Patent Description:
Articles of footwear serve both functional purposes (e.g., protecting and cushioning the wearer's feet) and aesthetic purposes (e.g., for style). In addition to providing shoes that fulfill these purposes, shoe manufacturers seek to improve manufacturing efficiency. Thus, articles of footwear that can be made efficiently while still achieving the wearer's functional and aesthetic needs are desirable.

Articles of footwear with dispensed components are disclosed. The components may be formed via an automated dispensing process that is done robotically.

In some embodiments, the first continuous dispensed component forms additional layers. In some embodiments, the second layer is disposed directly on top of the additional layers. In some embodiments, the starting point is disposed at a midfoot of the sole.

In some embodiments, the sole also includes a non-dispensed component disposed within the perimeter of the sole.

In some embodiments, the upper includes a dispensed component. In some embodiments, the first continuous dispensed component is directly coupled to the upper. In some embodiments, the sole includes a substrate disposed between the upper and the first continuous dispensed component. In some embodiments, the upper includes a circular knit material. In some embodiments, the first continuous dispensed component forms additional layers.

A method of making a sole for an article of footwear is defined by claim <NUM>.

In some embodiments, the first layer is continuously dispensed onto an upper of the article of footwear. In some embodiments, the first layer is continuously dispensed onto a circular knit material disposed around a last. In some embodiments, the first layer is continuously dispensed onto another component of the sole. In some embodiments, the location is disposed at a medial edge of the sole.

<CIT> refers to a sole including one or more extruded members, which can be formed by extruding extruded member in a controlled geometric pattern. Thereby the thickness of the extruded member can be varied within a layer or from one layer to the next. This happens by changing the extruder speed or by changing the aperture size of the extruder nozzle without stopping the extruder. Further, the shape of extruded member can also be changed within a layer or from one layer to the next. The extruded member can be formed into a plurality of layers to create the sole, wherein each layer can be positioned directly on top of a preceding layer, or layers can be formed at an angle with respect to a preceding layer.

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

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

The term "invention" or "present invention" as used herein is a nonlimiting term and is not intended to refer to any single embodiment of the particular invention but encompasses all possible embodiments as defined by the appended claims.

The following examples are illustrative, but not limiting, of the present invention. Other suitable modifications and adaptations of the variety of conditions and parameters normally encountered in the field, and which would be apparent to those skilled in the art, are within the scope of the invention as defined by the appended claims.

Embodiments of the present invention provide articles of footwear having one or more dispensed components created by an automated dispensing process. It is understood that while the term "dispensed" is generally used herein to refer to certain materials, these materials may also be "extruded. " Thus, the term "dispensed component" includes components that are dispensed and components that are extruded. These dispensed components may be dispensed from a mechanical device. In some embodiments, the dispensed components are <NUM>-D printed. In some embodiments, the dispensed components are not <NUM>-D printed.

In some embodiments, an upper and/or a sole of the article of footwear may have one or more dispensed components. In some embodiments, an upper and/or a sole, or portions thereof, can be formed from one or more dispensed components. In some embodiments, the dispensed component can be a single, continuous piece of solid material. A dispensed footwear component can have advantages over traditionally-formed components, such as those made by casting, pouring, injection molding, screen-printing, or thermo-plastically forming. For example, a dispensed component can be customized without having to machine a new, expensive mold. The use of dispensed components can also allow for the use of shapes and geometries that are difficult to achieve using conventional upper or bottom molding techniques. Moreover, the data and knowledge to make a dispensed component can be quickly deployed to any location that houses equipment and material suitable for processing.

Various physical properties of the dispensed component can be manipulated, adjusted, altered, and/or modified. For example, in some embodiments, the width, length, shape, wall thickness, color, density, elasticity, material, viscosity, hardness, number of layers, etc. of the dispensed component can vary along the dispensed component or between a first and second dispensed component. As an example, a dispensed component on an upper may be less viscous than a dispensed component on a sole, which can help the dispensed component on the upper lay flat. As another example, a dispensed upper component may be rigid in a first portion, flexible in a second portion that is continuous with the first portion, and rigid in a third portion that is continuous with the second portion. The dispensed upper component may similarly vary in other characteristics, such as color or in the number of layers.

In some embodiments, the dispensed component can be made of rubber, foam (e.g., dispensed polyurethane foam), silicone, plastic including thermoplastic (e.g., polyurethane (such as TPU), nylon, or polypropylene), or any other suitable material. In some embodiments, the dispensed component can be made of a composite material. In some embodiments, the cross-section of the dispensed component can be substantially circular, oval, rectangular, triangular, square, or any other suitable shape or design (e.g., star-shaped). In some embodiments, the cross-section of the dispensed component can be relatively flat (i.e., low profile). Moreover, the cross-section of the dispensed component may be adjusted dynamically and may vary throughout the automated dispensing process.

In some embodiments, the dispensed component can be dispensed directly onto the article of footwear, such as directly onto the sole (e.g., insole, midsole, and/or outsole) or the upper. For example, the dispensed component can be dispensed directly onto a formed upper on a last (e.g., a flat knit upper, a circular knit upper, a formed three-dimensional knit, a sock, a fully-finished traditionally-lasted upper, etc.). The upper may be made of a textile fabric, leather, synthetic, or film product. In some embodiments, the dispensing or extruding is done automatically (i.e., robotically). In some embodiments, a scanner may scan the upper and then robotically dispense the dispensed component onto the upper based on the scan.

In some embodiments, the dispensed component may bond (e.g., by thermal fusion, chemical adhesion, or mechanical locking) to a portion of the article of footwear. In some embodiments, the dispensed component may form a portion of the sole of the article of footwear. In some embodiments, one or more dispensed components may form the entire sole of the article of footwear. In some embodiments, a single, continuous dispensed component forms a medial sidewall and a lateral sidewall. In some embodiments, the sidewalls each have multiple layers (all formed from the single, continuous dispensed component). In some embodiments, the layers are disposed directly on top of each other so that they are aligned with each other. In some embodiments, the continuous dispensed component has a starting point (i.e., where it is first dispensed). In some embodiments, each layer begins and ends at the starting point and the continuous dispensed component continuously dispenses to form a step up region from one layer to the next. Forming the sole with a dispensed component may provide flexibility and speed in development and manufacturing of the sole, while still meeting the functional and aesthetic purposes of the sole.

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

According to the invention, dispensed components are utilized in an article of footwear <NUM>, as shown, for example, in <FIG>. According to the invention, article of footwear <NUM> comprises an upper <NUM> and a sole <NUM>. Upper <NUM> and sole <NUM> are coupled together. In some embodiments, upper <NUM> comprises one or more dispensed components <NUM> According to the invention, sole <NUM> comprises one or more dispensed components <NUM>. In some embodiments, article of footwear <NUM> comprises both upper dispensed component(s) <NUM> and sole dispensed component(s) <NUM> (see <FIG>). However, in some embodiments, article of footwear <NUM> may include only sole dispensed component(s) <NUM> and not both.

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

Upper <NUM> may be made of a variety of materials (e.g., a textile fabric, woven or knit goods, leather, synthetic, a film product, etc.). For example, upper <NUM> may be a circular knit material. In some embodiments, upper <NUM> may be made of a combination of these materials.

At least a portion of sole <NUM> may be made with dispensed component <NUM>. Dispensed component <NUM> may provide a sole <NUM> that fulfills both functional and aesthetic purposes and can be manufactured efficiently. In some embodiments, sole <NUM> is made entirely of one or more dispensed components <NUM>.

According to the invention, first dispensed component <NUM> forms a medial sidewall <NUM> (see <FIG>). According to the invention, first dispensed component <NUM> forms a lateral sidewall <NUM> (see <FIG>). According to the invention, first dispensed component <NUM> forms a perimeter <NUM> of sole <NUM>. Perimeter <NUM> extends around the entire perimeter of article of footwear <NUM>. Periimeter. <NUM> (including medial sidewall <NUM> and lateral sidewall <NUM>) is formed by a single, continuous dispensed component <NUM>.

In some embodiments, continuous dispensed component <NUM> forms a plurality of layers <NUM>, <NUM>, <NUM>, <NUM> to form medial sidewall <NUM> and lateral sidewall <NUM>. In some embodiments, first layer <NUM> of continuous dispensed component <NUM> is dispensed directly onto a bottom surface of the upper <NUM> to form at least a portion of sole <NUM> (see <FIG> and <FIG>). In some embodiments, first layer <NUM> of continuous dispensed component <NUM> is dispensed onto a substrate <NUM> (see <FIG>). In some embodiments, subsequent layers are dispensed directly onto the previous layer. Thus, in the completed sole <NUM>, first layer <NUM> may be disposed directly on top of second layer <NUM>, second layer <NUM> may be disposed directly on top third layer <NUM>, and third layer <NUM> may be disposed directly on top of fourth layer <NUM>. In some embodiments, each of layers <NUM>, <NUM>, <NUM>, <NUM> are aligned with each other.

According to the invention, first layer <NUM> comprises a starting point at location <NUM> where first continuous dispensed component <NUM> is first dispensed.

In some embodiments, location <NUM> is disposed at a medial edge of sole <NUM>.

In some embodiments, location <NUM> is disposed at a lateral edge of sole <NUM>.

In some embodiments, location <NUM> is disposed in a midfoot <NUM> of sole <NUM>, as.

shown, for example, in <FIG>. In some embodiments, location <NUM> is.

disposed in a heel <NUM> or a forefoot <NUM> of sole <NUM>.

According to the invention, first layer <NUM> extends from location <NUM> around perimeter <NUM> of sole <NUM> until it again reaches location <NUM>. Thus, first layer <NUM> begins and ends at location <NUM>. According to the invention, first continuous dispensed component <NUM> continues to be dispensed onto first layer <NUM>, thus forming second layer <NUM>. Second layer <NUM> may follow first layer <NUM> around perimeter <NUM> of sole <NUM> until it reaches location <NUM>. For example, second layer <NUM> may be aligned with first layer <NUM>. Thus, second layer <NUM> may begin and end at location <NUM>. According to the invention, second layer <NUM> is dispensed onto first layer <NUM> so that first layer <NUM> is disposed directly on top of second layer <NUM>.

Additional layers, such as third layer <NUM> and fourth layer <NUM>, may be formed using the same dispensing process. This dispensing process forms a step up region <NUM> disposed at location <NUM>. At step up region <NUM>, continuous dispensed component <NUM> steps up from one layer to the next. Thus, multiple layers (for example, each of layers <NUM>, <NUM>, <NUM>, <NUM>) may be formed from a single continuous dispensed component <NUM>. The combined layers <NUM>, <NUM>, <NUM>, <NUM> may form both medial sidewall <NUM> (as shown in <FIG>) and lateral sidewall <NUM> (as shown in <FIG>). According to the invention, the first continuous dispensed component <NUM> forms a perimeter of sole <NUM>. According to the invention, the first continuous dispensed component <NUM> extends around a perimeter of article of footwear <NUM>.

<FIG> illustrate an example dispensing process to form sole <NUM> with continuous dispensed component <NUM>. In some embodiments, first continuous dispensed component <NUM> is dispensed directly onto upper <NUM> to form sole <NUM>. For example, in some embodiments, upper <NUM> is disposed on a last <NUM>.

In some embodiments, upper <NUM> may be a knit material, such as a circular knit material <NUM> (see <FIG>). In some embodiments, upper <NUM> comprises a flat knit material. In some embodiments, upper <NUM> comprises a woven material. In some embodiments, upper comprises a leno woven material. In some embodiments, upper comprises a mesh. Other types of materials may also be used for upper with the dispensing process.

In some embodiments, as shown, for example, in <FIG>, the component is dispensed from a nozzle <NUM>. In some embodiments, the relative position of nozzle <NUM> and upper is adjustable. In some embodiments, nozzle <NUM> is movable. In some embodiments, last <NUM> is movable. In some embodiments, both nozzle <NUM> and last <NUM> are movable. Nozzle <NUM> may be disposed at location <NUM> when it begins dispensing. In some embodiments, nozzle <NUM>, last <NUM>, or both begins to move when nozzle <NUM> starts dispensing. As the relative position of nozzle <NUM> and upper changes, nozzle <NUM> continuously dispenses first layer <NUM>, as shown in <FIG>. Any pattern may be used for first layer <NUM>. In some embodiments, the pattern of first layer <NUM> goes around the perimeter of upper to form perimeter <NUM> of sole <NUM>.

In some embodiments, nozzle <NUM> returns again to location <NUM>, as shown, for example, in <FIG>. As nozzle <NUM> passes over location <NUM>, nozzle <NUM> continues to dispense a continuous component, thus forming step up region <NUM> where continuous dispensed component <NUM> steps up from first layer <NUM> to second layer <NUM>. Thus, the transition from first layer <NUM> to second layer <NUM> may be a smooth transition without discontinuity. According to the invention, second layer <NUM> is continuous with step up region <NUM> and first layer <NUM>. According to the invention, first continuous dispensed component <NUM> continuously transitions from first layer <NUM> to second layer <NUM> at the starting point or location <NUM>.

In some embodiments, nozzle <NUM> continues to dispense component <NUM> to form second layer <NUM>, as shown, for example, in <FIG>. As discussed above, second layer <NUM> is aligned with first layer <NUM>. Thus, when article of footwear <NUM> is in use, first layer <NUM> is disposed directly on top of second layer <NUM>. Additional layers (e.g., third layer <NUM> and fourth layer <NUM>) may be formed by continuing this same dispensing process. Each transition between layers is located at step up region <NUM>, which is at location <NUM>.

A similar dispensing process may be used even when continuous dispensed component <NUM> is not dispensed directly onto upper <NUM>. For example, sole <NUM> may include a substrate <NUM> (see <FIG>) and first continuous dispensed component <NUM> may be dispensed onto substrate <NUM> in a similar manner as the process described with respect to <FIG>. As shown in <FIG>, in some embodiments, substrate <NUM> is disposed between upper and first continuous dispensed component <NUM>.

This dispensing process forms an aesthetically pleasing sole. Other than step up region <NUM>, each layer <NUM>, <NUM>, <NUM>, <NUM> appears to be a distinct layer separate from other layers, giving sole <NUM> a clean look, as shown, for example, in <FIG>. Even at step up region <NUM>, because each layer steps up together, sole <NUM> maintains a clean look, as shown, for example, in <FIG>.

According to the invention, sole <NUM> comprises at least two additional components <NUM> in addition to first dispensed component <NUM>, as shown, for example, in <FIG> and <FIG>. According to the invention, additional components <NUM> are disposed within perimeter <NUM> (e.g., between medial sidewall <NUM> and lateral sidewall <NUM>), as shown, for example, in <FIG>. In some embodiments, additional component <NUM> is a non-dispensed component. According to the invention, as in <FIG>, additional component <NUM> is a dispensed component. According to the invention, sole <NUM> includes an additiona, or second, component <NUM> that is formed with a dispensed component in a similar manner as described above with respect to continuous dispensed component <NUM>, but is dispensed within continuous dispensed component <NUM>, as shown in <FIG> and <FIG>. For example, sole <NUM> in <FIG> and <FIG> includes additional component <NUM> that follows along an interior side of continuous dispensed component <NUM>, thus forming a smaller version of medial sidewall <NUM> and lateral sidewall <NUM> within perimeter <NUM>. In some embodiments, additional component <NUM> may be dispensed with a different pattern than continuous dispensed component <NUM>. According to the invention, as shown in <FIG> and <FIG>, sole <NUM> may include a further, or third, additional component <NUM> disposed in forefoot <NUM>. Although additional component <NUM> may have a different pattern, the formation of layers may be the same as continuous dispensed component <NUM>. Additional components <NUM> may function to provide additional support for the wearer.

In some embodiments, sole <NUM> comprises an outsole <NUM>. In some embodiments, outsole <NUM> comprises a non-dispensed component. In some embodiments outsole <NUM> comprises a dispensed component <NUM>. In some embodiments, outsole <NUM> may be formed with the same continuous dispensed component <NUM> that forms layers <NUM>, <NUM>, <NUM>, <NUM>. In some embodiments, even where outsole <NUM> is the same continuous dispensed component <NUM> that forms layers <NUM>, <NUM>, <NUM>, <NUM>, at least one characteristic of dispensed component is different for outsole <NUM> than for the other layers <NUM>, <NUM>, <NUM>, <NUM>. For example, outsole <NUM> may be a different color, viscosity, density, thickness, etc., or a combination of these characteristics. In some embodiments, outsole <NUM> is disposed on continuous dispensed component <NUM> and additional components <NUM> (see <FIG>). In some embodiments, outsole <NUM> includes multiple, distinct pieces. For example, outsole <NUM> may include a first piece that is disposed on continuous dispensed component <NUM> and an additional component <NUM> and a second piece that is disposed only on a different additional component <NUM>. In some embodiments, outsole <NUM> includes only a single piece.

Various embodiments described herein provide an article of footwear that protects and cushions the wearer's foot, while also fulfilling aesthetic purposes. Moreover, manufacturing this article of footwear is efficient. Further variations of the embodiments described above may also be provided in accordance with the appended claims.

The foregoing description of the specific embodiments will so fully reveal the general nature of the invention that others can, by applying knowledge within the skill of the art, readily modify and/or adapt for various applications such specific embodiments, without undue experimentation, without departing from the general concept of the present invention. It is to be understood that the phraseology or terminology herein is for the purpose of description and not of limitation, such that the terminology or phraseology of the present specification is to be interpreted by the skilled artisan in light of the teachings and guidance.

Claim 1:
A sole (<NUM>) for an article of footwear, the sole comprising:
a first continuous dispensed component (<NUM>) forming a first layer (<NUM>) and a second layer (<NUM>);
wherein the first layer (<NUM>) is disposed directly on top of the second layer (<NUM>),
wherein the first continuous dispensed component forms a perimeter of the sole, the perimeter of the sole forming a medial sidewall (<NUM>) and a lateral sidewall (<NUM>),
wherein the first layer (<NUM>) comprises a starting point where the first continuous dispensed component (<NUM>) is first dispensed,
wherein the first layer is a top layer of both the medial sidewall and the lateral sidewall and extends entirely around the perimeter of the sole, and
wherein the first continuous dispensed component (<NUM>) continuously transitions from the first layer (<NUM>) to the second layer (<NUM>) at the starting point;
a second dispensed component (<NUM>) disposed within the perimeter of the sole (<NUM>) and following along the entire interior side of the first continuous dispensed component (<NUM>); and
a third dispensed component (<NUM>) disposed within the second dispensed component (<NUM>) and in a forefoot (<NUM>) of the sole (<NUM>).