Patent Description:
Traditionally, an article of footwear is formed with an upper and a sole that are joined subsequent to the formation of each. This process includes the positioning and aligning of the separate components to then be bonded with various techniques, such as an adhesive. <CIT> describes a method for manufacturing a footwear comprising placing in a mold assembly a preformed section of appropriate material forming part of the footwear in such a manner that a part of said preformed section protrudes into a molding cavity for molding another section of said footwear, injecting molding material into said cavity and thereby integrally connecting said preformed section with the latter section. <CIT> describes a method of moulding a sole of a plastic material and a welt on a shoe upper, wherein a mould is used comprising a last, upon which a shoe upper is arranged, an upper moulding part divided along a longitudinal middle plane and including two halves being laterally movable in relation to the lower mould part between an open and a closed mould position.

The claimed invention is defined by the subject-matter of the independent claim <NUM>. Additional embodiments are defined by the dependent claims.

Aspects hereof contemplate an article of footwear having an upper that is directly attached with the sole. The sole has a film extending up sidewalls of the sole to a film edge that is prior to the sidewall and the upper joining. Method of manufacture of the article of footwear includes steps of positioning a film over a mold cavity and then securing the film to the mold. The film is heated and then drawn into the mold cavity under a vacuum. The film forms a liner of the mold cavity. A foam composition is injected into the lined mold cavity. As the foam composition expands, the foam composition interacts with and mechanically engages with the upper that is positioned at the mold cavity to allow for the mechanical engagement that results in the direct attach of the sole to the upper. The film is then trimmed from the sole sidewalls at the film edge.

This summary is provided to enlighten and not limit the scope of methods and systems provided hereafter in complete detail.

Examples useful for the understanding of the claimed invention are described in detail herein with reference to the attached drawing figures, wherein:.

Traditional methods of manufacturing an article of footwear include a variety of processes that are performed in sequence to result in the formation of the footwear (e.g., shoe, cleat, sandal, slipper, and boot). In an effort to reduce manufacturing time, manufacturing cost, and potential defects, an elimination or consolidation of steps being performed is sought. Traditional shoe manufacturing, such as an athletic shoe, includes the formation of a footwear upper ("upper"), the portion of the shoe that secures the shoe to a wearer's foot. The upper is then joined with a footwear bottom unit, which is commonly referred to as a sole. The sole may be comprised of a variety of materials and/or components, such as an outsole, a midsole, and/or an insole. However, any combination of materials/components may be formed and produced in connection with the manufacture of a shoe.

Traditional manufacturing techniques for a shoe include the joining of a formed upper with a formed sole. This joining may be accomplished through use of an adhesive applied to one or more surfaces to be joined of the upper and the sole and then positioning the upper and the sole in contact for the adhesive to couple the components into an article of footwear. This step of joining the upper and the sole introduces a manufacturing process that adds time, cost, and the potential for defects. For example, if the adhesive extends beyond an area to be joined (e.g., beyond a biteline of the upper), the adhesive may be visible and cause a degradation of the aesthetic characteristics of the shoe. Further, the sole and the upper may not be properly aligned during the joining causing a defective shoe. Additionally, the joining process introduces adhesives or other bonding materials into the footwear that can affect performance and feel of the finished article. Further yet, the adhesive or bonding material adds material cost and additional manufacturing inventory to the planning and production for the shoe.

As a result, a concept of direct bottoming (or sometimes referred to as direct attach) is provided. Direct bottoming, for purposes of the present disclosure, includes the formation of at least a portion (e.g., a foamed midsole) of the sole with the upper present and results in the sole being joined with the upper. For example, it is contemplated that a molding operation is performed where a polymeric foam composition (e.g., polyurethane "PU") is injected into a mold cavity wherein a plantar portion (e.g., under foot portion) of the upper is positioned at the mold cavity. As the polymeric foam composition expands during a foaming process, the polymeric composition interacts with the plantar region of the upper to form at least a mechanical engagement between the polymeric foam composition and the upper material. As the polymeric foam composition cures, the physical engagement between the polymeric foam composition and the upper forms a bond coupling the two together with sufficient bond strength for use as an article of footwear. A direct bottoming process allows for the reduction of materials and or steps during the method of manufacturing. For example, the direct bonding between the polymeric foam composition as it cures and the upper can eliminate the use of an adhesive, in some aspects. Further, as the sole is molded in the presence of the upper, alignment, size, and fit of the sole and upper are better ensured.

Direct bottoming of an article of footwear does, however, adjust processing steps for the forming of the footwear relative to a traditional manufacturing process. For example, as the sole is not formed until it is joined with the upper, refinements and processing of the sole is done in the presence of the upper. Tooling, such as a mold, used when forming the direct attached sole may create tooling marks in the sole. A tooling mark is an unintended feature that results from the manufacturing of the sole. Tooling marks may result from intersections of tooling portions (e.g., a medial ring intersecting with a lateral ring to result in a line or other feature at the junction of the tooling portions). The tooling marks may be addressed through buffing, cutting, polishing, and other operations to reduce or eliminate the presence of the tooling marks. However, in direct bottoming manufacturing, the upper is present during the rectification steps to the sole, which may expose the upper to opportunities for damage or other defects.

Aspects hereof contemplate forming an article of footwear through a direct bottoming process that limits unintended tooling-induced features, allows for customization in a sequential manufacturing process, reduces materials, and eliminates manufacturing processes.

Specifically, turning to <FIG>, which depicts an article footwear <NUM>, in accordance with aspects hereof. The article of footwear <NUM> is formed with an upper <NUM> comprising a medial side <NUM>, a lateral side <NUM>, a toe end <NUM>, a heel end <NUM>, and a plantar region <NUM> extending between the medial side <NUM>, the lateral side <NUM>, the toe end <NUM>, and the heel end <NUM>. The article of footwear also includes a sole <NUM> having a medial side <NUM>, a lateral side <NUM>, a toe end <NUM>, a heel end <NUM>, an upper-facing surface <NUM> extending between the medial side <NUM>, the lateral side <NUM>, the toe end <NUM>, and the heel end <NUM>, a ground-facing surface <NUM> opposite the upper-facing surface <NUM>, a medial sidewall <NUM> extending between the ground-facing surface <NUM> and the upper-facing surface <NUM> along the medial side <NUM>, and a lateral sidewall <NUM> extending between the ground-facing surface <NUM> and the upper-facing surface <NUM> along the lateral side <NUM>. The sole <NUM> includes a polymeric foam composition <NUM> forming at least a portion of the upper-facing surface <NUM> and mechanically engaged with the upper plantar region <NUM>. The sole also comprised of a polymeric film composition <NUM> forming at least a portion of the medial sidewall <NUM> from the ground-facing surface <NUM> toward the upper <NUM> at a medial film edge <NUM> and also forming at least a portion of the lateral sidewall <NUM> from the ground-facing surface <NUM> toward the upper <NUM> at a lateral film edge <NUM>. There is at least <NUM> between the upper-facing surface <NUM> at the medial sidewall <NUM> and the medial film edge <NUM> forming a medial exposed portion <NUM> and there is at least <NUM> between the upper-facing surface <NUM> at the lateral sidewall <NUM> and the lateral film edge <NUM> forming a lateral exposed portion <NUM>. The article of footwear <NUM> is also comprised of an outsole <NUM>, in the depicted example.

As will be provided in greater detail herein, the sole <NUM> is formed from the polymeric foam composition <NUM> that is direct attached to the upper <NUM> during the sole <NUM> forming process. The sole <NUM> also includes the polymeric film composition <NUM> that forms an exterior surface of the sole along portions of the sidewall(s). This polymeric film composition <NUM> is effective to provide a variety of different visual characteristics to the article of footwear <NUM>, such as variations in coloration, texture, and graphics, and other finishes. Further, it is contemplated that the polymeric film composition <NUM> provides a protective barrier to the polymeric foam composition <NUM> from the environment. For example, the polymeric film composition <NUM> may protect against hydrolysis and ultraviolet radiation effects on the polymeric foam composition <NUM>. Further yet, the polymeric film composition <NUM> reduces unintended tool marking features from being formed by the manufacturing tools as the polymeric film composition serves as a liner between the tooling (e.g., a mold <NUM> of <FIG>) and the polymeric foam composition <NUM>. The liner formed by the polymeric film composition <NUM> is effective to transition between tooling portions that would otherwise create a tooling mark feature that would subsequently be processed away.

Exposed regions, such as the medial exposed portion <NUM> and the lateral exposed portion <NUM>, provide several advantages to the aspects contemplated herein. For example, the exposed regions are a region at which the polymeric film composition <NUM> is not present on an exterior surface of the article of footwear <NUM>. Terminating the polymeric film composition <NUM> at the film edges, such as the medial film edge <NUM> and the lateral film edge <NUM>, allows for an efficient and effective termination of the polymeric film composition <NUM>. For example, the exposed region provides area in which a trimming operation may be performed on the polymeric film composition <NUM> (as best seen in <FIG> hereinafter). Without the exposed region of at least <NUM> between the film edge and the upper, a cutting tool may not properly access and cleanly cut excess polymeric film composition from the polymeric foam composition. Further, the exposed region provides more opportunities for design flexibility in the article of footwear. Having the exposed region between the polymeric film composition <NUM> and the upper <NUM> allows for a difference in visual characteristics, such as material, texture, color, reflectance, graphics, and the like. The footwear may therefore be designed to have a variety of appearances as a result of the inclusion of the exposed region. An exposed region may extend around the entire article of footwear or it may extend only along some portions, such as the medial side and the lateral side. The exposed portion may have a constant band thickness or the exposed portion may have a variable band thickness.

The polymeric foam composition <NUM> may be any polymeric composition. Foam is a cellular structure with either open celled or closed cell structures of polymeric composition and voids, such as gas voids. In an exemplary aspect, the polymeric foam composition is a polyurethane ("PU") composition. The PU may be chemically foamed or mechanically foamed during the curing process to result in a polymeric foamed composition. The polymeric foam composition may include additional components, such as colorants and other additives. While PU composition is specifically listed, other polymeric compositions are contemplated, such as ethylene-vinyl acetate, low-density polyethylene, nitrile rubber, polychloroprene, polyimide, polypropylene, polystyrene, polyvinyl chloride, silicone, and the like. However, as will be discussed in greater detail, bonding affinity between the polymeric foam composition <NUM> and the polymeric film composition <NUM> during the curing phase of the polymeric foam composition <NUM> drives manufacturing efficiencies. An exemplary combination of materials that have sufficient bonding affinity are PU as the polymeric foam composition <NUM> and thermoplastic polyurethane ("TPU") as the polymeric film composition <NUM>.

The polymeric film composition <NUM> may be any polymeric composition. Film is a thin layer of polymeric composition having a thickness in a range of about <NUM> microns to about <NUM> microns. In an exemplary aspect, the polymeric film composition prior to being inserted into a mold cavity (or subsequent), as will be discussed hereinafter, has a thickness in a range of about <NUM> microns to about <NUM> microns. Within this exemplary range, the polymeric film composition <NUM> provides sufficient durability to serve as an exterior surface on an article of footwear, has sufficient resilience to be formed as a liner of a mold cavity during manufacturing, and is sufficiently thick to obscure tooling irregularities that would otherwise generate unintended tool markings in the polymeric foam composition <NUM>, for example. Other thickness ranges are contemplated and vary with a polymeric composition selected. In an exemplary aspect the polymeric film composition <NUM> is a TPU composition. Further, in an exemplary aspect, the polymeric film composition <NUM> is a TPU composition having a thickness of <NUM> to <NUM> microns. Further yet, in an exemplary aspect the polymeric film composition <NUM> is a non-porous film capable of being formed as a liner in a mold cavity under vacuum.

The polymeric film composition <NUM> may have a variety of visual characteristics. Visual characteristics include, but are not limited to, material, sheen, coloration, reflectance, texture, graphical presentation, and the like. As will be appreciated throughout, the polymeric film composition <NUM> may be changed from one shoe to the next shoe during a continuous manufacturing process. As a result during a continuous production run, shoes having different visual characteristics may result from a common manufacturing process without significant alteration of the manufacturing mechanisms. Instead, it is contemplated that a different polymeric film composition may be provided during the manufacturing process. This convenience and flexibility allows for continued use of the capital equipment while still offering customized manufacturing options. For example, a first shoe may be produced with a first polymeric film composition having a first visual characteristic and the subsequent shoe to be produced without stopping production may use a second polymeric film composition having a different visual characteristic.

The upper <NUM> may be formed from any material, such as animal-based fibers (e.g., wool, hair, silk), plant-based fiber, and/or synthetic fibers. In an exemplary aspect, the upper <NUM> is formed from a textile material having one or more fibers in the plantar region <NUM>. The fibers in the plantar region <NUM> provide a surface to which the polymeric foam composition <NUM> may interact and mechanically bond therewith. For example, the upper <NUM> may be formed from a knit, woven, braided, non-woven, and the like textile comprising one or more yarns, filaments, and/or fibers that provide a surface amenable for direct bottoming. In some aspect, the upper <NUM> in at least the plantar region <NUM> includes a porous structure that allows a yet-to-be cured (e.g., fluid-like properties that allow the polymeric composition to flow around and/or through the porous structure) polymeric composition to infiltrate and/or at least partially encapsulate some of the fibrous elements forming the textile. Once encapsulated, the polymeric composition cures to a solid or more resilient state (e.g., cures as a foamed polymeric composition) forming a mechanical bond with the upper <NUM> through the interaction with the encapsulated fibrous elements. Further, it is contemplated that a chemical bond may additionally or alternatively be formed by the polymeric composition and the upper as the polymeric composition cures to a foamed polymeric composition state. The chemical bond is contemplated when compositions having an affinity for chemical bonding, such as an upper having PU and/or TPU compositions forming at least a portion of the plantar region <NUM> (e.g., a knit upper having TPU and/or PU yarns integrally knit in at least the plantar region <NUM>) and the polymeric foam composition <NUM> comprises a PU composition. In this example, the upper and the polymeric foam composition form a direct bottom bond through mechanical engagement and/or chemical engagement of the various compositions.

Similarly, it is contemplated that a chemical bond may be formed between the polymeric foam composition <NUM> and the polymeric film composition <NUM> to join the two compositions. As such, it is contemplated that the polymeric foam composition <NUM> and the polymeric film composition <NUM> are selected to have a sufficient chemical bonding affinity to resist delamination. An exemplary combination of material compositions with sufficient delamination resistance includes the polymeric foam composition <NUM> as a PU composition and the polymeric film composition <NUM> as a TPU composition. Other compositions are contemplated.

Returning to <FIG>, the article of footwear <NUM> is depicted as an athletic shoe; however, it is contemplated that any type of article of footwear may result from aspects provided herein. Of focus in the following discussions are the sole <NUM> and the compositions of the sole <NUM> at different locations. Specifically, the polymeric film composition <NUM> is depicted as extending in a superior direction from the ground-facing surface <NUM> toward the upper <NUM>. In actuality for the specific configuration provided in <FIG>, the polymeric film composition <NUM> is a continuous film material extending across the ground-facing surface <NUM> and forming the exterior of that surface while continuing, uninterrupted, up the medial sidewall <NUM> and the lateral sidewall <NUM>. Therefore, in this example, the polymeric film composition <NUM> forms the exterior surface of the sole <NUM> from the film edge (e.g., the medial film edge <NUM> and the lateral film edge <NUM>) inferiorly. The outsole <NUM> may optionally be secured to the sole <NUM> in some aspects tot hen form an exterior surface of the article of footwear <NUM> at a ground-contacting region. As used herein, anatomical relational terms, such as superior, inferior, proximal, distal, medial, lateral, and the like are in relation to an article of footwear in a traditional as-worn configuration on a user in and standing position. Therefore an inferior direction extends towards a traditional ground-contacting surface and a superior direction extends in a direction more proximal to the wearer in the as-worn configuration.

The exposed regions of the sole <NUM>, such as the medial exposed portion <NUM> and the lateral exposed portion <NUM>, are at least a <NUM> band extending between the upper <NUM> intersection with the sole <NUM> and the film edge. As provided previously, the exposed region provides various advantages to the examples provided herein. For example, ease of trimming the polymeric film composition <NUM> with reduced interference of the upper <NUM>, design flexibility with variations in visual characteristics of between the upper <NUM>, the exposed region, and the polymeric film composition <NUM>. The exposed region may have a length extending between the upper <NUM> and the film edge of any length. However, in an exemplary aspect the exposed region has a length of at least <NUM>. In an additional exemplary aspect the length is at least <NUM> and less than <NUM>. In yet another exemplary aspect, the exposed region length is between about <NUM> and about <NUM>. The provided range of exposed area length extending between the upper and the film edge provides sufficient area to allow for trimming operations while still providing sufficient coverage and protection of the polymeric foam composition <NUM> by the polymeric film composition <NUM>.

<FIG> depicts a cross section of the article of footwear <NUM>, in accordance with aspects hereof. The upper <NUM>, the sole <NUM>, and the outsole <NUM> are illustrated. The sole <NUM> is formed from the polymeric foam composition <NUM> and the polymeric film composition <NUM>. The sole <NUM> has angled sidewalls, as seen in <FIG>. Specifically, a first distance <NUM> at the ground-facing surface <NUM> is greater than a second distance <NUM> at the upper-facing surface <NUM> in this medial to lateral cross section view. The first distance <NUM> and the second distance <NUM> are measured from the medial side <NUM> to the lateral side <NUM>. An angled sidewall with direct bottomed footwear is possible, in an exemplary aspect, as a result of the polymeric film composition <NUM> serving as a liner to the mold cavity for easier release of the sole <NUM> therefrom relative to a non-liner configuration.

As also depicted in <FIG>, the polymeric film composition <NUM> extends underfoot forming the ground-facing surface <NUM> of the sole <NUM>. As will be appreciated in <FIG>, the polymeric film composition <NUM> extends underfoot to form a liner for a mold cavity prior to the mold cavity receiving the polymeric composition that will foam as the polymeric foam composition <NUM>. In aspects provided, the polymeric film composition <NUM> is formed into a liner through use of vacuum pressure drawn through the mold cavity and, in a specific example, through a bottom plate of the mold cavity that forms the ground-facing surface. To effectively draw the polymeric film composition <NUM> with a vacuum has the polymeric film composition <NUM> as a continuous film that extends over the mold cavity and is drawn down into the mold cavity while maintaining continuity to ensure a pressure differential (e.g., lower pressure created by the vacuum between the mold cavity and the film and a relatively higher pressure on the opposite surface of the film at atmospheric pressure) that forms the films to the mold cavity surfaces. Therefore, the polymeric film composition <NUM> extends across the ground-facing surface <NUM> from the sidewalls.

The polymeric foam composition <NUM> extends as a continuous foam composition from the polymeric film composition <NUM> on the ground-facing surface124 and the sidewalls to the upper-facing surface <NUM> at a location of mechanical engagement with the upper <NUM>. While not depicted, it is contemplated that one or more inserts may be encapsulated in the sole <NUM>. For example, as will be depicted in <FIG>, it is contemplated that an insert (e.g., air bag, stability element, support element, foam element) may be positioned in the mold cavity having the polymeric film composition <NUM> as a liner and prior to the polymeric foam composition <NUM> being inserted. The insert may be positioned within the mold cavity prior to the positioning of the upper <NUM> at the mold. Alternatively, it is contemplated that the insert may be positioned on the upper <NUM>, such as the plantar region <NUM>, to position the insert into the mold cavity when the upper <NUM> is positioned at the mold, as will be described hereinafter. Regardless of the initial positioning of the insert, this encapsulated insert is maintained in a relative position of the sole <NUM> by the compositions forming the sole <NUM> and provides varied functional characteristics (e.g., impact attenuation, resilience, support) at a specified location of the sole <NUM>.

The article of footwear <NUM> as depicted in <FIG> shows the upper <NUM> lateral side <NUM>, the medial side <NUM>, and the plantar region <NUM>. At the plantar region <NUM> the polymeric foam composition <NUM> is mechanically engaged with the upper <NUM>. While not depicted, in some aspects it is contemplated that the cross sectional view will depicts at least a portion of the polymeric foam composition <NUM> extending into the material forming the plantar region <NUM> forming a mechanical bond. The sole <NUM> is depicted with the lateral exposed portion <NUM> and the medial exposed portion <NUM>. The exposed portions extend between the upper <NUM> and the respective lateral film edge <NUM> and the medial film edge <NUM>. Continuing in an inferior direction from the film edge, the polymeric film composition <NUM> extends down along the sidewalls, such as the medial sidewall <NUM> and the lateral sidewall <NUM>, to form the ground-facing surface <NUM>. As depicted in <FIG>, the polymeric film composition <NUM> is a continuous and relatively non-porous material that is able to be drawn as a liner into a mold cavity through vacuum pressure. The outsole <NUM> is depicted as being joined with the polymeric film composition <NUM> at the ground-facing surface <NUM>. A first distance <NUM> extending between the medial side and the lateral side at the ground-facing surface <NUM> is provided. A second distance <NUM> extending between the medial side and the lateral side at the upper-facing surface <NUM> is provided. The first distance <NUM> is greater than the second distance <NUM> as the medial sidewall <NUM> and the lateral sidewall <NUM> angle towards one another in the superior direction (i.e., away from the ground-facing surface <NUM> towards the upper-facing surface <NUM>).

<FIG> depicts an exploded view of the article of footwear <NUM> prior to trimming the polymeric film composition, in accordance with aspects hereof. The upper <NUM>, the polymeric foam composition <NUM>, the polymeric film composition <NUM>, and the outsole <NUM> are illustrated. The sole <NUM> is comprised of the polymeric foam composition <NUM> and the polymeric film composition <NUM>, in this exemplary aspect. While the outsole <NUM> is depicted, it is optional in some exemplary aspects. It is contemplated that the polymeric film composition <NUM> may serve as a ground contacting surface in some examples. Further, it is contemplated that the polymeric film composition <NUM> may have traction elements (e.g., lugs, treads) integral to the film or formed into the film during the molding operation with the polymeric foam composition <NUM>, in yet another exemplary aspect.

The polymeric film composition <NUM> is depicted having the trimmed portion <NUM> extending from what will be the film edges, such as the medial film edge <NUM> and the lateral film edge <NUM> following a trimming operation. The outsole is depicted having a plurality of the outsole apertures <NUM>. As previously discussed, the outsole aperture <NUM> provides a conduit through which vacuum may transfer from the bottom plate to the mold cavity to effectively draw the polymeric film composition <NUM> into the mold cavity. In an exemplary aspect, the outsole <NUM> is comprised of a plurality of the apertures extending through the outsole <NUM> to allow for an even and complete draw of the polymeric film composition132 into the mold cavity.

While a specific size, shape, and configuration of the various components forming the article of footwear <NUM> are provided in <FIG>, they are illustrative in nature. Instead, it is contemplated that any size, shape, configuration and style may be associated with any one or more of the components and features of those components. For example, the upper <NUM> and/or the sole <NUM> may be and size, shape, and configuration. Further, the outsole <NUM> may be omitted or altered in various aspects. Further yet, as previously discussed, it is contemplated that one or more inserts may be provided in connection with direct bottomed footwear. The insert may be relatively positioned in a variety of ways. For example, the insert may be positioned between an outsole and a film layer. The insert may be positioned between a film layer and a foam material. The insert may be positioned between a foam material and the upper. A plurality of inserts may be positioned at a variety of locations and relative positions. Further yet, additional elements may be included, such as a sock liner, insole, or other components used in connection with an article of footwear. Additionally, it is contemplated that a primer, adhesive, or other bonding supplement may be used in connection with any of the components of the article of footwear <NUM> to aid in assembly.

<FIG> depicts an exemplary system having a mold <NUM> shown in cross-section for making an article of footwear, in accordance with aspects hereof. The mold <NUM> is comprised of an inner ring <NUM> (also referred to as an "inner ring mold" hereinafter), an outer ring <NUM> (also referred to as an "outer ring mold" hereinafter), and a bottom plate <NUM>. However, while a specific configuration, such as an inner ring and an outer ring, is depicted in connection with the figures, it is contemplated that alternative tooling and configurations may instead be implemented. The system also includes a vacuum source <NUM>. The vacuum source <NUM> is effective to generate a vacuum, such as negative pressure relative ambient conditions. The vacuum source <NUM> may generate the vacuum through a variety of methods, such as a fan, impeller, coanda, venturi, and the like. The vacuum source <NUM> is operatively coupled, such as through tubing, with one or more components, such as the bottom plate <NUM>. The operative coupling between the vacuum source and the bottom plate <NUM> allows for vacuum to be drawn through the bottom plate <NUM> at one or more bottom plate vacuum ports <NUM> that extend through to a bottom plate top surface that forms a molding surface for the mold cavity. The bottom plate vacuum ports <NUM> allow for vacuum to be drawn through the mold cavity <NUM> and to pull in the polymeric film composition <NUM> to form a liner of the mold cavity <NUM>.

In an optional configuration depicted in <FIG>, and further illustrated in <FIG> hereinafter, the vacuum source <NUM> (or a separate vacuum source) may be operatively coupled with the mold <NUM> in a manner to secure the polymeric film composition <NUM> prior to the film being drawn into the mold cavity <NUM>. In this example, the vacuum source <NUM> is operatively coupled with the inner ring <NUM> to provide a vacuum at inner ring vacuum port <NUM>, which will be discussed in greater detail at <FIG>.

The system of <FIG> also includes a heat source <NUM>. The heat source <NUM> is effective to heat the polymeric film composition <NUM> to aid in the polymeric film composition <NUM> being drawn into the mold cavity <NUM> by vacuum. The heat source <NUM> may be any heat source, such as a radiant heat source. The heat source <NUM> may operate with electrically resistive elements, infrared radiation (e.g., near and/or far range), and/or the like. For example, the heat source <NUM>, as seen in <FIG>, may be positioned in proximity to the polymeric film composition <NUM> and apply a flash of thermal energy to the polymeric film composition <NUM> to increase the temperature of the polymeric film composition <NUM> above ambient temperature. In some examples the temperature is raised to a temperature above ambient temperatures but below a melting temperature of the polymeric film composition <NUM>. The increase in temperature allows for the polymeric film composition <NUM> to more easily comply with the mold cavity <NUM> as it is drawn in to the mold cavity <NUM>. Easier compliance of the polymeric film composition <NUM> while being drawn allows the polymeric film composition <NUM> to conform to the features of the mold surfaces with minimized polymeric film composition <NUM> creasing and other deformations. Further, application of the thermal energy to the polymeric film composition <NUM> can reduce an amount of vacuum used to line the mold cavity <NUM> with the polymeric film composition <NUM>.

As will be discussed in connection with <FIG>, a variety of configurations and techniques are contemplated for securing the polymeric film composition <NUM> to the mold <NUM> during the vacuum drawing of the polymeric film composition <NUM> into the mold cavity <NUM>.

The system of <FIG> also depicted a robotic arm <NUM>. The robotic arm <NUM> represents any conveyance mechanism (e.g., multi-axis robot, X-Y plane movement gantry). The robotic arm is effective to manipulate one or more tools and or one or more components in the system of <FIG>. For example, the robotic arm may be effective, in an exemplary aspect, to position the polymeric film composition <NUM> on the mold <NUM> from a film source <NUM>. The robotic arm may be adapted with a claw, vacuum pickup tool, adhesion tool, hook, and/or the like to secure the polymeric film composition <NUM>, move the polymeric film composition <NUM>, and then position the polymeric film composition <NUM> at the mold <NUM> for being drawn into the mold cavity <NUM>. Additionally or alternative, the robotic arm <NUM> is effective to position the heat source <NUM> at an appropriate position relative the polymeric film composition <NUM> for heating the polymeric film composition <NUM>. Further yet, the polymeric film composition <NUM> (or a variation thereof) may be effective to position the upper <NUM> relative to the mold <NUM> for the direct bottoming operation.

The film source <NUM> may be an inventory of films, such as the polymeric film composition <NUM>, having varied characteristics. The varied characteristics may include varied visual characteristics, such as color, texture, reflectance, and the like. The film source <NUM> may also include an inventor of films have different physical attributes. For example, different compositions, different thicknesses, different sizes. For example, the film source <NUM> may include various sizes of polymeric film compositions that are sized appropriate for a size or style of footwear being manufactured.

A material source <NUM> is a source of the polymeric foam composition <NUM>. The material source <NUM> may be comprised of various compositions that are mixed and interact as being injected into the mold cavity <NUM> by an injector <NUM>. The material source <NUM> may be comprised of a plurality of sources, such as a separate source for different elements forming the polymeric foam composition <NUM>.

A vision system <NUM> is provided with the system of <FIG>. The vision system <NUM> is effective to capture an image or plurality of images (e.g., video) of the mold and one or more components. The vision system <NUM> may be used to ensure placement of components relative to the tooling or relative to other components. For example, the vision system <NUM> may be effective to aid in the pick and place operations performed by the robotic arm <NUM>. Further yet, the vision system <NUM> may be effective to identify the tooling and therefore the appropriate processes and/or components to process. Additionally, the vision system <NUM> may be used to evaluate quality metrics and to adjust process parameters or processes as a result of the determinations.

Returning to the mold <NUM>, a variety of mold surfaces are present in the mold cavity <NUM>. For example, a first mold surface <NUM> is formed by a top surface of the bottom plate <NUM>. A second mold surface <NUM> is formed by a combination of molding surfaces. For example, a medial sidewall <NUM> of the inner ring <NUM> and a medial sidewall <NUM> of the outer ring <NUM> may form the second mold surface <NUM>. In different tooling configurations the second mold surface is formed from portions of the tooling that form the sidewalls of the sole. On the lateral side, a lateral sidewall <NUM> of the inner ring <NUM> and a lateral sidewall <NUM> of the outer ring <NUM> form a sidewall molding surface of the mold <NUM>. The inner ring <NUM> is comprised of a top surface <NUM>. The top surface <NUM> is a surface that supports the polymeric film composition <NUM> as it is drawn into the mold cavity to form a liner of the mold cavity. The top surface <NUM> is a location, in an exemplary aspect, of the inner ring vacuum port <NUM>. In aspects depicted in <FIG>, the inner ring top surface <NUM> is a surface for positioning a compression ring <NUM> around a lip formed in the inner ring top surface <NUM> to secure the polymeric film composition <NUM> to the mold through a compression fit prior to drawing the polymeric film composition <NUM> into the mold cavity <NUM>. Further yet, as will be depicted in <FIG>, the inner ring top surface <NUM> provides a securement location for one or more mold securements to extend through film apertures to secure the polymeric film composition <NUM> to the mold <NUM>.

A bottom plate actuator <NUM> is provided to linearly move the bottom plate <NUM> in an inferior and superior direction relative to the article of footwear to be manufactured. The bottom plate actuator <NUM> may be a hydraulic, pneumatic, electric, or the like actuator. The bottom plate actuator <NUM> is effective to position the bottom plate at different vertical positions depending on the process being performed, the article being manufactured, and/or the materials being used. For example, as some polymeric compositions have different foaming reactions that have different volume changes resulting, a different height of the bottom plate <NUM> relative to a location of the upper <NUM> may be desired and therefore adjusted by the bottom plate actuator <NUM>. Additionally, it is contemplated that the bottom plate <NUM> is positioned at a first height prior to injecting the polymeric foam composition <NUM> and then raised to a second height that is closer to the upper <NUM> after the polymeric foam composition <NUM> is injected. This changing of the bottom plate <NUM> after injection can be an effective mechanism to clear the injection run that supplies the material through the mold and/or to provide sufficient volume for injecting the material the length of the mold cavity with varied injections pressures without having the upper <NUM> interfere with the injection stream, for example.

The system of <FIG> also includes ring actuators, such as the medial ring actuator <NUM> and a lateral ring actuator <NUM>. The medial ring actuator <NUM> and the lateral ring actuator <NUM> may be any actuator, such as be a hydraulic, pneumatic, electric, or the like actuator. The ring actuators are effective to position the respective mold ring portion during a manufacturing process. For example, and as shown in <FIG> and <FIG>, the medial ring actuator <NUM> and the lateral ring actuator <NUM> are effective to secure the outer respective rings about the upper <NUM>. The medial ring actuator <NUM> and the lateral ring actuator <NUM> move the respective outer rings of the mold to enclose the mold cavity with the plantar portion of the lasted upper <NUM>. As the injected polymeric foam composition <NUM> expands during foaming, the mold <NUM> forms the polymeric foam composition into a net-sized, shape that is mechanically engaged with the upper <NUM> because the polymeric foam composition <NUM> is enclosed in the mold cavity after the medial ring actuator <NUM> and the lateral ring actuator <NUM> move the outer rings into contact with the upper <NUM>.

The mold <NUM> is contemplated that include the inner ring <NUM> and optionally the outer ring <NUM>. Further, as will be discussed in greater detail hereinafter, one or more polymeric film composition securements are contemplated. The film securements include, but are not limited to pins, a compression ring, a magnetic ring or plate, and/or a vacuum port. It is understood that the inner ring <NUM> in combination or individually with the outer ring <NUM> may form the mold <NUM>. When in combination as depicted in <FIG>, the outer ring <NUM> slidably engages with the inner ring <NUM> to position the lateral sidewall <NUM> and the medial sidewall <NUM> in appropriate positions to secure the upper and to form the exposed regions of the footwear sidewall. This movement of the outer ring <NUM> therefore presents a molding surface at an appropriate position and it secures and forms a seal around the lasted upper for the injection of the polymeric foam composition. In aspects where the outer ring <NUM> is omitted, it is contemplated that the mold may still secure and seal around a lasted upper with a variety of techniques, such as a split inner ring that is able to close around an upper positioned in a mold cavity, as discussed herein with respect to the outer ring.

The various film securements will be discussed in detail in <FIG> hereinafter. However, in general, the various film securement configurations are effective to secure a polymeric film composition over a mold cavity to allow the polymeric film composition to be drawn into the mold cavity and to then form a liner of the mold cavity. Therefore, variations on positions of elements comprising the film securement are contemplated.

While specific components are depicted in <FIG>, it is understood that any of the components may be omitted. Further, it is contemplated that any number of a listed component may be used in a system. Further yet, the components of <FIG> are exemplary in nature and are not limiting.

<FIG> depicts the mold <NUM> having the outer ring <NUM>, the inner ring <NUM>, and the bottom plate <NUM> exposed, in accordance with aspects hereof. The mold <NUM> in <FIG> is in a configuration prepared for a direct bottoming process, as will be sequentially show in illustrative nature in the following figures.

<FIG> depicts the mold <NUM> with the outsole <NUM> placed on the bottom plate <NUM> within the inner ring <NUM>, in accordance with aspect hereof. In this example, the outsole aperture <NUM> aligns with the bottom plate vacuum port <NUM> allowing for a conduit through which vacuum may reach and affect the polymeric film composition <NUM>. It is contemplated that an adhesive or other bonding agent may be applied to the outsole <NUM> to aid in a bond between the outsole <NUM> and the polymeric film composition <NUM>. That adhesive or bonding agent may be applied at this step prior to forming the polymeric film composition132 into a liner that is vacuum secured to the outsole <NUM>. This vacuum securing may aid in bonding the outsole <NUM> and the polymeric film composition <NUM>.

<FIG> depicts a first configuration for securing the polymeric film composition <NUM> to the mold for being drawn into the mold cavity to form a liner, in accordance with aspects hereof. In this first configuration, a plurality of mold securements <NUM>, as best seen in the cross section of <FIG>, extend through film apertures <NUM> of the polymeric film composition <NUM>. This mechanical engagement by the mold securements <NUM> anchors the polymeric film composition <NUM> to the mold <NUM> as it is drawn into the mold cavity. Without an anchoring, regardless of type of anchor configuration, the polymeric film composition <NUM> may be pulled beyond the top surface of the mold and allow for a vacuum seal to be broken, which would negate the effectiveness of the vacuum to pull the polymeric film composition <NUM> into the mold cavity as a liner.

<FIG> depicts a cross section along line <NUM>-<NUM> of <FIG> after being drawn by vacuum to form a liner, in accordance with aspects hereof. The polymeric film composition <NUM> extends from the top surface <NUM> along the lateral sidewall <NUM>, across the outsole <NUM> on the bottom plate <NUM> to the medial sidewall <NUM> and up to the inner ring top surface <NUM> on the medial side. The polymeric film composition <NUM> may be formed with the film apertures <NUM> at predefined locations that ensure a consistent tension across the mold cavity based on a known distance between the pluralities of film apertures <NUM>. Alternatively, the film apertures <NUM> may be formed by the mold securement <NUM>. For example, the mold securement <NUM> may puncture the polymeric film composition <NUM> at a location selected by an operator. In this way, the amount of tension resulting in the polymeric film composition <NUM> as it extends across the mold cavity may be adjusted at the time of securement to accommodate variations in materials, sizes, styles, and the like. Further, it is contemplated that some of the film apertures <NUM> may be pre-formed and others are formed by contact with their respective mold securement <NUM>.

The mold securement <NUM> may be a pin, a hook, or any other protrusion extending from a portion of the mold <NUM> to which the polymeric film composition <NUM> is proximate (e.g., contacts, near) and that is outside the mold cavity <NUM>. The mold securement <NUM> may be integrally formed with the mold <NUM> or it may be added after initial tooling generation is performed. For example, one or more pins may be inserted into the mold <NUM> to serve as mold securements <NUM>.

<FIG> depicts the interaction of the inner ring <NUM> and the outer ring <NUM>. As the polymeric film composition <NUM> turns from the inner ring sidewalls, such as the medial sidewall <NUM>, to the top surface <NUM>, the sole sidewall molding surface is then formed by the outer ring <NUM> at the medial sidewall <NUM>. It is this medial sidewall <NUM> that forms the medial exposed portion <NUM> on the sole <NUM>. Similarly, the lateral sidewall <NUM> forms the lateral exposed portion <NUM> of the sole <NUM>. Having the inner ring <NUM> defining the mold surfaces supporting the liner formed by the polymeric film composition <NUM> and the outer ring defining the mold surface of exposed portion, a film edge may be formed on the sidewall away from the upper <NUM>, in an exemplary aspect.

It is understood that the dimensions of the outer ring sidewall surfaces may be adjusted to change a width of exposed portion on the sole <NUM> sidewall. For example, if a larger exposed portion is intended, the size of the outer ring sidewall may be increase. Conversely, if the size of the exposed portion is intended to be decreased, the size of the outer ring sidewall is decreased.

<FIG> depicts a simplified securement of the polymeric film composition <NUM> to the mold using compression, in accordance with aspects hereof. Specifically, a compression ring <NUM> is formed to compress the polymeric film composition <NUM> around a perimeter element, such as the depicted lip, of the top surface <NUM>. The compression ring <NUM> is formed from a material, such as steel, aluminum, polytetrafluoroethylene, and the like. Because aspects contemplate heating the polymeric film composition <NUM>, the compression ring <NUM> is formed from a material that tolerates thermal cycles with temperatures exceeding <NUM> Celsius. Not only should the compression ring <NUM> have tolerance for temperatures above <NUM> Celsius, but the compression ring <NUM> should not degrade or deform with the repeated thermal cycles. The compression ring <NUM> is sized to encircle the top surface <NUM> while also capturing and maintaining the polymeric film composition <NUM> in the appropriate position. Therefore, appropriate sizing of the compression ring <NUM> that remains consistent through manufacturing cycles ensures a consistent securement of the polymeric film composition <NUM>.

Because the compression ring <NUM> extends around the perimeter in the aspects provided, the securements of the polymeric film composition <NUM> is uniform around the mold cavity. Lack of uniformity in the securement can result in creases or other deformations of the polymeric film composition <NUM> as it is drawn into the mold cavity as a liner. Further, the polymeric film composition <NUM> may be provided an intended amount of tension or sag prior to being secured. For example, a predetermined amount of the polymeric film composition <NUM> may extend into the mold cavity prior to the placement of the compression ring <NUM>. The excess polymeric film composition <NUM> in the mold cavity prior to securement may limit an amount of elongation that is needed from the polymeric film composition <NUM> to form the liner of the mold cavity.

<FIG> depicts a cross section of <FIG> after the polymeric film composition <NUM> has been drawn down as a liner of the mold cavity <NUM>, in accordance with aspect hereof. The compression ring <NUM> compresses the polymeric film composition <NUM> between the inner ring <NUM> at the top surface <NUM>. As the polymeric film composition <NUM> transitions from the sidewalls, such as the lateral sidewall <NUM> to the top surface <NUM>, the trimmed portion <NUM> is formed from the polymeric film composition <NUM>. The trimmed portion <NUM> is the portion of the polymeric film composition <NUM> that is not joined with the polymeric foam composition <NUM> and that will be trimmed as depicted in <FIG> hereinafter.

<FIG> depicts an additional polymeric film composition <NUM> securement option over the mold cavity, in accordance with aspects hereof. In this example, a vacuum pressure is applied to the polymeric film composition <NUM> outside of the mold cavity <NUM> and prior to the polymeric film composition <NUM> being drawn into the mold cavity <NUM> to form a liner. A series of apertures extend through the inner ring as vacuum ports <NUM>. The vacuum apertures are conduits for vacuum that apply aid in securing the polymeric film composition <NUM> to the top surface <NUM>.

<FIG> depicts a cross section of <FIG> after the polymeric film composition <NUM> has been drawn down as a liner of the mold cavity <NUM>, in accordance with aspects hereof. In this example, it is contemplated that the polymeric film composition <NUM> is positioned over the mold cavity and concurrently or subsequently a vacuum is drawn through the vacuum ports <NUM> that create a securement force by vacuum at the top surface <NUM> of the polymeric film composition <NUM>. Once the polymeric film composition <NUM> is secured to the mold <NUM> by the vacuum port <NUM>, the bottom plate vacuum ports <NUM> may draw a vacuum there through to elongate and pull the polymeric film composition <NUM> into the mold cavity to form a liner. While the polymeric film composition <NUM> is being pulled down to form a liner, the polymeric film composition <NUM> is secured at the top surface by continued vacuum from the vacuum port <NUM>.

The vacuum ports may be positioned as a plurality of ports extending around the mold cavity perimeter. The vacuum ports <NUM> may be spaced every <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or more. Depending on a size of the vacuum port <NUM>, the amount of vacuum pressure, the material characteristics, and the mold cavity size, the positioning and spacing of the vacuum ports may be adjusted. Further, it is contemplated that the vacuum ports <NUM> are positioned closer together at regions of the mold cavity having a longer sidewall surface. As a greater elongation may occur for the longer sidewall pull, a stronger securement is contemplated. For example, in a heel region having a thicker polymeric foam composition from the ground-facing surface to the upper-facing surface thank in a toe region, the perimeter of the mold cavity near the heel region has a higher concentration of vacuum ports <NUM> than in the perimeter of the toe region, for example.

Aspects herein contemplated a variable vacuum securement force generated through the vacuum ports <NUM>. As will also be discussed with respect to a magnetic securement technique provided in <FIG> hereinafter, the variable vacuum securement force may ensure unintended elongation of the polymeric film composition <NUM> is limited by allowing intentional slippage of the polymeric film composition <NUM> along the inner ring <NUM> during the drawing of the polymeric film composition <NUM> in to the mold cavity as a liner. For example, one or more of the vacuum ports used for securing the polymeric film composition <NUM> may reduce a vacuum pressure applied at different processes of the operation. In an example, as the polymeric film composition <NUM> is heated, a first securement force is generated by the vacuum ports <NUM>. At least partially through the vacuum draw of the polymeric film composition <NUM> into the mold cavity, a second securement force is generated by the vacuum ports <NUM>. The second securement force is less than the first securement force to allow slippage of the polymeric film composition <NUM> along the inner ring <NUM>. This slippage allows for a formation of a liner of the mold cavity while also preventing over elongation of the polymeric film composition that could affect a visual characteristic of the polymeric film composition. Examples of affected visual characteristics include, but are not limited to, a distortion or other deformation of a graphic or text element on the polymeric film composition <NUM>. Another example includes a dimensional texture on the polymeric film composition <NUM> that is muted or otherwise lessened by over elongation. As such, aspects contemplate allow for intentional slippage of at a least a portion of a polymeric film composition relative to the mold to limit unintended visual characteristic effects.

<FIG> depicts a fourth exemplary technique for securing the polymeric film composition <NUM> to the mold using magnetic attraction between a magnetic ring <NUM> and the inner ring <NUM>, in accordance with aspects hereof. The magnetic attraction may be generated through any combination of magnetic force, such as magnets <NUM> incorporated in the magnetic ring <NUM>, magnets <NUM> (as seen in <FIG> hereinafter) incorporated in the inner ring <NUM>, magnetized magnetic ring <NUM>, and/or magnetized inner ring <NUM>. Further, the magnetic attraction may be magnetic materials and/or electromagnetic systems that generate a magnetic force in response to electrical input.

The magnetic ring <NUM> may be any shape. In an exemplary aspect the magnetic ring <NUM>, as depicted, is a ring-like structure that is effective to cover at least the edge of the inner ring <NUM> that defines the mold cavity <NUM>. For example, the magnetic ring may have a width from an interior perimeter (e.g., central aperture) to an exterior perimeter of <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, and greater. The greater the width, the more universal the magnetic ring <NUM> may be for different sized molds and different styles of molds. Therefore, a universal magnetic ring <NUM> configuration all for the number of magnetic ring <NUM> variations to be limited to increase efficiency and reduce tooling inventory. However, it is contemplated that the magnetic ring <NUM> includes at least one aperture, in an exemplary aspect, that allows for air to pass through the magnetic ring <NUM>, such as in a central region over the mold cavity <NUM>. This aperture allows for pressure to be equalized to ambient pressure on a top surface of the polymeric film composition <NUM> as the polymeric film composition <NUM> is drawn into the mold cavity <NUM> to form a liner. The aperture extending through the magnetic ring <NUM> allows a pressure differential to be formed across the polymeric film composition <NUM> as the vacuum is drawn through the bottom plate <NUM>, as seen in <FIG>.

The magnetic ring <NUM> may be constructed from any material. Similar to the compression ring <NUM>, the magnetic ring <NUM> is formed from a material, such as steel, other ferrous metals, aluminum, polytetrafluoroethylene, other polymers, and the like. Because aspects contemplate heating the polymeric film composition <NUM>, the magnetic ring <NUM> is formed from a material that tolerates thermal cycles with temperatures exceeding <NUM> Celsius. Depending on the magnetic attraction configuration, the magnetic ring <NUM> may be formed from a ferrous material or at least incorporate a ferrous material. For example, if a permanent magnet, electric magnet, or other source of magnetic energy is incorporated with the inner ring <NUM>, the magnetic ring <NUM> may be a passive component that is attracted to the magnetic energy source within the inner ring <NUM>. Additionally or alternatively, the magnetic ring <NUM> may include a magnetic energy source, such as a permanent magnet, an electromagnet, or other magnetic energy source. Regardless of the magnetic energy source and position, it is contemplated that a compressive force is generated between the magnetic ring <NUM> and the ring <NUM> around the perimeter of the mold cavity <NUM> using magnetic attraction between the magnetic ring <NUM> and the ring <NUM>.

As depicted in <FIG>, a plurality of the magnets <NUM> are positioned around a circumference of the magnetic ring <NUM> and within the width of the magnetic ring between the exterior perimeter and the center aperture. Each of the magnets may have a common polarity orientation within the magnetic ring <NUM> to allow for varied positioning and a standardized attraction to a mold. Alternatively, it is contemplated that the polarity orientation of each of the magnets <NUM> may be varied to provide a self-alignment characteristic of the magnetic ring <NUM> to the underlying mold. If magnets, such as the plurality of magnets <NUM>, are incorporated within the magnetic ring <NUM>, any number of magnets may be used. For example, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or any number of magnets may be incorporated. Further, it is contemplated that an even spacing or an irregular spacing may be implemented in the positioning of the magnets in the magnetic ring <NUM>. A uniform spacing between the magnets <NUM> may aid in providing a uniform compression around a perimeter. An irregular positioning of the magnets <NUM> may be leveraged to achieve greater magnetic compressive force in a specific location, such as where the compressed polymeric film composition <NUM> is more prone to elongation. As will be depicted in <FIG>, it is also contemplated that the magnets may be omitted from the magnetic ring in some aspects. As the magnetic ring may be constructed having a ferrous metal, magnetic energy source (e.g., permanent magnet or electromagnet) may be in the mold itself and generate a compressive force on the polymeric film composition <NUM> through a magnetic attraction to the magnetic ring containing a ferrous metal.

<FIG> depicts a cross section view of the film securement using the magnetic ring <NUM> of <FIG>, in accordance with aspects hereof. Similar to the aspects previously discussed with connection to <FIG> and <FIG>, the polymeric film composition <NUM> is secured during a vacuum draw into the mold cavity formed at least by the ring <NUM> and the bottom plate <NUM>. At the top surface <NUM> of the ring <NUM> the magnetic ring <NUM> compresses the polymeric film composition <NUM>. The compressive force is generated through a magnetic attraction. The magnetic attraction may be generated as a result of attractive polarities of opposing magnets <NUM> in the ring <NUM> and the magnets <NUM> of the magnetic ring <NUM>. Or, as previously discussed, one or more of the ring <NUM> and the magnetic ring <NUM> may be attracted to a magnetic energy source, For example, the ring <NUM> and/or the magnetic ring <NUM> may include a ferrous material (or other magnetically attracted material) that is attracted to an opposing magnetic energy source.

The magnets <NUM> may be positioned at any location of the mold, but in the illustrated example the magnets <NUM> are incorporated at the top surface <NUM>. The positioning of the magnets <NUM> may be aligned with the positioning of the magnets <NUM> of the magnetic ring <NUM>. This coordination and alignment of the magnets <NUM> and the magnets <NUM> allows for an efficient use of magnetic energy potential between the magnets <NUM> and the magnets <NUM>.

Similar to the vacuum pressure securement technique of <FIG>, it is contemplated that the magnetic securement technique of <FIG> may be applied as a variable securement. If the magnetic compression is generated, at least in part, through an electromagnetic source, the force generated by the electromagnetic source may be adjusted during a process. For example, it is contemplated that the magnetic ring <NUM> may secure the polymeric film composition <NUM> to the mold prior to heating the polymeric film composition <NUM>. During the heating process a first compression is generated between the magnetic ring <NUM> and the mold. During a vacuum draw process, a second compression may be generated between the magnetic ring <NUM> and the mold. The first compression may be greater than the second compression to allow for the polymeric film composition <NUM> to not only elongate during the vacuum draw, but to also slidably move between the magnetic ring <NUM> and the mold. Selectively adjusting a timing and/or positioning of compressive force applied to the polymeric film composition <NUM> may effectively limit unintended deformation of the polymeric film composition <NUM>. Examples include the polymeric film composition having a graphic or other element (text) visible on the surface such that an irregular or over-elongation distorts the visual impression of the polymeric film composition. Another example includes a polymeric film composition having as dimensional texture. Excessive elongation of the dimensionally textured polymeric film composition can reduce and distort the dimensional texture. Consequently, aspects contemplate reducing a compressive force between the magnetic ring <NUM> and the mold through an adjustment of magnetic force generated, such as a force generated by an electromagnet. The adjustment of compression, in this example, allows for intentional slippage and limited elongation of the polymeric film composition <NUM>.

An exemplary use of the magnetic ring <NUM> technique includes positioning the polymeric film composition <NUM> over the mold cavity <NUM>. The magnetic ring <NUM> is then positioned over the polymeric film composition <NUM> and in proximity to the mold. A magnetic attraction between the magnetic ring <NUM> and the mold results in a compression of the polymeric film composition <NUM> between the mold and the magnetic ring <NUM> that secure the polymeric film composition <NUM> for being drawn into the mold cavity <NUM>. After the polymeric film composition <NUM> is drawn into the mold cavity <NUM>, the magnetic ring <NUM> may be removed from the polymeric film composition <NUM>. The upper may then be positioned at the mold for a direct bottoming operation.

<FIG> depicts an alternative configuration for the magnetic ring <NUM> in a cross section, in accordance with aspects hereof. Specifically, the magnetic ring <NUM> of <FIG> is constructed from a ferrous metal, such as steel. Magnetic ring may be cut from the materials, such as a sheet of steel. The magnetic ring may have a thickness of <NUM>-<NUM> in a first aspect and a thickness of <NUM>-<NUM> in a second aspect. The ferrous magnetic ring is attracted or more magnetic energy sources (e.g. permanent magnet, electromagnet) at the mold, such as the ring <NUM>. The magnetic energy source may be countersunk into the top surface of the ring <NUM>. The magnetic ring <NUM> may be any shape. In an exemplary aspect, the magnetic ring <NUM> has an exterior perimeter that is at least as big and shape to extend outside of the mold cavity at the top surface of the inner ring <NUM>. Stated differently, the size and shape of the inner ring <NUM> is sufficient to compress the polymeric film composition <NUM> at the top surface of the ring <NUM>.

<FIG> depicts the heat source <NUM> heating the polymeric film composition <NUM>, in accordance with aspects hereof. For example, after securing the polymeric film composition <NUM> to the mold by any method, such as those methods provided in <FIG> and prior to applying a vacuum to draw the polymeric film composition <NUM> into the mold cavity, the heat source <NUM> may heat the polymeric film composition <NUM>. Once heated, the polymeric film composition <NUM> is more prone to elongation by a vacuum draw through the mold cavity. Further, as a result of heating by the heat source <NUM>, the polymeric film composition <NUM> may be more compliant to the mold surfaces to result in a higher resolution of detail that is captured by the polymeric film composition <NUM> from the mold surfaces and molded into sole <NUM>.

<FIG> depicts the polymeric film composition <NUM> drawn down into the mold cavity to form a liner of the mold cavity, in accordance with aspects hereof. While film apertures <NUM> are depicted, it is understood that any securement technique may be implemented and the illustrated technique is not limiting. With the polymeric film composition <NUM> drawn down by vacuum through the bottom plate, the medial film edge <NUM> and the lateral film edge <NUM> are exposed and represent a location where trimming will be performed to create the trimmed portion <NUM>. In this step, the vacuum may be maintained for a predefined period of time to ensure acceptable contact between the polymeric film composition <NUM> and the mold surfaces. Alternatively, the vacuum may cease once the polymeric film composition <NUM> reaches a predefined temp that is lower than at the start of applying the vacuum to draw the polymeric film composition <NUM> down as a liner. Additionally, the vacuum may be maintained through subsequent processing steps, such as injection of the polymeric foam composition.

<FIG> depicts a step of applying the upper <NUM> to a last <NUM> in a step commonly referred to as lasting, in accordance with aspects hereof. The last <NUM> is a tool that provides a defined shape to the upper <NUM> such that after the direct bottoming process, the upper <NUM> maintains a similar shape, at least in part, as a result of the engagement with the resilient sole. The plantar region <NUM> is prominently illustrated in this example. As discussed, the plantar region <NUM> will form the engagement surface for the sole during the direct bottoming process to follow.

<FIG> depicts the lasted upper <NUM> being positioned relative to the mold <NUM>, in accordance with aspects hereof. The outer ring <NUM> is separated by the actuators provided in <FIG>. The slit outer ring configuration allows for the positioning of the upper <NUM> in the mold <NUM> as intended to expose the plantar region to the molding cavity for direct bottoming to occur.

<FIG> depicts the outer ring <NUM> in the closed configuration for direct bottoming to the lasted upper <NUM>, in accordance with aspects hereof. When in the closed configuration, the outer ring <NUM> compresses the lasted upper to form a seal at the transition from the sole to be direct bottomed and the upper <NUM>. The injector <NUM> is positioned at the mold to inject a composition into the mold cavity that will foam and be the polymeric foam composition <NUM> discussed herein. While not depicted, it is contemplated that after the injector <NUM> injects the polymeric foam composition <NUM>, the bottom plate raises to obscure the channel through which the polymeric foam composition <NUM> passed to reach the mold cavity. This obstruction seals the mold cavity to contain the expanding polymeric foam composition <NUM> within the mold cavity defined by the mold <NUM> and the secured upper <NUM>. As provided previously the polymeric foam composition <NUM> and the polymeric film composition <NUM> may bond, mechanically and/or chemically as the polymeric foam composition <NUM> cures in the mold cavity in contact with the polymeric film composition <NUM>.

<FIG> depicts a ground-contacting surface of the article of footwear <NUM> following the direct bottoming operation of <FIG>, in accordance with aspects hereof. Depicted is the trimmed portion <NUM> of the polymeric film composition <NUM> prior to being trimmed. Also depicted is the polymeric film composition <NUM> as exposed through the outsole apertures <NUM> of the outsole <NUM>.

<FIG> depicts a trimming operation of the polymeric film composition <NUM>, in accordance with aspects hereof. A cutting tool <NUM> is effective to cut the polymeric film composition <NUM> to spate the trimmed portion <NUM> from the sole. The cutting tool <NUM> may be any cutting tool, such as a knife, hot wire, laser, and the like. In an exemplary aspect, the cutting tool is an oscillating cutter that rests against the surface to be trimmed and cuts the material as the article is moved past the cutting portion. As the trimmed portion133 is removed, the location of the cut forms the film edge, such as the lateral film edge <NUM> in the exemplary aspect. Below the lateral film edge <NUM>, in the inferior direction, is the polymeric film composition <NUM> forming an exterior surface of the sole. Above the lateral film edge <NUM>, in the superior direction, is the lateral exposed portion <NUM>.

The trimming operation produces a crisp and definite transition between the polymeric film composition <NUM> and the polymeric foam composition <NUM>. Therefore, a painting or printing operation is avoided to provide a precise transition between the materials.

<FIG> depicts an alternative operation of inserting an insert <NUM> prior to direct bottoming the upper <NUM>, in accordance with aspects hereof. In this example, the polymeric film composition <NUM> has been formed into a liner in the mold cavity and prior to injection the polymeric foam composition <NUM>; the insert <NUM> is positioned in the mold cavity. In this example, an air bag to assist in impact attenuation and function of the sole is provided; however, as provided herein above, the insert may be a variety of materials and functions. Further, the insert may be positioned at a variety of location within the mold cavity, such as the arch, the ball region, and a combination of region. Further, as previously discussed, it is contemplated that any number of inserts of any combination of functions may be inserted into the mold cavity to be included during the direct bottoming process.

While the insert <NUM> is depicted as being placed into the mold cavity prior to positioning the upper <NUM> at the mold, it is contemplated that the insert <NUM> may alternatively be positioned at the mold with the upper <NUM>. For example, the insert <NUM> may be temporarily or permanently secured to the upper <NUM> such that when the upper <NUM> is positioned at the mold, the insert <NUM> is also positioned at the mold. In aspects, some inserts when placed in the mold cavity prior to injecting the polymeric foam composition may interfere with an injection stream of the polymeric foam composition. Similarly, some inserts, such as an air bag or foam component may float on the injected foam composition and, as a result, be repositioned prior to a solidification of the polymeric foam composition. Therefore, aspects contemplate injecting the polymeric foam composition into the lined mold cavity prior to the insertion of the insert <NUM>. The insertion may be incorporated with the positioning of the upper <NUM> or it may be a separate intervening step.

<FIG> depicts a flow diagram representing a method <NUM> of manufacturing an article of footwear, in accordance with aspects hereof. At a block <NUM> a film, such as the polymeric film composition <NUM> of <FIG>, is positioned over a mold cavity, such as the mold cavity <NUM> of <FIG>. The positioning of the film may be accomplished by a human operator or an automated machine, such as a robotic arm. The positioning may be a mere placement or it may be an alignment that provides a predefined tension or sag to the film across the mold cavity. Referring to <FIG>, <FIG>, and <FIG> provide examples of placing a film.

At a block <NUM> the film is secured over the mold cavity. Exemplary techniques for securing the film were discussed at least in connection with <FIG> herein above.

At a block <NUM> thermal energy is applied to the film. The thermal energy may be in the form of infrared energy that is effective to heat the film to an elevated temperature that is below a glass transition temperature of the film. The elevated temperature allows for sufficient elongation of the film during a drawing process into the mold cavity.

At a block <NUM> a vacuum is drawn through the mold cavity to form a liner of the mold cavity with the film. Because the film was secured in the block <NUM>, the vacuum causes a deformation of the film from a pressure differential on the opposing sides of the film. This pressure differential allows the film to be drawn into the mold cavity and conform to the mold surfaces.

At a block <NUM> a material composition, such as the polymeric foam composition <NUM> of <FIG> is injected into the lined mold cavity. As the mold cavity is a sealed environment, the material expands and forms to the mold surfaces. In addition to forming to the mold surfaces, the material mechanically engages and intermingles with materials of an upper positioned at the mold cavity, as listed at a block <NUM>. It is understood that the upper may be positioned at the mold cavity prior to injecting the material. Therefore the order of the block <NUM> and the block <NUM> may be altered in various aspects. Regardless of the order of operation, the intermingling and interaction of the foamed material and the upper, the result is a bond is formed between the upper and the now-created sole. This bond is a direct bottoming operation that eliminates, in some aspect the use of adhesive to join the upper with the sole. Instead the creation of the sole itself results in a joining of the sole with the upper.

At a block <NUM> the article of footwear formed in the preceding blocks is removed from the mold cavity. In some aspects the mold may split or otherwise open to allow for the removal of the article of footwear from the mold.

At a block <NUM> the film is trimmed from the sole such that an exposed portion (a portion of the foamed material not covered in the film) is formed between the film and the upper on the sole sidewall. This exposed portion may be at least <NUM>. The exposed portion may have a range of <NUM> to <NUM>, in exemplary aspect. The exposed portion may be in a range of about <NUM> to <NUM>. Regardless, the exposed portion provides an area for the trimming operation to occur without interference from the upper. Further, the exposed region provides an aesthetic differentiator along the sidewall while still allowing the film to provide functional advantages discussed herein above along the sidewall(s).

As can be appreciated, the methods of forming the article of footwear provided herein are conducive to custom manufacturing. For example, it is contemplated that in a continuous manufacturing process different article of footwear are produced having different characteristics. For example, a first article of footwear may have a first visual characteristic and an immediately subsequently manufactured article of footwear has a different visual characteristic. This may be accomplished by inserting an alternative film while keeping other parameters constant. The alternative film may have a different color, texture, graphic, and the like. Further, it is contemplated that a different polymeric foam composition may be used on the first article of footwear as compared to the immediate subsequent article of footwear. For example a different additive, such as a colorant, may be incorporated with the polymeric foam composition at injection. This is different from traditional shoe manufacturing that maintains an inventor of both the upper and the sole to be joined. With the contemplated direct bottoming operation, the sole is manufactured at the time of joining. As a result, the manufactured sole may be customized as needed without keeping an inventory of different soles. Beyond visual characteristics that may be customized, the function of the sole may be customized through the inclusion of one or more inserts, as provided herein.

Further, as the film, such as the polymeric film composition, is effective to cure tooling marks formed by the mold and other tools, interchangeable mold components may be used. Traditionally, an interchangeable mold portion results in a tooling mark in the formed article as a result of a transition from the mold surface to the interchangeable component surface, which can generate a line at that transition. In the contemplated methods herein, the film cures the potential tooling marking by normalizing the surface transition between the mold surface and the interchangeable component surface. It is this normalization that allows for the interchangeable portions to be exchanged in a common mold to customize the formed sole. The interchangeable component may an embossments (e.g., positive space in the molded article) or debossments (e.g., negative space in the molded article) that generate logos, graphics, textures, and the like. As a result, a continuously operating manufacturing line may produce different article of footwear through the selection of films, foams, interchangeable components in the mold, and/or the like.

Claim 1:
An article of footwear mold (<NUM>) comprising:
an inner ring mold (<NUM>) having an inner medial sidewall molding surface (<NUM>) and an inner lateral sidewall molding surface (<NUM>);
an outer ring mold (<NUM>) having an outer medial sidewall molding surface (<NUM>) and an outer lateral sidewall molding surface (<NUM>), wherein the inner medial sidewall molding surface (<NUM>) and the outer medial sidewall molding surface (<NUM>) in combination form a medial sidewall molding surface (<NUM>) of the article of footwear mold (<NUM>) and the inner lateral sidewall molding surface (<NUM>) and the outer lateral sidewall molding surface (<NUM>) in combination form a lateral sidewall molding surface (<NUM>) of the article of footwear mold;
and
a bottom plate (<NUM>) positioned between the inner medial sidewall molding surface (<NUM>) and the inner lateral sidewall molding surface (<NUM>);
characterized in that the article of footwear mold (<NUM>) further comprises a polymeric film composition securement;
wherein the polymeric film composition securement comprises a vacuum port at a top surface of the inner ring mold (<NUM>).