral path as it dispenses. With reference to <FIG>, dispensing programming may define the path <NUM> of a dispensing nozzle <NUM> (<FIG>). In some embodiments, the spiral path <NUM> comprises a circular shape. In some embodiments, the spiral path <NUM> comprises an elliptical shape. With reference to <FIG> and <FIG>, in some embodiments, dispensing programming may define starting point <NUM> and dispensing of first layer <NUM>, step up region <NUM>, and subsequent layers <NUM> for each spiral dispensed component <NUM>. In some embodiments, dispensing programming may define parameters for the spiral geometry of spiral dispensed components <NUM>. In some embodiments, the parameters may be defined to modify a physical property of spiral dispensed component <NUM>. In some embodiments, the path of dispensing nozzle <NUM> modifies physical properties of spiral dispensed component <NUM>. In some embodiments, the physical properties may include the size, shape, and placement of spiral dispensed component <NUM>. The parameters and physical properties defined by dispensing programing will be described further below.

As shown in <FIG>, in some embodiments, upper <NUM> is secured on a last <NUM>. In some embodiments, upper <NUM> is inverted on last <NUM>. In some embodiments, dispensed components <NUM> are dispensed directly onto upper <NUM> to form sole <NUM> as upper <NUM> is secured on last <NUM>.

In some embodiments, as shown, for example, in <FIG>, dispensed component <NUM> is dispensed from a dispensing nozzle <NUM>. In some embodiments, the relative position of dispensing nozzle <NUM> and upper <NUM> is adjustable. In some embodiments, dispensing programming may define the path of a dispensing nozzle <NUM>. In some embodiments, the path of dispensing nozzle <NUM> may be defined to modify a physical property of dispensed component <NUM>, such as a geometry. In some embodiments, the path of dispensing nozzle <NUM> may be defined to create dispensed component <NUM> with a spiral geometry, such that spiral dispensed component <NUM> is created.

With reference to <FIG>, in some embodiments, dispensing nozzle <NUM> is movable. In some embodiments, last <NUM> is movable. In some embodiments, both dispensing nozzle <NUM> and last <NUM> are movable. In some embodiments, dispensing nozzle <NUM> and/or last <NUM>, begin to move when dispensing nozzle <NUM> starts dispensing. In some embodiments, last <NUM> is positioned on a rotating fixture or table. As the relative position of dispensing nozzle <NUM> and upper <NUM> changes, dispensing nozzle <NUM> continuously dispenses dispensed component <NUM> (e.g., spiral dispensed components <NUM>). In some embodiments, moving dispensing nozzle <NUM>, last <NUM>, or both facilitates continuous dispensing along various parts of article of footwear <NUM> (e.g., the upper quarters, vamp, and collars, tongue). Additionally, movement expands the dispensing scope. In contrast, other processes are limited in scope, e.g., by tooling restrictions.

With reference to <FIG>, in some embodiments, the placement of starting point <NUM> may be a physical property of spiral dispensed component <NUM> defined by the dispensing programming. In some embodiments, starting point <NUM> is a point along an axis <NUM>. Accordingly, in some embodiments, first layer <NUM> begins and ends at starting point <NUM> such that first layer <NUM> begins and ends along axis <NUM>. In some embodiments, subsequent layer <NUM> begins at step up region <NUM>. In some embodiments, step up region <NUM> coincides with axis <NUM>. Accordingly, in some embodiments, subsequent layer <NUM> begins along axis <NUM>. In some embodiments, end point <NUM> of subsequent layer <NUM> is where subsequent layer <NUM> is last dispensed. In some embodiments, end point <NUM> is a point along axis <NUM>. Accordingly, in some embodiments, subsequent layer <NUM> ends at end point <NUM> along axis <NUM>. In some embodiments, first layer <NUM> and subsequent layer <NUM> begin and end along axis <NUM>. In some embodiments, the placement of end point <NUM> may be a physical property of spiral dispensed component <NUM> defined by the dispensing programming.

In some embodiments, the parameters defined by dispensing programming may include a dosing rate (e.g., the amount of material that is dispensed during a unit of time) and/or a velocity for the dispensing nozzle. The dosing rate and the velocity for the dispensing nozzle may be controlled during the dispensing process to form one or more spiral dispensed components <NUM>. For example, after positioning an upper <NUM> on a last <NUM>, the dispensing nozzle <NUM> may dispense a material onto the upper <NUM> at a first location (e.g., one of the locations of spiral path <NUM> shown in <FIG>) while controlling the nozzle to follow the spiral path <NUM>. In some embodiments, this dispensing forms a first spiral dispensed component <NUM> having a spiral geometry with layers (first layer <NUM> and subsequent layers <NUM>) stacked on top of each other, as discussed above. The dispensing nozzle <NUM> may then dispense the material onto the upper <NUM> at a second location (e.g., another one of the locations of spiral path <NUM> shown in <FIG>) while controlling the nozzle to follow the spiral path <NUM>. In some embodiments, this dispensing forms a second spiral dispensed component <NUM> having a spiral geometry with layers (first layer <NUM> and subsequent layers <NUM>) stacked on top of each other, as discussed above. These spiral dispensed components <NUM> form a portion of sole <NUM>, as shown in <FIG> and <FIG>.

The dosing rate and the velocity for the dispensing nozzle <NUM> may be controlled throughout this process. In some embodiments, controlling the dosing rate and the velocity for the dispensing nozzle <NUM> comprises adjusting the dosing rate or the velocity for the dispensing nozzle <NUM> while dispensing the material. In some embodiments, the dosing rate and the velocity for the dispensing nozzle <NUM> are kept constant during the dispensing process.

In some embodiments, the physical property affected by the dispensing programming may be a layer thickness (e.g., a first layer <NUM> and/or subsequent layer <NUM> thickness). With reference to <FIG>, in some embodiments, decreasing the velocity for the dispensing nozzle <NUM> and/or increasing the dosing rate may result in a larger layer thickness. Accordingly, decreasing the velocity for the dispensing nozzle <NUM> and/or increasing the dosing rate may result in a thicker first layer <NUM> and thicker subsequent layers <NUM>. As shown in <FIG>, the layer thickness with a slower velocity for the dispensing nozzle <NUM> and/or higher dosing rate may be TA.

With reference to <FIG>, in some embodiments, increasing the velocity for the dispensing nozzle <NUM> and/or decreasing the dosing rate may result in a smaller layer thickness. As shown in <FIG>, the layer thickness with a faster velocity for the dispensing nozzle <NUM> and/or lower dosing rate may be TB. In some embodiments, TA (<FIG>) may be greater than TB. In some embodiments, a greater number of subsequent layers <NUM> may stack onto each other to build a higher sole thickness with a layer thickness of TB as compared to a spiral dispensed component <NUM> having layers with a layer thickness of TA.

As noted above, spiral dispensed component <NUM> may have a non-hollow spiral geometry or a hollow spiral geometry. With reference to <FIG>, where spiral dispensed component <NUM> has a hollow spiral geometry, in some embodiments, a hollow central portion <NUM> of spiral dispensed component <NUM> may be subsequently filled with dispensed material <NUM>. Accordingly, in some embodiments, dispensing programming defines the path <NUM> (<FIG>) of dispensing nozzle <NUM> (<FIG>) such that dispensing nozzle <NUM> creates first layer and subsequent layers <NUM> to form a hollow central portion <NUM> and then dispenses material <NUM> into central portion <NUM> after forming the last subsequent layer <NUM>.

In some embodiments, end point <NUM> of subsequent layer <NUM> is where subsequent layer <NUM> is last dispensed. In some embodiments, after dispensing end point <NUM>, no further subsequent layers <NUM> are dispensed to create a spiral dispensed component <NUM>. In some embodiments, after dispensing end point <NUM>, dispensing nozzle <NUM> (<FIG>) fills central portion <NUM> with dispensed material. In some embodiments, starting point <NUM>, first layer <NUM>, step up region <NUM>, subsequent layer <NUM>, end point <NUM>, and central portion <NUM> are continuously dispensed.

Central portion <NUM> may be filled with dispensed material <NUM> after end point <NUM> is dispensed. As shown in <FIG>, in some embodiments, central portion <NUM> is filled with dispensed material <NUM> up to a point that is lower than end point <NUM> relative to vertical axis <NUM> (<FIG> and <FIG>). In some embodiments, central portion <NUM> is filled with dispensed material <NUM> up to a point that is coplanar with end point <NUM>. In some embodiments, central portion <NUM> is filled with dispensed material <NUM> up to a point that is higher than end point <NUM> relative to vertical axis <NUM>.

With reference to <FIG>, in some embodiments, outer end <NUM> of first layer <NUM> contacts outer end <NUM> of a first layer <NUM> of another spiral dispensed component <NUM>. In some embodiments, outer end <NUM> of subsequent layer <NUM> contacts outer end <NUM> of a subsequent layer <NUM> of another spiral dispensed component <NUM>. Accordingly, layers (e.g., first layer <NUM> and/or subsequent layers <NUM>) of a spiral dispensed component <NUM> may contact layers of another spiral dispensed component <NUM>, while each spiral dispensed component <NUM> retains its shape.

In some embodiments, spiral dispensed components <NUM> may create a rearfoot region <NUM>, a midfoot region <NUM>, and/or a forefoot region <NUM> of sole <NUM> as shown in <FIG>. In some embodiments, spiral dispensed components <NUM> may create an outsole <NUM> of sole <NUM>. Accordingly, spiral dispensed components <NUM> (e.g., dispensed component <NUM> having a spiral geometry) may be disposed throughout the sole <NUM>. For example, there may be spiral dispensed components in a rearfoot region <NUM>, a midfoot region <NUM>, and/or a forefoot region <NUM> of sole <NUM>.

In some embodiments, spiral dispensed component <NUM> may be varied at different areas of sole <NUM> (e.g., rearfoot region <NUM>, midfoot region <NUM>, and/or forefoot region <NUM>). In some embodiments, dispensing programming may define parameters to vary physical properties of spiral dispensed component <NUM> at different areas of sole <NUM>. In some embodiments, spiral dispensed component <NUM> may be varied based on a number of layers (e.g., a number of subsequent layers <NUM> disposed on first layer <NUM>). In some embodiments, increasing the number of layers and/or a thickness of each layer may create height in a direction parallel to vertical axis <NUM> (<FIG> and <FIG>). Increasing height in a direction parallel to vertical axis <NUM> may increase an overall thickness of sole <NUM> to enhance protection and cushioning for a wearer's feet and achieve a larger footwear bottom. In some embodiments, layers (e.g., first layer <NUM> and/or subsequent layer <NUM>) comprises an elliptical shape. In some embodiments, comprising an elliptical shape increases the width of the layer. Increasing the width of layers may decrease the curing time. In some embodiments, the length of a layer may be increased in a direction parallel to longitudinal axis <NUM> (longitudinal axis <NUM> is shown in <FIG>), which runs along a longitudinal direction of the article of footwear <NUM>. In some embodiments, the width of a layer may be increased in a direction parallel to lateral axis <NUM> (lateral axis <NUM> is shown in <FIG> and <FIG>), which runs along a lateral direction of the article of footwear <NUM>.

In some embodiments, forefoot region <NUM> comprises between two and six spiral dispensed components <NUM> disposed adjacent to each other along longitudinal axis <NUM> (<FIG>). In some embodiments, forefoot region <NUM> comprises two spiral dispensed components <NUM> disposed adjacent to each other in a longitudinal direction (e.g., parallel to longitudinal axis <NUM>). In some embodiments, midfoot region <NUM> comprises between two and six spiral dispensed components <NUM> disposed adjacent to each other in a longitudinal direction. In some embodiments, midfoot region <NUM> comprises three spiral dispensed components <NUM> disposed adjacent to each other in a longitudinal direction. In some embodiments, midfoot region <NUM> comprises two spiral dispensed components <NUM> disposed adjacent to each other in a longitudinal direction parallel. In some embodiments, rearfoot region <NUM> comprises between two and six spiral dispensed components <NUM> disposed adjacent to each other in a longitudinal direction. In some embodiments, rearfoot region <NUM> comprises three spiral dispensed components <NUM> disposed adjacent to each other in a longitudinal direction. In some embodiments, rearfoot region <NUM> comprises two spiral dispensed components <NUM> disposed adjacent to each other in a longitudinal direction. Other numbers of spiral dispensed components <NUM> disposed adjacent to each other in a longitudinal direction may be used in the various regions of sole <NUM>. The spiral dispensed components <NUM> may be aligned in the longitudinal direction or be offset from each other.

In some embodiments, forefoot region <NUM> comprises between two and six spiral dispensed components <NUM> disposed adjacent to each other in a lateral direction (e.g., parallel to lateral axis <NUM> shown in <FIG> and <FIG>). In some embodiments, forefoot region <NUM> comprises two spiral dispensed components <NUM> disposed adjacent to each other in a lateral direction. In some embodiments, midfoot region <NUM> comprises between two and six spiral dispensed components <NUM> disposed adjacent to each other in a lateral direction. In some embodiments, midfoot region <NUM> comprises three spiral dispensed components <NUM> disposed adjacent to each other in a lateral direction. In some embodiments, midfoot region <NUM> comprises two spiral dispensed components <NUM> disposed adjacent to each other in a lateral direction. In some embodiments, rearfoot region <NUM> comprises between two and six spiral dispensed components <NUM> disposed adjacent to each other in a lateral direction. In some embodiments, rearfoot region <NUM> comprises three spiral dispensed components <NUM> disposed adjacent to each other in a lateral direction. In some embodiments, rearfoot region <NUM> comprises two spiral dispensed components <NUM> disposed adjacent to each other in a lateral direction. Other numbers of spiral dispensed components <NUM> disposed adjacent to each other in a lateral direction may be used in the various regions of sole <NUM>. The spiral dispensed components <NUM> may be aligned in the lateral direction or be offset from each other.

Varying the number of spiral dispensed components <NUM> at different areas of sole <NUM> may facilitate targeted protection and cushioning for a wearer's foot. Additionally, increasing the number of spiral dispensed components <NUM> disposed in a direction parallel to longitudinal axis <NUM> (<FIG>) and/or lateral axis <NUM> (<FIG> and <FIG>) may increase an overall length and/or width of sole <NUM> in a direction parallel to longitudinal axis <NUM> and/or lateral axis <NUM>, respectively. Increasing the length and/or width of sole <NUM> may increase an overall size of sole <NUM> to enhance protection and cushioning and achieve a larger footwear bottom. Dispensing provides flexibility for varying the number of spiral dispensed components <NUM> in a direction parallel to longitudinal axis <NUM> and/or lateral axis <NUM>.

In some embodiments, the radius of spiral dispensed component <NUM> may be varied. In some embodiments, the radius of spiral dispensed component <NUM> may be a parameter defined by dispensing programming. In some embodiments, spiral dispensed component <NUM> disposed on rearfoot region <NUM> of sole <NUM> comprises a rearfoot radius <NUM>. In some embodiments, spiral dispensed component <NUM> disposed on midfoot region <NUM> of sole <NUM> comprises a midfoot radius <NUM>. In some embodiments, spiral dispensed component <NUM> disposed on forefoot region <NUM> of sole <NUM> comprises a forefoot radius <NUM>. In some embodiments, rearfoot radius <NUM> may be the same or different from midfoot radius <NUM>. In some embodiments, rearfoot radius <NUM> may be the same or different from forefoot radius <NUM>. In some embodiments, midfoot radius <NUM> may be the same or different from forefoot radius <NUM>. In some embodiments, rearfoot radius <NUM> may be bigger than midfoot radius <NUM>. In some embodiments, midfoot radius <NUM> may be bigger than forefoot radius <NUM>.

As shown in <FIG>, in some embodiments, a dispensed component <NUM> may form a top member <NUM>. In some embodiments, top member <NUM> is disposed on one or more other dispensed components <NUM>, e.g., spiral dispensed components <NUM>. For example, top member <NUM> may be dispensed over the last subsequent layer <NUM> of a plurality of spiral dispensed components <NUM>. In some embodiments, top member <NUM> is disposed on rearfoot region <NUM>, midfoot region <NUM>, and/or forefoot region <NUM> of sole <NUM>. In some embodiments, outsole <NUM> comprises top member <NUM>. In some embodiments, the top member <NUM> may be dispensed so that it extends back and forth medio-laterally. For example, top member <NUM> may extend back and forth medio-laterally on a medial side of sole <NUM> and/or on a lateral side of sole <NUM>. In some embodiments, two dispensed components <NUM> make up top member <NUM> and extend back and forth medio-laterally, with one on the medial side and one on the lateral side of sole <NUM>. In some embodiments, a single continuous dispensed component <NUM> makes up top member <NUM> and extends back and forth medio-laterally (e.g., first on the medial side and then on the lateral side of sole <NUM>, or vice versa).

In some embodiments, dispensing programming may manipulate the path of a dispensing nozzle <NUM> (<FIG>) by defining dispensing parameters such as movement direction, rate, thickness, and time to dispense top member <NUM> comprising a varied design. In some embodiments, dispensing nozzle <NUM> may utilize different output geometries to dispense top member <NUM> comprising a varied design. In some embodiments, top member <NUM> comprises one or more layers and angles to create a varied design. In some embodiments, top member <NUM> comprises varying thicknesses. For example, in some embodiments, top member <NUM> comprises a thickness at rearfoot region <NUM> of sole <NUM> that is different from a thickness at midfoot region <NUM> of sole <NUM>. In this way, top member <NUM> exemplifies the benefits of localized dispensing to provide targeted protection, cushioning, and/or traction. The dispensing process may facilitate dynamic designing required to create top member <NUM>.

With reference to <FIG>, in some embodiments, spiral dispensed components <NUM> may extend onto a medial side <NUM> of upper <NUM>. In some embodiments, spiral dispensed components <NUM> may extend onto a lateral side <NUM> of upper <NUM>. In some embodiments, at least first layer <NUM> of spiral dispensed component <NUM> may extend onto medial side <NUM> or lateral side <NUM> of upper <NUM>. In some embodiments, first layer <NUM> and at least one subsequent layer <NUM> may extend onto medial side <NUM> or lateral side <NUM> of upper <NUM>. Accordingly, spiral dispensed components <NUM> may expand beyond upper <NUM> to build a larger footwear bottom by extending onto upper <NUM> itself.

Sole <NUM> may also extend in lateral and longitudinal directions beyond upper <NUM>. As shown in <FIG>, in some embodiments, sole <NUM> may extend in a direction parallel to longitudinal axis <NUM> (<FIG>) beyond upper <NUM> (e.g., rearward beyond rearfoot region <NUM> of upper <NUM> or forward beyond forefoot region <NUM> of upper <NUM>). In some embodiments, one or more spiral dispensed component <NUM> may extend in a direction parallel to longitudinal axis <NUM> rearward beyond rearfoot region <NUM> of upper <NUM>. In some embodiments, one or more spiral dispensed component <NUM> may extend in a direction parallel to longitudinal axis <NUM> forward beyond forefoot region <NUM> of upper <NUM>. In some embodiments, sole <NUM> and components thereof extending beyond upper <NUM> in a direction parallel to longitudinal axis <NUM> may increase an overall length of sole <NUM>, thus increasing an overall size of sole <NUM> to enhance protection and cushioning of a wearer's feet by attaining a larger footwear bottom.

As shown in <FIG>, in some embodiments, sole <NUM> may extend in a direction parallel to lateral axis <NUM> beyond upper <NUM> (e.g., in a lateral direction beyond medial side <NUM>, beyond lateral side <NUM>, or both). For example, one or more spiral dispensed component <NUM> may extend in a direction parallel to lateral axis <NUM> beyond medial side <NUM> of upper <NUM> and one or more spiral dispensed component <NUM> may extend in a direction parallel to lateral axis <NUM> beyond lateral side <NUM> of upper <NUM>. Sole <NUM> and components thereof extending beyond upper <NUM> in a direction parallel to lateral axis <NUM> may increase an overall width of sole <NUM>, thereby increasing an overall size of sole <NUM> to enhance cushioning and achieve a larger footwear bottom.

Varying the size of sole <NUM> and components thereof is facilitated by the flexibility provided by dispensing. Based on the foregoing, the size, placement, design, and/or number of spiral dispensed components <NUM> along upper <NUM> may be varied using dispensing to influence protection and cushioning effects. Additionally, sole <NUM> may incrementally extend beyond upper <NUM> in a direction parallel to lateral axis <NUM> from rearfoot region <NUM> and forefoot region <NUM> such that sole <NUM> extends laterally in a consistent matter. Further, each stepping up layers of spiral dispensed component <NUM> (e.g., first layer <NUM> and/or subsequent layer <NUM>) may be created in a controlled manner. In some embodiments, dispensing programming may define parameters, such as overall and localized height, width, and length to define physical height, width, and length properties of sole <NUM>.

Spiral dispensed components <NUM> may be used in other ways to form parts of sole <NUM>. For example, instead of being arranged in a vertical direction to create height, spiral dispensed components <NUM> may be arranged horizontally, as shown, for example, in <FIG> In some embodiments, spiral dispensed components <NUM> may be dispensed as a stand-alone component (e.g., by dispensing onto a non-stick material) that is subsequently integrated into a sole <NUM>. Such spiral dispensed components <NUM> may be hollow or non-hollow, as discussed above. In some embodiments, spiral dispensed component <NUM> may be arranged in sole <NUM> with subsequent layers <NUM> stacked in a direction along longitudinal axis <NUM> (<FIG>). As shown in <FIG>, in some embodiments, spiral dispensed component <NUM> may be arranged in sole <NUM> with first layer <NUM> and subsequent layers <NUM> stacked in a direction parallel to lateral axis <NUM> (<FIG> and <FIG>). In some embodiments, spiral dispensed components <NUM> arranged horizontally may be disposed between an outsole <NUM> and another portion of a midsole (e.g., a dispensed portion or a non-dispensed portion).

In some embodiments, sole <NUM> may include a sidewall <NUM>. Sidewall <NUM> includes a top line <NUM>, which defines its upper perimeter. Sidewall <NUM> (including top line <NUM>) may be formed by spiral dispensed components <NUM>. In some embodiments, sidewall <NUM> (including top line <NUM>) may be formed by other types of dispensed components of various shapes. In some embodiments, sidewall <NUM> may include a base layer of dispensed material over which other shapes of dispensed components (such as spiral dispensed components <NUM>) are dispensed. In some embodiments, top line <NUM> may be formed by such a base layer. In some embodiments, top line <NUM> of sole <NUM> may be disposed along bottom edge <NUM> of upper <NUM>. In some embodiments, top line <NUM> may extend onto upper <NUM> either entirely or partially. In some embodiments, top line <NUM> may be linear around upper <NUM>. In some embodiments, top line <NUM> may vary around upper <NUM> (e.g., top line <NUM> may comprise curves and/or edges as it extends around upper <NUM>). In some embodiments, top line <NUM> may be continuous. In some embodiments, top line <NUM> may be discontinuous (e.g. top line <NUM> may be discontinuous between at least one or more spiral dispensed components <NUM> if sole <NUM> is comprised of discretely dispensed spiral dispensed components <NUM> or independent groupings of spiral dispensed components <NUM>). In some embodiments, top line <NUM> is formed by controlling dispensing. Top line <NUM> may be defined and dispensed accordingly, as various structures described herein may facilitate controlled dispensing and limit fluid dripping.

Various structures that may be used to better control the dispensing process and limit fluid dripping are described below with reference to <FIG>. Structures may support adherence of dispensed components to article of footwear <NUM>, such as to upper <NUM>. Other structures may limit fluid dripping as dispensed components <NUM> are dispensed to create sole <NUM>. Such structures may provide a consistent top line <NUM> of the sidewall <NUM> formed by the dispensed components <NUM>. In some embodiments, these structures are removable so that the structures may be removed once the dispensed material is cured. In some embodiments, these structures are part of the article of footwear <NUM>. For example, the structure may be an integral part of the upper <NUM> or it may be a separate component that is coupled to the upper <NUM>.

As shown in <FIG>, in some embodiments, upper <NUM> comprises a textured area <NUM>. In some embodiments, bottom surface <NUM> of upper <NUM> comprises a textured area <NUM>. In some embodiments, textured area <NUM> comprises a localized geometry. In some embodiments, textured area <NUM> comprises one or more raised structures <NUM>. In some embodiments, raised structure <NUM> is disposed on upper <NUM>. In some embodiments, raised structure <NUM> is formed from upper <NUM>. In some embodiments, raised structure <NUM> comprises knit material <NUM> of upper <NUM>. In some embodiments, textured area <NUM> comprises one or more recesses <NUM>. In some embodiments, recesses <NUM> are formed in upper <NUM>. In some embodiments, textured area <NUM> comprises one or more raised structures <NUM> and one or more recesses <NUM>.

In some embodiments, dispensed component <NUM> is disposed on textured area <NUM> of upper <NUM>. Textured area <NUM> may enhance dispensing control to improve dispensing consistency and achieve a particular geometry of dispensed component <NUM>. Textured area <NUM> may also improve adherence of dispensed component <NUM>, which may provide structure and support to spiral dispensed component <NUM> and parts thereof. First layer <NUM> adherence, control, and support may increase the stability of subsequent layers <NUM> and spiral dispensed component <NUM> overall.

As noted above, a variety of structures may be used to limit fluid dripping as dispensed components <NUM> are dispensed to create sole <NUM>, thus controlling to the dispensing to form a desired top line. Such structures provide a boundary component. Various configurations for a boundary component are discussed below. A boundary component may facilitate dispensing control on upper <NUM> by limiting fluid dripping. When attached to upper <NUM> on last <NUM>, the boundary component may isolate dispensed material such that the dispensed material does not flow to the underside of the boundary component. In this way, boundary components may create a barrier (e.g., a shutoff) between the dispensed material and upper <NUM>.

As shown in <FIG>, in some embodiments, a frame <NUM> is used as the boundary component for controlling dispensing on upper <NUM>. In some embodiments, frame <NUM> is slipped onto last <NUM>. In some embodiments, frame <NUM> is secured around last <NUM> via a friction fit. In some embodiments, frame <NUM> is secured onto last <NUM> around upper <NUM> disposed on last <NUM>. With reference to <FIG>, in some embodiments, frame <NUM> may enhance dispensing control of dispensed components <NUM> and limit fluid dripping. Accordingly, as dispensing material is disposed onto upper <NUM>, the material does not drip beyond frame <NUM>. In some embodiments, frame <NUM> is non-stick such that dispensing material does not adhere to frame <NUM>. In some embodiments, frame <NUM> is coated with Teflon™. In some embodiments, frame <NUM> may limit dispensing material from dripping beyond frame <NUM>. In some embodiments, frame <NUM> remains as part of the finished article of footwear <NUM>.

As shown in <FIG>, in some embodiments, a frame <NUM> is used as the boundary component for controlling dispensing on upper <NUM>. In some embodiments, frame <NUM> comprises a forefoot part <NUM> and a heel part <NUM>. In some embodiments, forefoot part <NUM> and heel part <NUM> are separate parts that are slipped onto last <NUM>. In some embodiments, forefoot part <NUM> and heel part <NUM> secure around last <NUM> via a friction fit. In some embodiments, forefoot part <NUM> and heel part <NUM> contact each other when secured to last <NUM> such that frame <NUM> extends entirely around last <NUM>. In some embodiments, there is a gap between forefoot part <NUM> and heel part <NUM>. With reference to <FIG>, in some embodiments, forefoot part <NUM> and heel part <NUM> are not separate components, but portions of one integral frame <NUM>. In some embodiments, forefoot part <NUM> and heel part <NUM> are secured around upper <NUM> disposed on last <NUM>. In some embodiments, frame <NUM> is non-stick such that dispensing material does not adhere to frame <NUM>. In some embodiments, frame <NUM> is coated with Teflon™.

Frame <NUM> may also include one or more intermediate members <NUM>. To provide structural support to frame <NUM>. As shown in <FIG>, intermediate members <NUM> may extend across the width of frame <NUM>. In some embodiments, frame <NUM> may include between one and ten intermediate members <NUM>, such as between two and five intermediate members <NUM>, such as three intermediate members <NUM>. Frame <NUM> may include intermediate members <NUM> on forefoot part <NUM> and/or heel part <NUM>. For example, forefoot part <NUM> may include two intermediate members <NUM> and heel part <NUM> may include one intermediate member <NUM>. In some embodiments with separable forefoot part <NUM> and heel part <NUM>, intermediate members <NUM> may bound the open ends of forefoot part <NUM> and heel part <NUM>. Intermediate members <NUM> may rest on top of last <NUM>, which may help secure frame <NUM> in place during the dispensing process.

As shown in <FIG>, in some embodiments, forefoot part <NUM> and heel part <NUM> each comprise a gutter <NUM>. In some embodiments, gutter <NUM> is u-shaped and extends around forefoot part <NUM> and heel part <NUM>. In some embodiments, gutter <NUM> may catch dispensed material, as the material is disposed onto upper <NUM> (<FIG>). Accordingly, gutter <NUM> may be a dam that collects residual dispensed material. In this way, frame <NUM> may help limit material dripping onto upper <NUM> and last <NUM>, and may collect excess material in gutter <NUM>. In some embodiments, gutter <NUM> comprises a thickness of approximately one millimeter. In some embodiments, frame <NUM> remains as part of the finished article of footwear <NUM>.

In some embodiments, forefoot part <NUM> and/or heel part <NUM> are thin and/or flexible. As shown in <FIG>, in some embodiments, forefoot part <NUM> and/or heel part <NUM> comprises spring wire <NUM>. In some embodiments, spring wire <NUM> may be made of a spring grade metal. In some embodiments, spring wire <NUM> is attached to the forefoot part <NUM> and/or heel part <NUM>. For example, frame <NUM> may include a recess <NUM> that extends around forefoot part <NUM> and/or heel part <NUM>. In some embodiments, recess <NUM> is disposed along gutter <NUM>. In some embodiments, recess <NUM> is disposed on top of gutter <NUM>. In some embodiments, recess <NUM> is disposed along the underside of gutter <NUM>. Recess <NUM> may receive spring wire <NUM> (e.g., spring wire <NUM> may clip into recess <NUM>). Spring wire <NUM> may reinforce frame <NUM> in creating a barrier (e.g., a shutoff) between frame <NUM> and upper <NUM> by making frame <NUM> more robust. Accordingly, dispensed material is less likely to or prevented from flowing past frame <NUM> and onto upper <NUM>. In this way, spring wire <NUM> supports frame <NUM> in forming a boundary component for controlling dispensing on upper <NUM> and isolating the underside of frame <NUM> from dispensed material collected by frame <NUM>.

Other types of frames may also be used as the boundary component. In some embodiments, rather than a frame that remains as part of the finished article of footwear, a removable frame may be used. For example, a frame <NUM>, as shown in <FIG>, may be used as the boundary component for controlling dispensing on upper <NUM>. In some embodiments, frame <NUM> is slipped onto last <NUM>. Rather than being secured around last <NUM> via a friction fit when it is slipped onto last <NUM>, frame <NUM> may include a cam lock system that adjusts the size of frame <NUM> to facilitate easy installation on and removal from last <NUM>. Thus, frame <NUM> may be secured around upper <NUM> disposed on last <NUM> by tightening frame <NUM> with cam locks <NUM>. In some embodiments, frame <NUM> comprises a forefoot part <NUM> and a heel part <NUM>. In some embodiments, forefoot part <NUM> and heel part <NUM> contact each other when tightened around last <NUM> such that frame <NUM> extends entirely around last <NUM>.

Forefoot part <NUM> and heel part <NUM> may be quickly and easily fit together and onto last <NUM>. In some embodiments, rods <NUM> separate forefoot part <NUM> and heel part <NUM>. Rods <NUM> may connect forefoot part <NUM> and heel part <NUM>. At least one of forefoot part <NUM> and heel part <NUM> may be pushed inward over rods <NUM> such that forefoot part <NUM> and heel part <NUM> are in contact via cam locks <NUM>. In some embodiments, as frame <NUM> is slipped onto last <NUM>, at least one of forefoot part <NUM> and heel part <NUM> may be pushed inward over rods <NUM> to secure frame <NUM> around upper <NUM> disposed on last <NUM>. In some embodiments, frame <NUM> is secured to last <NUM> via one or more cam locks <NUM>. Cam locks <NUM> may tighten frame <NUM> around upper <NUM> disposed on last <NUM>. In some embodiments, cam locks <NUM> may be disposed on forefoot part <NUM>. Additionally or alternatively, cam locks <NUM> may be disposed on heel part <NUM>. Each cam lock <NUM> may include a lever <NUM> that, when pushed, may pull forefoot part <NUM> and heel part <NUM> towards each other over rods <NUM>. In some embodiments, levers <NUM> may be released to allow forefoot part <NUM> and heel part <NUM> to extend away from each other such that rods <NUM> show between forefoot part <NUM> and heel part <NUM>. As forefoot part <NUM> and heel part <NUM> are extended away from each other, frame <NUM> may be removed from last <NUM>, which then allows upper <NUM> to be removed from last <NUM>.

In some embodiments, frame <NUM> is non-stick such that dispensing material does not adhere to frame <NUM>. In some embodiments, frame <NUM> is coated with Teflon™. As shown in <FIG>, in some embodiments, frame <NUM> (e.g., forefoot part <NUM> and/or heel part <NUM>) comprise a gutter <NUM>. In some embodiments, gutter <NUM> is u-shaped and extends around frame <NUM>. In some embodiments, gutter <NUM> may catch dispensed material, as the material is disposed onto upper <NUM>. In this way, frame <NUM> may limit material dripping onto upper <NUM> (<FIG>) and last <NUM>, and may collect excess material in gutter <NUM>. In some embodiments, gutter <NUM> comprises a thickness of approximately one millimeter. In some embodiments, frame <NUM> is opened or removed from last <NUM> once the dispensing material is ready and/or article of footwear <NUM> (<FIG>) is complete.

Various frames may be used to control dispensing on upper <NUM> (<FIG>), such as frame <NUM> shown in <FIG>. In some embodiments, frame <NUM> is secured around upper <NUM>. In some embodiments, frame <NUM> is cemented to upper <NUM>. With reference to <FIG>, in some embodiments, frame <NUM> is ring-shaped and extends around upper <NUM>. In some embodiments, frame <NUM> is a polypropylene ring. In this way, frame <NUM> may limit material dripping onto upper and last <NUM> (<FIG>). With reference to <FIG>, in some embodiments, frame <NUM> is pushed upwards relative to upper <NUM> to secure around upper <NUM>.

In some embodiments, a frame <NUM> shown in <FIG> is used for controlling dispensing on upper <NUM> (<FIG>). In some embodiments, last <NUM> is disposed within frame <NUM>. In some embodiments, frame <NUM> includes one or more recesses <NUM> to catch dispensed material, as the material is disposed onto upper <NUM>. In this way, frame <NUM> may limit material dripping onto upper <NUM> and last <NUM>, and may collect excess material in recess <NUM>. In some embodiments, frame <NUM> is removable. In some embodiments, frame <NUM> is removed once the dispensing material is ready and/or article of footwear <NUM> (<FIG>) is complete.

In some embodiments, the boundary component for dispensing control may be an integral part of the upper. This eliminates the need for a separate component. Various example boundary components are discussed below.

In some embodiments, the boundary component comprises a stitched together portion of upper <NUM>. As shown in <FIG>, in some embodiments, gathering stitches <NUM> may stitch together two portions <NUM> of upper <NUM> to form a boundary component <NUM> (<FIG>). Boundary component <NUM> may be a portion <NUM> of upper <NUM> between portions <NUM>. In some embodiments, two rows, upper row <NUM> and lower row <NUM>, are the portions <NUM> of upper <NUM> that are stitched together. Gathering stitches <NUM> may be stitched along upper row <NUM> and lower row <NUM>. In some embodiments, knit material <NUM> of upper <NUM> is elastic. In some embodiments, gathering stiches <NUM> along upper row <NUM> and lower row <NUM> pull portion <NUM> of upper <NUM> between upper row <NUM> and lower row <NUM>. As shown in <FIG>, portion <NUM> of upper <NUM> between upper row <NUM> and lower row <NUM> forms boundary component <NUM>. Boundary component <NUM> comprises knit material <NUM> of upper <NUM> such that it is integrated with upper <NUM>. Boundary component <NUM> extends from upper <NUM> to form a rim around upper <NUM>. In some embodiments, boundary component <NUM> may catch dispensed material, as the material is disposed onto upper <NUM>. In this way, boundary component <NUM> may limit material dripping onto upper <NUM> and last <NUM>, and may collect excess material on boundary component <NUM>. In some embodiments, gathering stitches <NUM> remain on upper <NUM> in a completed article of footwear <NUM>. In some embodiments, boundary component <NUM> may include a lace or a string. The lace or string may support dispensing control during a dispensing process (e.g., by providing a landmark or guide for dispensing).

Upper <NUM> may be knit to include one or more control structures to facilitate dispensing control during a dispensing process. As shown in <FIG>, in some embodiments, upper <NUM> can include a rear control structure <NUM>. In some embodiments, rear control structure <NUM> is formed from the knitting process. For example, a knitting pattern can be changed at the location of rear control structure <NUM> to form rear control structure <NUM> (e.g., using different types of knitting stitches, using additional yarns, etc.). The change in knitting pattern may add texture to the upper <NUM> at the desired location, thus forming a boundary component, such as rear control structure <NUM>. Rear control structure <NUM> may thus comprise knit material <NUM> of upper <NUM> such that it is integrated into upper <NUM>. In some embodiments, various portions of upper <NUM> may be stitched together to form rear control structure <NUM>.

As shown in <FIG>, in some embodiments, rear control structure <NUM> is disposed on rearfoot region <NUM> of upper <NUM>. In some embodiments, rear control structure <NUM> facilitates dispensing control during a dispensing process (e.g., by providing a landmark or guide for dispensing). In some embodiments, rear control structure <NUM> is part of a completed article of footwear <NUM>.

As shown in <FIG>, in some embodiments, upper <NUM> can include a bottom control structure <NUM> as a boundary component. In some embodiments, bottom control structure <NUM> is formed from the knitting process. For example, a knitting pattern can be changed at the location of bottom control structure <NUM> to form bottom control structure <NUM> (e.g., using different types of knitting stitches, using additional yarns, etc.). The change in knitting pattern may add texture to the upper <NUM> at the desired location, thus forming a boundary component, such as bottom control structure <NUM>. Bottom control structure <NUM> may thus comprise knit material <NUM> of upper <NUM> such that it is integrated into upper <NUM>. In some embodiments, various portions of upper <NUM> may be stitched together to form bottom control structure <NUM>. As shown in <FIG>, in some embodiments, bottom control structure <NUM> is disposed around bottom surface <NUM> of upper <NUM>. For example, bottom control structure <NUM> may extend entirely around upper <NUM>, or it may be disposed in only certain portions of upper <NUM> (e.g., on a medial side, lateral side, or both). In some embodiments, bottom control structure <NUM> facilitates dispensing control during a dispensing process (e.g., by providing a landmark or guide for dispensing). In some embodiments, bottom control structure <NUM> is part of a completed article of footwear <NUM>.

As noted above, any of the foregoing boundary components may be used to form a top line of dispensed components (e.g., top line <NUM>). The techniques may be used to form a top line for a spiral dispensed component <NUM>, as well as any other shape of dispensed component, such as a component that is dispensed on an upper simply to form a base layer of dispensed material, similar to top line <NUM>. Thus, the boundary components, like the top line, may take a variety of shapes, including a boundary component that extends mostly linearly along a medial and/or lateral side of the article of footwear or a boundary component that includes more curves (e.g., peaks and valleys) as it extends along a medial and/or lateral side of the article of footwear.

It is to be understood that the phraseology or terminology herein is for the purpose of description and not of limitation, such that the terminology or phraseology of the present specification is to be interpreted by the skilled artisan in light of the teachings and guidance.

Claim 1:
An article of footwear comprising:
an upper (<NUM>); and
a sole (<NUM>) coupled to the upper (<NUM>) and comprising dispensed components having a non- hollow spiral geometry, each spiral dispensed component extending vertically with layers (<NUM>) of the spiral geometry stacked on top of each other,
wherein the spiral dispensed components are disposed adjacent to each other along a longitudinal direction of the sole (<NUM>).