Patent Description:
Conventional articles of footwear normally include both an upper and sole structure. The upper generally forms an interior void that securely and comfortably receives a foot. The sole structure may be secured to the upper and is generally positioned between the foot and the ground. This sole structure may attenuate ground reaction forces, provide traction, as well as limit potentially harmful foot motion. Accordingly, the upper and sole structure operate together to provide a comfortable structure that is well suited for use in a wide variety of activities.

The sole structure generally comprises an outsole, and optionally, one or more of an insole or midsole. The outsole forms the element of the sole structure that makes contact with the ground and is usually fashioned from a durable and wear-resistant elastomeric material that may include a tread pattern to impart traction. When present, the insole represents a thin, compressible member that is typically located within the void of the upper and adjacent to the foot in order to enhance comfort. In addition, a midsole may optionally be included as a middle layer in the sole structure located between the outsole and the upper or the insole, when present. The purpose of a midsole is to assist in the attenuation of ground reaction forces. <CIT> discloses a method for the manufacture of sporting goods, in particular a shoe, wherein the shoe has a first component with a first connection surface and a second component with a second connection surface. The method includes activating at least one portion of the first connection surface by providing heat energy without contact, and connecting the first component with the second component by joining the first connection surface and the second connection surface.

<CIT> discloses a shaped footwear device intended to be used as a supportive insole or orthotic and a system and methods for making the same, in particular by use of UV radiation and UV curable materials.

Despite the various models and characteristics available with conventional footwear, new footwear models and constructions are continually desired to provide further development and advancement in the art.

The invention relates to a method of manufacturing an article of footwear as specified in claim <NUM> and to an article of footwear as specified in claim <NUM>. Additional embodiments are specified in the dependent claims. The present disclosure generally provides a method of forming an article of apparel or sporting equipment, such as garments and footwear that incorporates a component formed of an ultraviolet radiation (UV) curable material. The present disclosure also describes articles comprising a textile, and a shaped portion of a UV radiation cured material directly bonded to a surface of the textile. UV radiation curable materials can be used to form a durable portion of an article of apparel or sporting equipment, such as a portion of an interior or exterior surface of the article. For example, shaped portions of UV radiation curable elastomers can be adhered to and cured in contact with a textile without exposing the textile to the high temperatures and pressures which would be required to adhere conventional rubber to a textile in a vulcanization process.

The method of manufacturing such articles includes placing UV curable material in contact with a surface of a textile; using heat or pressure or both, to conform the UV radiation curable material to the contour or shape of the textile, adhering the UV radiation curable material to the surface of the textile; and exposing at least a portion of the UV radiation curable material to ultraviolet (UV) radiation. In the case of an article of footwear, the UV radiation curable material may be formed into an outsole and the textile may take the form of an upper. Alternatively or additionally, the UV radiation curable material may be applied as a layer covering all or a portion of an upper for an article of footwear. In one example, the upper may include an elastomeric element that at least partially encloses an interior void that is configured to receive a foot, , including but not limited to a bootie-like or sock-like upper. The UV radiation curable material may be exposed to the UV radiation in an amount and for a duration that is sufficient to partially cure or fully cure the UV radiation curable material. The use of these methods allows the manufacture of durable articles without the need for expensive tooling. The use of these methods also allows the direct bonding of materials to textiles without the need to expose the textiles to elevated temperatures for significant durations of time, as is required in vulcanization processes. Furthermore, the articles disclosed herein include regions in which the UV radiation curable material is bonded directly to a textile, without the need for adhesives or primer, thus eliminating the need for adhesives which may include toxic solvents.

The following description is merely exemplary in nature and is in no way intended to limit the present disclosure or its application or uses. For example, the molded article or a component thereof comprising an ultraviolet (UV) curable material made and used according to the teachings contained herein is described throughout the present disclosure in conjunction with footwear in order to more fully illustrate the composition and the use thereof. The incorporation and use of such a molded UV radiation curable article or component thereof in other applications, including apparel such as garments, sporting equipment, or the like, as well as components thereof, are contemplated to be within the scope of the present disclosure. It should be understood that throughout the description, corresponding reference numerals indicate like or corresponding parts and features.

The present disclosure generally provides a method of forming an article that includes or incorporates a UV radiation curable material. Referring to <FIG>, this method <NUM> comprises shaping one or more pieces of the UV radiation curable material <NUM>. The shaped UV radiation curable material may be placed in direct contact <NUM> with a surface or side of a textile. The shaped UV radiation curable material is adhered to the surface of the textile using heat, pressure, or a combination thereof <NUM>. After the shaped UV radiation curable material adheres <NUM> to the surface of the textile, at least a portion of the shaped UV radiation curable material that is adhered to the textile is cured by exposing the shaped UV radiation curable material to ultraviolet (UV) radiation, thereby forming an article that comprises UV radiation cured material bonded to the surface of the textile <NUM>. Following the curing, in some examples, a bond strength of the UV radiation cured material bonded to the textile is at least <NUM>% greater than a bond strength of the shaped UV radiation curable material adhered to the textile prior to the curing. Alternatively, the bond strength after curing is at least <NUM>% greater than before curing; or is at least <NUM>% greater than before curing.

An interface between the UV radiation curable material and the surface of the textile is created upon the adherence of one to the other. The interface between the adhered UV radiation curable material and the surface of the textile may be substantially free of additional materials. For example, the interface between the UV radiation curable material and the surface of the textile may be substantially free of adhesive materials, or primers, or both.

Referring now to <FIG>, the step of shaping the one or more pieces of the UV radiation curable material comprises providing an ultraviolet (UV) radiation curable material in the form of one or more flat pieces <NUM> and shaping the UV radiation curable material. For example, the shaping can include shaping the UV radiation curable material such that it resembles a pattern piece <NUM>. This pattern piece may have a predetermined shape.

The determination of at least one pattern piece having a predetermined shape <NUM> may be accomplished using a printed pattern piece that can be placed onto the flat piece of the UV radiation curable material to provide an outline of the pattern piece to which the UV radiation curable material will be shaped. The pattern piece may also be generated <NUM> using a computer program that can communicate with a mechanical device, including without limitation, a laser cutter, capable of cutting or trimming the flat piece of UV radiation curable material to the shape of the pattern piece.

Still referring to <FIG>, when desirable a texture may be applied <NUM> to a surface of the one or more pieces of UV radiation curable material, to the shaped UV radiation curable material, to the adhered UV radiation curable material, or any combination thereof prior the curing step. This texture may be applied on the side of the UV radiation curable material (e.g., inner surface) that directly contacts the textile in order to enhance adhesion therewith. This texture may also be applied on the side of the UV radiation curable material that does not make contact with the textile (e.g., outer surface) in order to provide a decorative design, a visual effect or enhance physical properties, such as, without limitation, the coefficient of friction, abrasion resistance, or the like. The outer surface of the UV radiation cured material may constitute at least a portion of an exterior surface of the article. The texture may be applied to the surface of the UV radiation curable material either before or after the material is adhered to the textile. Alternatively, the texture is applied after the UV radiation curable material is adhered to the textile. The texture may be applied to the surface of the UV radiation curable material prior to the UV radiation curable material being exposed to the ultraviolet (UV) radiation.

The process of applying the texture <NUM> to the surface of the UV radiation curable material may comprise providing a textured element having a texture located on at least one surface thereof and placing the textured surface of the textured element in contact with the surface of the UV radiation curable material. Alternatively, the textured element is placed in contact with the outer surface of the UV radiation curable material. The shape of the texture may be pulled or drawn into the surface of the UV radiation curable material. When desirable, additional force may be applied to push the shape of the texture into the UV radiation curable material. The textured element may be removed from the UV radiation curable material prior to curing or after at least partial curing of the UV radiation curable material.

The textured element may include, without limitation, an elastomeric element, such as a sheet, a release paper, the surface of a mold, or a bootie that fits over the combination of the textile and the shaped UV radiation curable material. Thus according to one aspect of the present disclosure, a textured elastomeric element may be placed over at least a portion of the UV radiation curable material and the textile. The textured elastomeric element may be removed after the UV radiation curable material adheres to the textile, or after at least partially curing the UV radiation curable material.

Any noticeable defects in the shaped or contoured UV radiation curable material may be repaired <NUM>. These repairs may include, but not be limited to, holes, scratches, blemishes, inclusions, cloudiness, blisters, and the like. The step of repairing any defects <NUM> in the shaped UV radiation curable material may include identifying one or more defects; forming a patch made of the UV radiation curable material; and applying the patch to the defect. Optionally, the defect may be removed by cutting or trimming around the defect prior to the application of the patch.

Referring now to <FIG>, the UV radiation curable material be obtained as flat pieces or sheets through a commercial source or formed into such pieces prior to use. The shaping <NUM> of the UV radiation curable material may include providing a predetermined amount of UV radiation curable material <NUM> and either extruding, molding, or pressing the material into the one or more flat pieces <NUM> using heat, pressure, or a combination thereof. The UV radiation curable material may be extruded, molded, or pressed into flat pieces having a thickness that is between about <NUM> millimeters (mm) and about <NUM>; alternatively, between about <NUM> to about <NUM>.

When more than one flat piece of UV radiation curable material is present, the pieces may have the same or different thicknesses and/or surface areas. For example, when two flat pieces of the UV radiation curable material is provided the thickness of the first flat piece may be greater than the thickness of the second flat piece. For example, if the thickness of the first flat piece is about <NUM>, the thickness of the second flat piece may be at least <NUM>; alternatively, at least <NUM>; alternatively, at least <NUM>; alternatively, about <NUM>.

The surface area of the second flat piece may also be greater than the surface area of the first flat piece. In general, each flat piece will have at least a first and second surface representing the flat surfaces located opposite one another, e.g., top and bottom surface, on the UV radiation curable material. In this case, the surface area of the second flat piece may be at least <NUM>% greater than the surface of the first flat piece; alternatively, at least <NUM>% greater; alternatively, at least <NUM>% greater; alternatively, at least <NUM>% greater.

The first surface of the first flat piece may be placed in direct contact with the surface of the textile with the second flat piece being placed on top of the first flat piece. The first surface of the second flat piece may be placed in direct contact with the second surface of the first flat piece, the second surface of the first flat piece being opposite the first surface of the first flat piece. The second surface of the second flat piece forms at least a portion of an outer surface of the article, so that the second surface of the second flat piece is opposite the first surface of the second flat piece.

Referring once again to <FIG>, when more than one flat piece of UV radiation curable material is present, the shape of the flat pieces may be the same or different. According to one aspect of the present disclosure, the step of determining the pattern <NUM> may comprise creating a first pattern and a second pattern, wherein the first pattern is different from the second pattern. The first flat piece of UV radiation curable material may be shaped <NUM> to resemble the first pattern, while the second flat piece of UV radiation curable material may be shaped to resemble the second pattern.

According to another aspect of the present disclosure, the first flat piece of UV radiation curable material may be placed in contact with the textile forming a first layer. The second flat piece of UV radiation curable material may be placed such that a portion of the second flat piece covers at least part of the first layer, thereby, forming a second layer. At least part of the second layer makes direct contact with the textile. One or more edges of the first layer may be blended together with the second layer, such that a smooth transition exists between the first and second layers.

Referring again to <FIG>, the step of adhering <NUM> the shaped UV radiation curable material to the textile may comprise increasing a temperature of at least a portion of the shaped UV radiation curable material while the shaped UV radiation curable material is in contact with the textile. The amount of heat applied to the UV radiation curable material is generally maintained between about ambient or room temperature and less than <NUM>. Alternatively, the temperature may range between about <NUM> and about <NUM>. The UV radiation curable material softens within this predetermined temperature range, such that the UV radiation curable material can be contoured or shaped as desired to conform to the shape of the molding surface. The temperature of the UV radiation curable material is generally reduced to a point wherein the material is no longer softened prior to the exposing the UV radiation curable material to ultraviolet (UV) radiation.

This step <NUM> of adhering the shaped UV radiation curable material to the textile may also comprise subjecting at least a portion of the shaped UV radiation curable material to increased pressure and/or vacuum while the shaped UV radiation curable material is in contact with the textile. The pressure that is applied to the UV radiation curable material is generally between about <NUM> kgf/cm<NUM> (~<NUM> psi) to about <NUM> kgf/cm<NUM> (~<NUM>,<NUM> psi). Alternatively, the amount of pressure applied ranges from about <NUM> kfg/cm<NUM> (~<NUM> psi) to about <NUM> kfg/cm<NUM> (~<NUM> psi); alternatively, between about <NUM> kfg/cm<NUM> (~<NUM> psi) to about <NUM> kfg/cm<NUM> (~<NUM> psi); and alternatively, between about <NUM> kfg/cm<NUM> (~<NUM> psi) to about <NUM> kfg/cm<NUM> (~<NUM>,<NUM> psi).

For the purpose of this disclosure the terms "about" and "substantially" are used herein with respect to measurable values and ranges due to expected variations known to those skilled in the art (e.g., limitations and variability in measurements).

For the purpose of this disclosure any range in parameters that is stated herein as being "between [a <NUM>st number] and [a <NUM>nd number]" or "between [a <NUM>st number] to [a <NUM>nd number]" is intended to be inclusive of the recited numbers. In other words the ranges are meant to be interpreted similarly as to a range that is specified as being "from [a <NUM>st number] to [a <NUM>nd number]".

Referring now to <FIG>, when desirable, various precautions or safeguards may be undertaken by one skilled in the art in order to protect <NUM> at least a portion of the UV radiation curable material from being exposed to UV radiation during one or more steps of the method. Such precautions or safeguards may include, but not be limited to, masking a portion of the UV radiation curable material or the surface upon which the material is in contact, as well as maintaining the UV radiation curable material in an environment that is absent any UV/visible light.

The surface against which the UV radiation curable material is placed when forming the flat pieces or sheet may be a single substantially planar surface or incorporated as part of a press, a compression mold, a mold used in an injection molding process, or a part used in any other known forming process, such as cast molding, thermoforming or vacuum forming, to name a few. The surface against which the UV radiation curable material is placed may be entirely or at least partially smooth or textured. The texturing of the surface may be done in a manner that provides the surface of the flat pieces or sheet with a greater degree of roughness or the formation of irregularities that will enhance the ability to bond a surface of another material or component thereto. This bonding or adherence may be accomplished with or without the use of an adhesive or cement. The texturing of the surface may also be done in order to impart a visible design or pattern to the surface of the sheet or flat pieces.

Referring once again to <FIG>, when applying the texture <NUM> to the surface of the one or more pieces of UV radiation curable material, to the shaped UV radiation curable material, to the adhered UV radiation curable material, or any combination thereof may comprise providing a texture element having a textured surface; placing the textured surface of the textured element in contact with the surface of the one or more pieces of UV radiation curable material, shaped UV radiation curable material, adhered UV radiation curable material; and pulling the shape of the texture into the surface of the one or more pieces. Optionally, a force may further be applied in order to push the shape of the texture into the surface of the one or more pieces. Alternatively, applying the texture to the surface of the adhered UV radiation curable material occurs after the adhering step <NUM>.

Referring now to <FIG>, theUV radiation curable material may also be subjected to cutting or trimming in order to shape the UV radiation curable material 87A, such that it resembles the desired pattern. In addition, any excess material or unnecessary material may further be cut or trimmed after the shaped material is placed in contact with the surface of the textile 87B. Additional UV material may also be trimmed or cut from the article as part of a finishing operation 87C. In this case, the cutting or trimming of the article may be performed after exposure to the UV radiation. Other finishing operations, which include but are not limited to, polishing embossing, steaming/ironing, brushing, or decorative stitching, to name a few can also be performed on the article without exceeding the scope of the present disclosure.

Still referring to <FIG>, after the UV radiation curable material is placed in direct contact with a surface of a textile and adhered thereto <NUM>, the shaped UV radiation curable material, textile and/or an adhered combination thereof may be contoured <NUM> to a predetermined shape. This contouring step <NUM> is generally done prior to curing <NUM>. This contouring step <NUM> may include, without limitation, at least one of pulling ends of the shaped UV radiation curable material or the adhered UV radiation curable material together, pinching ends of the shaped UV radiation curable material together; press seaming ends of the shaped UV radiation curable material or the adhered UV radiation curable material together; press seaming ends of the shaped UV radiation curable material or the adhered UV radiation curable material; and trimming away any excess shaped UV radiation curable material or the adhered UV radiation curable material, and combinations thereof. When desirable, this contouring step <NUM> may also comprise placing a first combination of the shaped UV radiation curable material and the textile on a contoured mechanical form or placing a second combination of the adhered UV radiation curable material the textile on a contoured mechanical form, and curing by exposing the at least a portion of the UV radiation curable material to the ultraviolet radiation while the first or second combination is on the contoured mechanical form. The mechanical form may be, without limitation, a shoe last.

The step of adhering <NUM> the UV radiation curable material to the textile may include, but not be limited to heating the UV radiation curable material while the UV radiation curable material is in contact with the textile and, optionally, increasing pressure or subjecting the UV radiation curable material to a vacuum <NUM>. The use of a vacuum, either a partial vacuum or a full, i.e., perfect, vacuum may pull the UV radiation curable into closer or more intimate contact with the surface of the textile.

Once the UV radiation curable material adheres <NUM> to the surface of the textile, at least a portion of the UV radiation curable material may be cured by exposure to ultraviolet (UV) radiation <NUM>, in an amount and for duration in time that is sufficient to at least partially cure the exposed portion of the UV radiation curable material. Alternatively, upon exposure to the UV radiation, the exposed portion of the UV radiation curable material may be fully or substantially cured. Alternatively, substantially all of the UV radiation curable material is exposed to the UV radiation and is at least partially cured; alternatively, fully cured.

For the purpose of this disclosure, the term "partially cured" is intended to denote the occurrence of at least about <NUM>%, alternatively, at least about <NUM>% of the total polymerization required to achieve a substantially full cure. The term "fully cured" is intended to mean a substantially full cure in which the degree of curing is such that the physical properties of the UV radiation curable material do not noticeably change upon further exposure to additional UV radiation.

The UV radiation curable material generally comprises one or more photopolymers or light-activated resins that will undergo a cross-linking reaction upon exposure to ultraviolet (UV) radiation. The UV radiation curable material may comprise a mixture of various multifunctional monomers, oligomers, and/or low molecular weight polymers or copolymers, along with one or more photoinitiator(s) that can undergo polymerization in the presence of UV radiation. Upon exposure to UV radiation, the photoinitiator decomposes into a reactive species that activates polymerization of specific functional groups that are present in the multifunctional oligomers, monomers, or polymers.

As used herein, the term "polymer" refers to a molecule having polymerized units of one or more species of monomer. The term "polymer" is understood to include both homopolymers and copolymers. The term "copolymer" refers to a polymer having polymerized units of two or more species of monomers, and is understood to include terpolymers. As used herein, reference to "a" polymer or other chemical compound refers one or more molecules of the polymer or chemical compound, rather than being limited to a single molecule of the polymer or chemical compound. Furthermore, the one or more molecules may or may not be identical, so long as they fall under the category of the chemical compound. Thus, for example, "a" polyurethane is interpreted to include one or more polymer molecules of the polyurethane, where the polymer molecules may or may not be identical (e.g., different molecular weights).

The end result of curing a light-activated resin in this manner is the formation of a thermoset or cross-linked polymer network. Thus the UV radiation curable material may be described as being an UV radiation curable elastomer. Alternatively, the UV radiation curable material may comprise an UV radiation curable rubber. The UV radiation curable material may comprise one or more thermoset polymers, thermoplastic polymers, or combinations thereof. When desirable, the one or more thermoplastic polymers may be one or more thermoplastic polyurethanes (TPU).

Several specific examples of various monomers that may be used in the UV radiation curable material include, but are not limited to, styrene and styrenic compounds, vinyl ethers, N-vinyl carbazoles, lactones, lactams, cyclic ethers, cyclic acetals, and cyclic siloxanes. Several specific examples of oligomers and low molecular weight polymers or copolymers that may be incorporated into the UV radiation curable material include, without limitation, epoxides, urethanes, polyethers, or polyesters, each of which provide specific properties to the resulting material. Each of these oligomers or polymers may be functionalized using an acrylate. Alternatively, the UV radiation curable material may include a mixture of urethane and acrylate oligomers or a copolymer thereof.

Photoinitiation may occur via a free radical mechanism, an ionic mechanism, or a combination thereof. Under an ionic mechanism, the polymerizable oligomers, monomers, or polymers are doped with either anionic or cationic photoinitiators. Several examples of such photoinitiators, include without limitation, onium salts, organometallic compounds, and pyridinium salts. In the free radical mechanism, the photoinitiators generate free-radicals by the abstraction of a hydrogen atom from a donor or co-initiator compound (i.e., a <NUM>-component system), or by the cleavage of a molecule (i.e., a <NUM>-component system). Several specific examples of abstraction type photoinitiators, include but are not limited to, benzophenone, xanthones, and quinones with common donor compounds being aliphatic amines. Several specific examples of cleavage-type photoinitiators include, without limitation, benzoin ethers, acetophenones, benzoyl oximes, and acylphosphines. Photocurable materials that form through the free-radical mechanism undergo chain-growth polymerization, which includes three basic steps: initiation, chain propagation, and chain termination. Alternatively, the photoinitiators are independently selected and may include phosphine oxides, benzophenones, a-hydroxy-alkyl aryl ketones, thioxanthones, anthraquinones, acetophenones, benzoins and benzoin ethers, ketals, imidazoles, phenylglyoxylic acids, peroxides, and sulfur-containing compounds.

The amount of photoinitiators present in the UV radiation curable material is determined by the effective amount necessary to induce crosslinking of the UV radiation curable material. This amount may range from about <NUM> weight percent (wt. %) to about <NUM> wt. %, alternatively, from about <NUM> wt. % to about <NUM> wt. %, and alternatively, from about <NUM> wt. % to about <NUM> wt. % based on the weight of the UV radiation curable material. A single type of photoinitiator or a mixture of different photoinitiators may be used.

For the purpose of this disclosure, the term "weight" refers to a mass value, such as having the units of grams, kilograms, and the like. Further, the recitations of numerical ranges by endpoints include the endpoints and all numbers within that numerical range. For example, a concentration ranging from <NUM>% by weight to <NUM>% by weight includes concentrations of <NUM>% by weight, <NUM>% by weight, and all concentrations there between (e.g., <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, etc.).

According to one aspect of the present disclosure, the UV radiation curable material may comprise, consist of, or consist essentially of a millable polyurethane gum that includes ethylenic unsaturation, one or more photoinitiators, and at least one additional crosslinking additive that comprise two or more ethylenically unsaturated groups. The millable polyurethanes may be prepared by the reaction of a di- or polyisocyanate with bis(hydroxyl)-functional compounds, at least one of which contains ethylenic unsaturation. Alternatively, unsaturated polyester polyols may be used, alone or in combination with other isocyanate-reactive components, such as polyoxyalkylene glycols and/or diols capable of providing pendent ethylenic unsaturation. A commercial example of such a UV radiation curable material is Millathane® UV (TSE Industries Inc. , Clearwater, FL). Further description of such a UV radiation curable material is provided in <CIT>, the entire content of which is hereby incorporated by reference.

For the purpose of this disclosure, the terms "at least one" and "one or more of' an element are used interchangeably and may have the same meaning. These terms, which refer to the inclusion of a single element or a plurality of the elements, may also be represented by the suffix "(s)"at the end of the element. For example, "at least one polyurethane", "one or more polyurethanes", and "polyurethane(s)" may be used interchangeably and are intended to have the same meaning.

The additional crosslinking additive present in the curable polyurethane composition may include any low molecular weight compounds that contain two or more ethylenically unsaturated groups. These unsaturated groups may include, without limitation, glycerol diallyl ether, <NUM>,<NUM>-hexanediol di(meth)acrylate, triallylisocyanurate, trimethylolpropane di(meth)acrylate, trimethylolpropane tri(meth)acrylate, glycerol di(meth)acrylate, glycerol tri(meth)acrylate, propoxylated glycerol triacrylate, <NUM>,<NUM>-divinyltetramethyldisiloxane, divinylbenzene, and the like. The molecular weight of this additional crosslinking additive may be less than about <NUM> Da, alternatively less than about <NUM> Da, alternatively less than about <NUM> Da. The concentration of the crosslinking additive in the UV radiation curable material is selected based upon the amount of ethylenic unsaturated groups that are desired. The concentration of this additive may range from about <NUM> wt. % to about <NUM> wt. %, alternatively, from about <NUM> wt. % to about <NUM> wt. %, and alternatively, from about <NUM> wt. % to about <NUM> wt. % based on the overall weight of the UV radiation curable material.

When desirable, the UV radiation curable material may optionally comprise one or more additional processing aids, including without limitation, plasticizers, mold release agents, lubricants, antioxidants, flame retardants, dyes, pigments, reinforcing and non-reinforcing fillers, fiber reinforcements, and light stabilizers or UV absorbers. When an UV absorber is incorporated into the UV radiation curable material in order to enhance the environmental stability thereof, it may be necessary or desirable to use a more powerful UV light source to achieve full cure of the material, or use an UV light source having an output wavelength that is in a range within the UV spectrum at which the UV absorber exhibits a reduced level of absorbance.

The reinforcing fillers that may optionally be incorporated into the UV radiation curable material may be organic, i.e. polymeric, or inorganic in nature. These fillers may exhibit a mean, weight average particle sizes that is ≤ <NUM>, alternatively, in the range between about <NUM> nanometers (nm) to about <NUM>. Several specific examples of reinforcing fillers include, but are not limited to, pyrogenic (i.e., fumed) metal oxides, such as alumina, titania, ceria, silica, and the like; colloidal metal oxides, such as colloidal alumina or silica; carbon black and acetylene black; metal hydroxides, such as aluminum hydroxide; glass or polymer microspheres; or limestone, talc, clay, and the like. The amount of filler present in the UV radiation curable material is selected based upon the requirements associated with a particular end use. Typically, the amount of reinforcing filler present in the UV radiation curable material ranges from <NUM> wt. % to about <NUM> wt. % based on the total weight of the UV radiation curable material. Fillers having the same chemical composition may be considered to be non-reinforcing fillers when their mean, weight average particle size is greater than <NUM>, alternatively, in the range of about <NUM> to about <NUM>.

The UV radiation curable material may be cured by irradiation with UV light transmitting a wavelength that is the same as the excitation wavelength exhibited by the photoinitiator present. The UV light may be produced from any known source, including without limitation, low, medium, or high pressure mercury vapor lamps, xenon lamps, quartz halogen lamps, or lasers operating in the short wavelength portion of the spectra, e.g., in the range of about <NUM> to about <NUM>. Several more specific examples of UV light sources include, but are not limited to, short-wave UV lamps, gas-discharge lamps, ultraviolet LEDs, UV lasers, tunable vacuum ultraviolet (VUV) obtained from sum and difference frequency mixing, or plasma and synchrotron sources of extreme UV radiation.

The duration in time that the UV radiation curable material is irradiated with UV radiation is variable and based upon the nature and type of reactive oligomers, monomers, or polymers present in the UV radiation curable material, as well as type and concentration of the crosslinking additives, photoinitiators, and fillers, as well as the type and power associated with the available UV light source. The duration of UV exposure may range less than a second to several hours; alternatively, the exposure time is between about <NUM> second and about <NUM> hour; alternatively, between about <NUM> seconds and <NUM> minutes. The UV radiation curable material may be irradiated at ambient or room temperature within the confines of a molding operation or at a temperature associated with the component formed in a molding or extrusion process. When desirable the molded part may be subjected to a cooling step prior to irradiation with UV light. Although, no thermal cure is necessary, a dual cure system may be used when desirable.

According to another aspect of the present disclosure, the article may be, without limitation, apparel, sporting equipment, or footwear. Alternatively, the article is component of apparel, sporting equipment, or footwear. The article of apparel or component of apparel may be a garment or a component of a garment. The component of the article of footwear may be an outsole, for example. As used herein, the terms "article of footwear" and "footwear" are intended to be used interchangeably to refer to the same article. Typically, the term "article of footwear" will be used in a first instance, and the term "footwear" may be subsequently used to refer to the same article for ease of readability.

An article of footwear or shoe may be designed for a variety of uses, such as sporting, athletic, military, work-related, recreational, or casual use. The article of footwear may be used outdoors on paved or unpaved surfaces (in part or in whole), such as on a ground surface including one or more of grass, turf, gravel, sand, dirt, clay, mud, and the like, intended for the performance of an athletic competition or as a general outdoor surface. The article of footwear may also be desirably used with indoor activities, such as indoor sports, shopping, and everyday work.

Referring now to <FIG>, an article <NUM> is shown that comprises, consists of, or consists essentially of textile <NUM> and a shaped portion of an ultraviolet (UV) radiation cured material <NUM> having a predetermined shape. The interface <NUM> located between the bonded UV radiation cured material <NUM> and the surface of the textile <NUM> may be substantially free of additional materials, including without limitation adhesive materials or primer materials.

As shown in <FIG>, when the article <NUM> is an article of footwear <NUM> or a shoe <NUM>, the textile is an upper <NUM> for the article of footwear, a strobel for the article of footwear, or a combination of both the upper <NUM> and the strobel for the article of footwear. The UV radiation cured material <NUM> may be an outsole <NUM> or a component of the outsole or sole structure that is in contact with and attached or directly bonded <NUM> to the upper <NUM>. At least part of the outsole <NUM> or sole structure of the article of footwear comprises the UV radiation curable material as described above and further defined herein in an uncured or partially cured state until cured by exposure to UV radiation resulting in a UV radiation cured material directly bonded to the upper <NUM>.

Still referring to <FIG>, the outsole <NUM> refers to the very bottom of the shoe that is in direct contact with the ground. The outsole <NUM> may be relatively smooth or include one or more traction elements <NUM>. These traction elements <NUM> may provide enhanced traction, as well as provide support or flexibility to the outsole and/or provide an aesthetic design or look to the shoe. The traction elements <NUM> may include, but are not limited to a tread pattern, as well cleats, studs, spikes, or similar elements configured to enhance traction for a wearer during cutting, turning, stopping, accelerating, and backward movement.

Since the outsole <NUM> is the outer most sole of the shoe, it is directly exposed to abrasion and wear. Various portions of the outsole <NUM> may be constructed with different thickness and exhibit different degrees of flexibility. The materials that comprise the outsole <NUM> should provide some degree of waterproofing, durability, and possess a coefficient of friction that is high enough to prevent slipping. In some cases two or more materials of different densities can be incorporated into the outsole <NUM> to give a hard wearing outer surface and a softer, more flexible midsole <NUM> for greater comfort. The outsole <NUM> may be a single layer or may contain multiple layers of the same or similar material, provided at least a portion of the outsole <NUM> comprises an UV radiation curable material. Alternatively, substantially all of the outsole comprises an UV radiation curable material.

The outsole <NUM> may be directly or otherwise operably secured to the upper <NUM> using any suitable mechanism or method. As used herein, the terms "operably secured to", such as for an outsole that is operably secured to an upper, refers collectively to direct connections, indirect connections, integral formations, and combinations thereof. For instance, for an outsole that is operably secured to an upper, the outsole can be directly connected to the upper (e.g., adhered directly thereto or glued with a cement or an adhesive), can be integrally formed with the upper (e.g., as a unitary component), and combinations thereof.

Still referring to <FIG>, the upper <NUM> of the footwear <NUM> has a body which may be fabricated from materials known in the art for making articles of footwear, and is configured to receive a user's foot. The upper <NUM> of a shoe consists of all components of the shoe above the outsole <NUM>. The different components of the upper <NUM> may include a toe box, heal counter, and an Achilles notch, to name a few. These components are attached by stitches or more likely molded to become a single unit to which the outsole is attached.

The upper <NUM> or components of the upper <NUM> usually comprise a soft body made up of one or more lightweight materials. The materials used in the upper <NUM> provide stability, comfort, and a secure fit. For example, the upper may be made from or include one or more components made from one or more of natural or synthetic leather, a textile or both. The textile may include; a knit, braided, woven, or nonwoven textile made in whole or in part of a natural fiber; a knit, braided, woven or non-woven textile made in whole or in part of a synthetic polymer, a film of a synthetic polymer, etc.; and combinations thereof. The textile may include one or more natural or synthetic fibers or yarns. The synthetic yarns may comprise, consist of, or consist essentially of thermoplastic polyurethane (TPU), polyamide (e.g., Nylon®, etc.), polyester (e.g., polyethylene terephthalate or PET), polyolefin, or a mixture thereof.

The upper <NUM> and components of the upper <NUM> may be manufactured according to conventional techniques (e.g., molding, extrusion, thermoforming, stitching, knitting, etc.). While illustrated in <FIG> as a generic design, the upper <NUM> may alternatively have any desired aesthetic design, functional design, brand designators, or the like.

Still referring to <FIG>, the upper <NUM> may further comprise laces, flaps, straps, or other securing or foot engagement structures <NUM> used to securely hold the shoe <NUM> to a wearer's foot. A tongue member, bootie, or other similar type structure may be provided in or near the shoe instep area in order to increase comfort and/or to moderate the pressure or feel applied to the wearer's foot by any foot engagement structures <NUM>.

When desirable, at least a portion of the upper <NUM> of the article of footwear, and in some embodiments substantially the entirety of the upper, may be formed of a knitted component. Thus the textile may be a knit textile with a circular knit textile being one specific example thereof. The knitted component may additionally or alternatively form another element of the article of footwear <NUM> such as the insole, for example.

The knitted component may have a first side forming an inner surface of the upper <NUM> (e.g., facing the void of the article of footwear <NUM>) and a second side forming an outer surface of the upper <NUM>. An upper <NUM> including the knitted component may substantially surround the void so as to substantially encompass the foot of a person when the article of footwear is in use. The first side and the second side of the knitted component may exhibit different characteristics (e.g., the first side may provide abrasion resistance and comfort while the second side may be relatively rigid and provide water resistance). The knitted component may be formed as an integral one-piece element during a knitting process, such as a weft knitting process (e.g., with a flat knitting machine or circular knitting machine), a warp knitting process, or any other suitable knitting process. That is, the knitting process may substantially form the knit structure of the knitted component without the need for significant post-knitting processes or steps. Alternatively, two or more portions of the knitted component may be formed separately and then attached. In some embodiments, the knitted component may be shaped after the knitting process to form and retain the desired shape of the upper (for example, by using a foot-shaped last). The shaping process may include attaching the knitted component to another object (e.g., a strobel) and/or attaching one portion of the knitted component to another portion of the knitted component at a seam by sewing, by using an adhesive, or by another suitable attachment process.

Forming the upper <NUM> with the knitted component may provide the upper <NUM> with advantageous characteristics including, but not limited to, a particular degree of elasticity (for example, as expressed in terms of Young's modulus), breathability, bendability, strength, moisture absorption, weight, and abrasion resistance. These characteristics may be accomplished by selecting a particular single layer or multi-layer knit structure (e.g., a ribbed knit structure, a single jersey knit structure, or a double jersey knit structure), by varying the size and tension of the knit structure, by using one or more yarns formed of a particular material (e.g., a polyester material, a monofilament material, or an elastic material such as spandex), by selecting yarns of a particular size (e.g., denier), or a combination thereof. The knitted component may also provide desirable aesthetic characteristics by incorporating yarns having different colors or other visual properties arranged in a particular pattern. The yarns and/or the knit structure of the knitted component may be varied at different locations such that the knitted component has two or more portions with different properties (e.g., a portion forming the throat area of the upper may be relatively elastic while another portion may be relatively inelastic). In some embodiments, the knitted component may incorporate one or more materials with properties that change in response to a stimulus (e.g., temperature, moisture, electrical current, magnetic field, or light). For example, the knitted component may include yarns formed of a thermoplastic polymer material (e.g., polyurethanes, polyamides, polyolefins, and nylons) that transitions from a solid state to a softened or liquid state when subjected to certain temperatures at or above its melting point and then transitions back to the solid state when cooled. The thermoplastic polymer material may provide the ability to heat and then cool a portion of the knitted component to thereby form an area of bonded or continuous material that exhibits certain advantageous properties including a relatively high degree of rigidity, strength, and water resistance, for example.

In some embodiments, the knitted component may include one or more yarns or strands that are at least partially inlaid or otherwise inserted within the knit structure of the knitted component during or after the knitting process, herein referred to as "tensile strands. " The tensile strands may be substantially inelastic so as to have a substantially fixed length. The tensile strands may extend through a plurality of courses of the knitted component or through a passage within the knitted component and may limit the stretch of the knitted component in at least one direction. For example, the tensile strands may extend approximately from a biteline of the upper to a throat area of the upper to limit the stretch of the upper in the lateral direction. The tensile strands may form one or more lace apertures for receiving a lace and/or may extend around at least a portion of a lace aperture formed in the knit structure of the knitted component.

When desirable, the article of footwear <NUM> or shoe <NUM> may also include a platform upon which the foot will rest that separates the upper <NUM> from the foot of the person wearing the shoe. This platform is typically a separate removable board called an insole (not shown) that is made of cellulose or other materials, such as thermoplastic or thermoset elastomers, capable of providing a cushion between the ground and the foot of the person wearing the shoe <NUM>. The insole may be treated with additives to inhibit bacterial growth. When desirable, the insole may be incorporated with, e.g., sewn into, the upper.

Referring once again to <FIG>, the outsole <NUM> of the shoe <NUM> may be engaged with or attached to the upper <NUM> being directly adhered thereto. However, when desirable, a portion of the outsole may be attached to the upper <NUM> through the use of additional means conventionally known or used in the construction of footwear <NUM>, such as through the use of cements or adhesives, by mechanical connectors, and by sewing or stitching, to name a few.

Referring now to <FIG>, a method of forming an article of footwear is provided that comprises, consists of, or consists essentially of the various steps and components used within the process or method previously described above in <FIG>, as well as any additional information subsequently provided below. This method <NUM> generally comprises receiving an upper <NUM>, wherein the upper is formed of a textile that has a predetermined contour. Alternatively, the upper is a bootie or a sock. An ultraviolet radiation (UV) curable material is provided <NUM> in the form of one or more sheets. At least one pattern having a predetermined shape is created <NUM>. The sheet of UV radiation curable material is altered <NUM>, such that it resembles the shape of the pattern. The shaped UV radiation curable material is then placed <NUM> such that at least a portion of the UV radiation curable material is in direct contact with the textile of the upper. The shaped UV radiation curable material is then conformed <NUM> to the contour of the textile, thereby, forming the outsole for the article of footwear. The UV radiation curable material is adhered <NUM> to the textile and exposed <NUM> to ultraviolet radiation (UV).

The attachment of the upper to the outsole may comprise heating the outsole or midsole to a temperature from about <NUM> up to about <NUM> in order to soften the UV radiation curable material and/or exposing the outsole to ultraviolet (UV) radiation <NUM> in an amount and for a duration that is sufficient to at least partially cure the UV radiation curable material. Alternatively, the amount of and/or duration of UV exposure is sufficient to fully cure the UV radiation curable material. Typically, the UV radiation curable material is cooled below its softening temperature after or prior to being exposed to the ultraviolet (UV) radiation. In other words, the step of contouring and/or adhering the UV radiation curable material may be performed as the temperature of the UV radiation curable material is increased to a temperature at which the material softens, followed by decreasing the temperature of the UV radiation curable material below a softening point, with the decrease in the temperature occurring before or after the UV curing has been accomplished.

Still referring to <FIG>, the strength of the attachment between the various components within the shoe may further be enhanced by applying an adhesive, a primer, or a combination thereof to a surface of one or more of the outsole or the upper <NUM>. Another means of enhancing the adhesion between the various components within the shoe is to apply a texture to at least one surface of the outsole, such that the attachment of the outsole to the upper exhibits an increase in bond strength as compared to the same attachment made without the surface texture being present. The strength of the attachment of the outsole to the upper is such that the attachments exhibits a bond strength that is maintained after exposure to a force that is greater than or equal to <NUM> kgf/cm; alternatively, after exposure to a force of <NUM> kgf/cm or greater as measured according to the Bond Strength Testing Protocol described below.

A primer is a preparatory coating applied to the surface of a material (e.g., <NUM>st surface) prior to adhesion to another material (e.g., <NUM>nd surface) with or without an adhesive. A primer ensures better adhesion of the primed <NUM>st surface to a <NUM>nd surface, increases the durability of the bond between the <NUM>st and <NUM>nd surfaces, and provides additional protection for the material (<NUM>st surface) to which the primer was applied. The primer may include, without limitation, pre-polymer solutions or dispersions of epoxies, urethanes, acrylics, cyanoacrylates, silicones, and combinations thereof.

When present, the adhesive may include, but not be limited to epoxy adhesives, urethane adhesives, acrylic adhesives, cyanoacrylate adhesives, silicone adhesives, modified silane polymers, hot melt adhesives, contact glue (e.g., solvent-borne adhesive comprising natural or synthetic rubber resins with or without halogenation, such as polychloroprene, etc.) or combinations thereof. Alternatively, the adhesive is a thermoplastic polyurethane (TPU), a cyanoacrylate, an acrylic, a contact adhesive, a silicone a modified silane polymer, or a mixture thereof.

The UV radiation curable material incorporated as at least a portion of the component, such as an outsole, for example, may be an UV radiation curable elastomer as previously described above and further defined herein. Alternatively, the UV radiation curable material is an UV radiation curable polyurethane rubber. The UV radiation curable may further comprise a vulcanized rubber, such as a nitrile rubber or the like. The UV radiation curable material comprise a thermoset or a thermoplastic polymer, including but not limited to a polyurethane.

The following specific examples are provided to illustrate the individual steps in the process <NUM> of <FIG> used to form an article of footwear <NUM> shown in <FIG> according to one aspect of the present disclosure. Referring now to <FIG>, an UV radiation curable material is provided <NUM> in the form of one or more sheets <NUM>, either by obtaining the sheet(s) preformed from a commercial source (not shown) or by preparing the sheet(s) <NUM> through the use of a press <NUM>. In other words, As shown in <FIG>, a predetermined amount of UV radiation curable material <NUM> is provided (see <FIG>) and then pressed into a sheet <NUM> having a predetermined thickness using heat, pressure, or a combination thereof (see <FIG>).

Referring now to <FIG>, at least one upper formed of a textile having a contour is received <NUM> and at least one pattern having a predetermined shape is created <NUM>. The upper <NUM> may be placed on a shoe last <NUM> to provide the desired contour. A first pattern <NUM> (see <FIG>) and a second pattern <NUM> (see <FIG>) may be formed that conforms to the shape predetermined by the shoe last <NUM> and upper <NUM>. In this specific example, the patterns <NUM>, <NUM> may be formed and shaped through the use tape that may be cut or trimmed. The shape of the first pattern <NUM> may be the underfoot area of the outsole in order to provide a pattern representing the core traction zone (see <FIG>). The shape of the second pattern <NUM> may provide a region that covers the underfoot area as well as a portion that wraps around for the sides of the upper <NUM> (see <FIG>). The second pattern <NUM> is removed from the upper <NUM> and flattened for use in shaping the UV radiation curable material (see <FIG>). The shape of the first pattern <NUM> and the second pattern <NUM> may be different (see <FIG>).

Referring now to <FIG>, the sheet(s) of UV radiation curable material are altered <NUM> so that they resemble the shape of the pattern(s). In this example, a first sheet 400A of the UV radiation curable material is cut or trimmed to the shape of the first pattern <NUM> (see <FIG>). A second sheet 400B of the UV radiation curable material is cut or trimmed to the shape of the second pattern <NUM> (see <FIG>). The thickness of the first sheet 400A is selected such that it is larger than the thickness of the second sheet 400B. The thickness of the first sheet is generally selected such that it is between about <NUM> and about <NUM>, while the thickness of the second sheet is between about <NUM> and about <NUM>. In the specific example shown, the thickness of the first sheet was about <NUM> millimeters (mm), while the thickness of the second sheet was about <NUM>.

Referring now to <FIG>, at least a portion of the shaped sheets of UV radiation curable material are placed into direct contact with the textile <NUM>. In this specific example, the first shaped sheet 700A is placed onto the upper <NUM> positioned on the shoe last <NUM> having the desired contour. The first shaped sheet 770A has the shape associated with the underfoot area. The second shaped sheet 700B is stacked on top of the first shaped sheet 700A, such that this second sheet 700B also covers the underfoot area, but also occupies some of the area that wraps on the side of the upper <NUM>. The surface area of the shaped second sheet 700B is larger than the surface area of the shaped first sheet 700A. Thus this second shaped sheet 700B will make direct contact with the upper <NUM> around the sides. A transition line <NUM>, which represents the transition from the second shaped sheet 700B to where the first shaped sheet 700A and second shaped sheet 700B overlap, may be visible (see <FIG>).

Referring now to <FIG>, the shaped UV radiation curable material is conformed to the contour of the textile <NUM>. In this respect, various edges or darts <NUM> of the second shaped sheet of UV radiation curable material 700B may be pulled together (see <FIG>). The edges or darts <NUM> may also be pinched together (see <FIG>). When pinched together the darts <NUM> may begin to stick or adhere to one another. This adherence can further be enhanced by forming a press seam <NUM> between two darts (see <FIG>). Any excess UV radiation curable material may be trimmed or cut away at any place on the UV radiation curable material. Alternatively, the excess material is removed from the corners of the darts (see <FIG>). In areas of the sheet 700B having a large surface area, the application of heat may be used to soften the UV radiation curable material and to tack the material to the textile of the upper <NUM>. Optionally, the UV radiation curable material and the textile may be subjected to a vacuum in order to provide more intimate contact between the UV radiation curable material and the textile of the upper. The heat source may include, but not be limited to, an iron <NUM> or a heated air dryer, to name a few.

Referring once again to <FIG>, the may also include repairing <NUM> any defects that form in the shaped and/or contoured UV radiation curable material. As shown in <FIG>, these defects may include, without limitation, a hole <NUM>, a blemish, a scratch, an inclusion, or cloudiness in one of the shaped sheets 700B. The step of repairing <NUM> the defects may include identifying one or more defects <NUM> (see <FIG>), forming an appropriate patch <NUM> made from UV radiation curable material (see <FIG>); and applying the patch <NUM> to UV radiation curable sheet 700B to fix the defect <NUM> (see <FIG>). The article of footwear <NUM> may be placed onto a vacuum source <NUM> to further pull the UV radiation curable material sheet 700B into the textile of the upper <NUM> (see <FIG>). Any additional UV radiation curable material 700B may be trimmed or cut and inconsistencies corrected while the article <NUM> is on the vacuum source <NUM> (see <FIG>).

Referring now to <FIG>, the UV radiation curable material may be adhered to the textile of the upper <NUM>. The adherence between the UV radiation curable sheets 700A, 700B and the textile of the upper <NUM> may be enhanced through the use of a vacuum source <NUM> (see <FIG>). The application of heat using any known means, such as a hot air gun <NUM>, may soften the UV radiation curable material 700A, 700B and enhance contact with the textile of the upper <NUM> (see <FIG>). For the specific example, the visibility of the transition line <NUM> may be reduced or eliminated by blending the edge of the first sheet 700A with the second sheet 700B of UV radiation curable material (see <FIG>). This blending may be accomplished by any known means, including but not limited to the use of a rubber pad or a silicone pad <NUM>. When properly blended a smooth transition occurs between the first and second sheets of UV radiation curable material 700A, 700B (see <FIG>).

Referring once again to <FIG>, the method <NUM> may further comprise applying a texture to a surface of the UV radiation curable material <NUM>. Thus a pattern may be applied to at least one surface of the outsole. This texture may be applied to the surface of the UV radiation curable material after the UV radiation curable material is adhered to the textile <NUM> and prior to being exposed to UV radiation <NUM>. As shown in <FIG>, the texture <NUM> may be applied to the UV radiation curable material placing a tool <NUM>, such as an elastomeric or rubber sheet, upon which the pattern resides in contact with the UV radiation curable material contoured in the desired shape of the article <NUM> (see <FIG>). When desirable this pattern may be a tread pattern <NUM>. A vacuum source may be used to pull the shape of the texture of the elastomeric sheet <NUM> into UV radiation curable material (see <FIG>). When desirable this texture <NUM> may provide a pattern, such as a tread pattern. The shape of the texture of the elastomeric sheet <NUM> may also be pushed into the UV radiation curable material <NUM> through the application of an additional force (see <FIG>). The texture <NUM> is shown in <FIG> in the shape of a tread pattern to be located on the area of the UV radiation curable material that is under the foot and will make contact with the ground surface during use.

Referring once again to <FIG>, the UV radiation curable material is exposed to UV radiation <NUM>. The UV radiation curable material <NUM> adhered to the upper <NUM> is at least partially cured, thereby, resulting in the creation of the article of footwear <NUM> as shown in <FIG>. According to another aspect of the present disclosure, the method <NUM> may further comprise finishing an article of footwear by exposing <NUM> the outsole to UV radiation, such that the outsole is fully cured. Other finishing operations, as previously described above may also be performed upon the shoe without exceeding the scope of the present disclosure.

The following specific examples are given to illustrate the attachment between the UV radiation curable material and the textile of the Upper in the article of footwear, formed according to the teachings of the present disclosure, as well as the bond strength formed there between, and should not be construed to limit the scope of the disclosure. Those skilled-in-the-art, in light of the present disclosure, will appreciate that many changes can be made in the specific embodiments which are disclosed herein and still obtain alike or similar result without departing from or exceeding the spirit or scope of the disclosure. One skilled in the art will further understand that any properties reported herein represent properties that are routinely measured and can be obtained by multiple different methods. The methods described herein represent one such method and other methods may be utilized without exceeding the scope of the present disclosure.

A bonding test is performed with the purpose of evaluating the strength of the adhesion bond along an interface of the UV radiation cured material and another material. For example, the adhesion bond can be a bond between an outsole and an upper of an article of footwear. In this test a flat component (e.g., a textile) is placed in contact with an UV radiation curable material on a flat surface, and then a compressive force of at least <NUM> kgf/cm<NUM> is applied to the combination of the component and the UV radiation curable material, leaving an edge region of the component and an opposing edge region of the UV radiation curable material which are not in contact or compressed. Following the compression, the combination of the component and the UV radiation curable material is then exposed UV radiation in an amount and for a duration that is sufficient to fully cure the UV radiation curable material, forming a composite sheet including the edge regions. The composite sheet is then cut into strips to form test specimens, with each test specimen including a length of the edge regions for grasping in a test apparatus capable of measuring applied force, such as an Instron testing system. Each strip has a width of <NUM> (<NUM> inch). Intervals are marked along the length of the strips with each interval being spaced apart by <NUM>. Depending upon the length of the strips, between <NUM> and <NUM> intervals may bemarked on each strip. The edge of textile and the UV radiation curable material of a molded specimen are then grasped at an edge region by the testing apparatus. The tabs are then pulled with an increasing amount of force until the surfaces of the textile and the UV radiation curable material are separated over the length of at least one interval. The amount of force required to separate the surfaces of the textile and the UV radiation curable material is measured by the testing apparatus. In order for a specimen to be considered as passing the bonding test, a minimum force of <NUM> kgf/cm force is required to separate the bonded surfaces of the component and the UV radiation cured material.

UV radiation curable polyurethane rubber (Millathane® UV, TSE Industries Inc. , Clearwater, FL) was attached using a compression molding process to a knit textile formed of TPU coated yarn (Runs A & B) manufactured by Sambu Fine Chemicals, Korea and to a knit textile formed of uncoated PET yarn (Runs C & D) manufactured by Unifi, Inc. (Greensboro, NC, USA). The combinations of the UV radiation curable polyurethane rubber and knit textiles were then exposed to UV light, fully curing the UV radiation curable polyurethane rubber. Each of the four cured samples was prepared and tested twice (Tests <NUM> & <NUM>) according to the Bond Strength Testing Protocol described above. The measured test results are summarized in Table <NUM>.

This example demonstrates that the UV radiation curable polyurethane rubber can be attached to a textile with the bond strength necessary to be used as an outsole in an article of footwear. More specifically, Runs A-D maintained their bond after application of a <NUM> kgf/cm force in the Bond Strength Test, and more than a <NUM> kgf/cm force was necessary to break the bonds.

Claim 1:
A method (<NUM>; <NUM>) of forming an article of footwear, the method comprising:
providing (<NUM>; <NUM>; <NUM>) one or more sheets (<NUM>, 400A, 400B) of an ultraviolet (UV) radiation curable material;
shaping (<NUM>; <NUM>) the one or more sheets (<NUM>, 400A, 400B) of the UV radiation curable material such that it resembles a pre-determined shape (<NUM>);
placing (<NUM>; <NUM>) the shaped UV radiation curable material (700A; 700B) in direct contact with a surface of a textile, wherein the textile is an upper for the article of footwear, a strobel for the article of footwear, or a combination of both the upper and the strobel for the article of footwear;
using heat or pressure (<NUM>) or both, adhering (<NUM>; <NUM>) the shaped UV radiation curable material to the surface of the textile, wherein the UV radiation cured material bonded to the textile is an outsole of the article of footwear; and
curing (<NUM>) at least a portion of the shaped UV radiation curable material adhered to the surface of the textile by exposing (<NUM>) the shaped UV radiation curable material to ultraviolet radiation, thereby forming the article, which comprises UV radiation cured material bonded to the surface of the textile;
wherein the method further comprises, prior to the curing (<NUM>), contouring (<NUM>; <NUM>) the shaped UV radiation curable material (700A; 700B) or contouring the adhered UV radiation curable material, or both.