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.

Document <CIT> describes an article of footwear including one or more first fluid containing cushion devices in direct or elastomeric load transmit-ting contact with a foot to provide superior comfort. One or more second, preferably thicker, fluid containing cushion devices are positioned in a load transmitting portion of the sole, between the foot and ground engaging surface of the footwear. The first cushion devices) at least partially overlap a portion of the second cushioning devices) and the two cushion devices are at least partially separated in any overlapping areas by a load distributing element.

Document <CIT> describes an integrated article of footwear including a waterproofing membrane direct attached to an upper of the footwear. An outsole is further secured to the membrane and/or the upper. In one embodiment, the membrane includes a visible aesthetic bead in the footwear forefoot region, but not the heel region. The membrane may be of greater thickness in the forefoot region to provide added rigidity. A heel cradle is positioned in the footwear heel region between the upper and the outsole. The footwear provides the durability of a direct attach construction in the forefoot and the comfort and cushion of an athletic construction in the heel of the shoe. A method for constructing the footwear includes direct attaching the membrane to an upper of the shoe. Optionally, a heel cradle is disposed in the heel region of the shoe, and the outsole is secured to the heel cradle and/or upper there.

Document <CIT> describes a method for producing shoes with shortened forming time, comprising using a first mold to produce a base, mean-while mounting a shoe upper unit on a shoe tree for soling; mounting the base in a second mold and filling the recessed part of the base with a plastic material to form a low density filling layer; sequentially mounting the base having a filling layer and the shoe tree having a shoe upper unit in a third mold; after closing the mold, filling a material solution into the mold cavity so that an inner base is formed be-tween the base, the filling layer and the shoe upper unit after completion of chemical reactions; and opening the mold to obtain a shoe.

Particular embodiments of the claimed invention are defined by the dependent claims.

The present invention is 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). While the present application is directed to an article of footwear, the term "shoe" will be used herein for simplicity. 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 attach (or sometimes referred to as direct bottoming) is provided. Direct attaching, 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 attaching 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. Therefore, when an insert, such as an airbag, is to be included in the direct attach footwear, the insert is present during the direct attach process. Examples herein provide for an insert that remains visible to an external observer of the sole while the insert is an integral portion of the sole. In some examples, the insert is an airbag that provides impact attenuation and other physical characteristics that different from the polymeric foam composition forming other portions of the sole. As a result, insert forms a portion of the sidewall of the sole while the polymeric foam composition forms another portion of the sole sidewall.

Aspects hereof contemplate forming an article of footwear through a direct bottoming process that includes an insert in the sole that forms a portion of the externally visible sole sidewall.

Specifically, turning to <FIG> that depicts an exemplary article footwear <NUM> and <FIG> that depicts a cross section of the article of footwear <NUM> along cutline <NUM>-<NUM> from <FIG>. 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 sidewall formed from 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 engaged with the upper plantar region <NUM>. The sole is also comprised of an insert <NUM> forming at least a portion of the medial sidewall <NUM> and/or the lateral sidewall <NUM>.

As provided herein, an insert <NUM> is a pre-formed component that is not molded as part of the direct-attach process, but instead captured, at least in part, by the direct-attached process forming a shoe. An example of an insert is an airbag. An airbag is a structure having a core containing a volume. The volume may have a pressure differential relative to ambient pressure. For example, an airbag may be formed from a polymer composition film to enclose an internal volume that is pressurized above ambient pressure, such as above <NUM> atmosphere (atm). Stated differently, an airbag maintains a volume that is maintained above atmospheric pressure. It is contemplated that an insert may be other containers, such as an airbag that also includes tangible materials. The tangible materials may be solid elements (e.g., foamed beads), fluids (e.g., liquid, gel), and/or other fillers contained in a volume, such as a bag similar to an airbag or in a molding volume formed, at least in part, through a mold used in the direct attach process. Further, an insert may be a stability element, a support element, a spring element, a traction element (e.g., cleat), and/or other supplemental component effective to enhance a sole for an article of footwear.

The insert forms a portion of a sidewall when the insert is external visible as a portion of the sole sidewall. Stated differently, the insert forms an external surface of the sole sidewall. As will be discussed in greater detail hereinafter, the insert is able to form a portion of a sidewall of the sole through the direct attach process by positioning the insert against a molding surface of a mold used during the direct attached process prior to injecting a polymeric composition, such as a polymeric foam composition. The contact between the insert and the molding surface prevents the injected polymeric composition from encasing the insert completely and therefore allowing the insert to form at least a portion of the sole sidewall external surface.

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> may also include an outsole <NUM>. As will be described in greater detail herein, the outsole <NUM> may be formed in a continuous direct attach process. Alternatively, the outsole may be inserted into a mold cavity used for forming the polymeric foam composition <NUM> for direct attach to the upper <NUM>. In yet further examples, the injected polymeric foam composition <NUM> may form the outsole without additional/alternative materials forming a ground-contacting material. Further yet, the insert <NUM> may form at least a portion of a ground-contacting surface to supplement or eliminate a separate outsole. As used herein, a ground-contacting surface and a ground-facing surface are not always equivalent. The ground-contacting surface is a surface intended to form an interaction with the ground. A ground-facing surface is similarly orient as a ground-contacting surface, but a ground-facing surface may contact intervening materials of the sole prior to the grounds. For example, a traditional midsole has a ground-facing surface that interfaces, at least in part, with an outsole. The outsole in this example has a ground-facing surface that is also the shoe's ground-contacting surface.

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 example, the polymeric foam composition is a polyurethane ("PU") composition. The PU may be chemically foamed or mechanically foamed during a 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 a polymeric composition <NUM> (as seen in <FIG>, for example) of an outsole 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 PU as the polymeric composition <NUM>.

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 example, 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 examples, 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 and/or flowable 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 foam composition and the upper as the polymeric foam 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 attach 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 composition <NUM> to join the two compositions. As such, it is contemplated that the polymeric foam composition <NUM> and the polymeric composition <NUM> are selected to have a sufficient chemical bonding affinity to resist delamination.

The insert <NUM> is contemplated as being formed from a material to which the polymeric foam composition <NUM> has sufficient bonding affinity to prevent a delamination between the insert <NUM> and the polymeric foam composition <NUM>. For example, the insert <NUM> may be formed having a surface with thermoplastic polyurethane (TPU) that bonds sufficiently with a PU composition forming the polymeric foam composition <NUM>. Further yet, in examples where an outsole is also formed during a direct attach process, a sufficient bonding affinity between the insert <NUM> and the polymeric composition <NUM> is selected. In this example, if the polymeric composition <NUM> forming the outsole <NUM> is a PU, then a TPU (or PU) material forming the insert <NUM> may be selected. In some examples, the insert is an airbag that is formed from a polymeric film. The polymeric film may be a laminated composite comprising a plurality of polymeric compositions. An exterior layer of the laminate composition may be formed from a material (e.g., TPU) to which a sufficient bonding affinity with one or more of the polymeric foam composition <NUM> and/or the polymeric composition <NUM> exist. The insert may be formed from other materials. For example, an insert may have a mechanical engagement portion, such as an aperture or other physical element that aid in securement to one or more of the polymeric foam composition <NUM> and/or the polymeric composition <NUM>.

The insert <NUM> may be located at any position of the sole <NUM>. In the example of <FIG>, the insert <NUM> is an airbag positioned in the heel end <NUM> and exposed on the sidewalls, such as the lateral sidewall <NUM>. The insert <NUM> extends toewardly from the heel end <NUM> to form a sole insert supporting a wearer's heel. The airbag may be pressurized to a sufficient level to provide impact attenuation and resilience to wearer impact forces. If the wearer has a heel strike in the shoe, where the heel end <NUM> make initial contact with the ground, the insert <NUM> enhances the ability of the shoe to absorb and respond to that impact. Similarly, depending on an intended use of the insert, it is understood that the insert may form any portion of the sole <NUM>. For example, the insert may be in a toe end, a medial side, a lateral side, and any combination thereof. Further, the insert may extend the whole length or width of the sole <NUM>.

<FIG> depicts a cross section of the article of footwear <NUM>. The upper <NUM> and the sole <NUM> are illustrated. The sole <NUM> is formed from the polymeric foam composition <NUM>, the insert <NUM>, and the outsole <NUM>.

As depicted in <FIG>, the insert <NUM> is vertically positioned between the polymeric foam composition <NUM> and the outsole <NUM>. The insert <NUM> is, however, forming a portion of both the medial sidewall <NUM> and the lateral sidewall <NUM>. Also depicted, the insert <NUM> forms an internal cavity <NUM>. The internal cavity <NUM> is a volume containing pressurized gas, such as pressurized nitrogen, above <NUM> atm (i.e., <NUM> pounds per square inch ("Psi")), above <NUM> Psi, or above <NUM> Psi. The internal cavity <NUM> is an enclosed volume effective to maintain for a prescribed period of time the pressurized gas. In other examples, the internal cavity <NUM> is filled with additional materials, such as foam beads, liquids, gels, and the like. Alternatively, an insert may not include an internal cavity, but instead may be a solid or semisolid component.

The outsole <NUM> is bonded with the insert <NUM>. The outsole <NUM> may be bonded through chemical and/or physical bonds, as discussed previously. As will be depicted in the <FIG>, one method of bonding the outsole <NUM> with the insert <NUM> is through contacting the outsole <NUM> with the insert <NUM> prior to the outsole <NUM> fully curing from a molding operation. Prior to a complete cure, the outsole <NUM> adheres with the insert <NUM> to couple the insert <NUM> and the outsole <NUM>. In alternative examples, an adhesive, such as a glue, may be applied to one or more of the insert <NUM> and/or the outsole <NUM> to form a bond there between.

As used herein, the term "couple" or derivations thereof (e.g., coupled) refer to elements that join, bond, attach, bind, connect, and/or unite. Therefore, when a first element is coupled with a second element, the first and second elements are permanently or temporarily joined as a physical unit. The coupling between two elements may be accomplished through mechanical connections and/or chemical adhesion. Two elements may be coupled through a manufacturing process (e.g., application of heat, application of pressure), through supplemental materials (e.g., glue, adhesive), through material state modification (e.g., connection due to curing, welding, melting), and the like. The coupling of two elements includes an engagement between the elements. Ann engagement is the coupling, through at least a physical contact, between the two elements. Ann engagement does not solely rely on a mechanical bond, but instead may also include or exclusively include a chemical bond between the elements engaged. In examples provided herein, an engagement results when a yet-to-be-cured polymeric foam composition contacts an upper material. The polymeric foam composition physically interacts (e.g., infiltrates, intermingles, contacts, encapsulates, seeps) with the upper to form an engagement. A directed attach sole is attached to an upper without additional adhesives used to join the upper and the sole. Stated differently, a direct attach generally does not use an adhesive to join an upper and sole, but instead, relies on the engagement created by injecting a polymeric foam composition into contact with the upper. While some direct attach soles are engaged with the upper through a mechanical connection between the polymeric foam composition and the upper, other direct attach soles are engaged with the upper through a chemical bond.

The polymeric foam composition <NUM> is depicted as extending between the upper <NUM> and the insert <NUM>. In this example, the polymeric foam composition <NUM> may serve a joining material between the upper <NUM> and the insert <NUM>. Further, in this example, the polymeric foam composition <NUM> forms an upper-facing surface <NUM>. The upper-facing surface <NUM> is a surface that interacts with the plantar region <NUM> of the upper <NUM> to form a coupling there between.

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 examples 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.

<FIG> depicts a first exemplary cross section of a mold <NUM>, in accordance with aspects of the method according to the claimed invention. The mold <NUM> is comprised of a top platen <NUM> (also referred to as a top plate herein) having a top platen molding surface <NUM>. The mold <NUM> is also comprised of a bottom plate <NUM> having a first molding surface <NUM> (also referred to as a bottom plate molding surface). The mold <NUM> forms a mold cavity <NUM>. The mold cavity, at this stage of the operation, is defined by the top platen molding surface <NUM>, the first molding surface <NUM>, and second molding surface <NUM> (also referred to as sidewall molding surfaces). Also depicted in the mold <NUM> is a single runner, a first runner <NUM>. A runner is a channel through which molding material passes to the mold cavity <NUM>. In an example, an injector <NUM> (e.g., as seen in <FIG> hereinafter) delivers and injects a molding materials (e.g., the polymeric foam composition <NUM> and the polymeric composition <NUM>) in the mold cavity <NUM>. The first runner <NUM> terminates at the mold cavity <NUM> with a first runner port <NUM> on the second molding surface <NUM>.

The top platen <NUM> is moveable in a vertical direction. As will be illustrated in <FIG>, the top platen <NUM> may be positioned by one or more mechanisms, such as a robotic arm. The vertical movement allows for the insertion, removal, and relative positioning of the top platen <NUM> within the mold cavity <NUM>. The top platen is a tooling that positions and delivers an insert for incorporation into a sole formed through a direct attach process. The top platen may also serve as a molding surface against which an outsole is partially molded. The bottom plate <NUM> is also depicted as moveable in a vertical location. The movement of the bottom plate <NUM> is illustrated in <FIG> hereinafter for positioning a molding surface, a material, or and insert appropriately for a direct attach process. The mold <NUM> is illustrated in simplified terms for purposes of description. It is contemplated that the mold <NUM> may be formed with any size, shape, and/or configuration. In use, the top platen molding surface <NUM> may be formed with a variety of curved surfaces or other features to appropriately mold an outsole or other component with an insert.

<FIG> depicts a second exemplary cross section of a mold <NUM>, in accordance with aspects of the method according to the claimed invention. A difference between the mold <NUM> of <FIG> and the mold <NUM> of <FIG> is a number of runners in the molds. The mold <NUM> is comprised of the first runner <NUM> and a second runner <NUM>. The second runner terminates in the mold cavity at a second runner port <NUM>. It is contemplated that in use any number of runners may be used. A different runner for each material to be injected is contemplated. A common runner for all different materials to be injected is also contemplated. Further, multiple runners for a common material to be injected is contemplated. The size, shape, and/or configuration of the runners may be adjusted and merely an example for purposes of illustration.

As will be highlighted in <FIG> hereinafter, the mold <NUM> having two runners allows for the polymeric composition forming the outsole to be injected through the second runner <NUM> at a position below the insert and the first runner <NUM> is used to inject the polymeric foam composition above the insert to form the cross section of a shoe depicted in <FIG>. However, as will be appreciated, it is contemplated that movement of the top platen <NUM> and/or the bottom plate <NUM> may be effective to position the insert appropriately relative to a single runner configuration to achieve the cross section of a shoe depicted in <FIG>.

<FIG> depict a series of steps for direct attaching a sole containing an insert to a lasted shoe upper in accordance with the claimed invention. The sequence of steps is illustrative in nature and is not limiting. It is contemplated that additional and/or alternative steps may be implemented. Further, the shape, size, and positioning of depicted elements is illustrative in nature and may instead reflect specific models and sizes of footwear being manufactured in reality.

<FIG> depicts the mold <NUM> receiving the top platen <NUM> having attached thereto the insert <NUM> by a mask <NUM>, in accordance with aspects of the method according to the claimed invention. The top platen <NUM> may be positioned by the molding machine and/or by a robotic mechanism, such as a robotic arm. As such, the insert <NUM> may be secured to the top platen <NUM> by an operator clear of the mold <NUM> structure. Once the insert <NUM> is secured to the top platen <NUM> by an operator (or machine), the top platen <NUM> is positioned in the mold <NUM> to form, at least in part, the mold cavity.

The insert <NUM> is secured to the top platen <NUM> for positioning in the mold cavity. The securement of the insert <NUM> may be accomplished using a variety of techniques, such as compression, adhesion, magnetism, clamps, and the like. <FIG> depicts a mask <NUM> for securing the insert <NUM> to the top platen <NUM>. The mask <NUM> is a U-shaped component that surrounds the sidewall forming portions of the insert <NUM>. The mask <NUM> may engage with a portion of the insert, such as an edge, a flange, an aperture, a surface, or the like to secure the insert <NUM> with a portion of tooling, such as the top platen <NUM>. In the present example, an outsole material will be injected into the mold cavity and intended to engage with a ground-facing portion of the insert <NUM>. As a result, the mask does not interfere with or obstruct the ground-facing surface of the insert <NUM> from contacting the to-be injected material. Instead, the mask <NUM> engages with the surfaces of the insert <NUM> forming the heel end and/or sidewalls to maintain the insert <NUM> to the top platen <NUM>. The mask <NUM> is secured, in this example, to the tooling through magnetism. For example, a mask magnet <NUM> is incorporated in the mask <NUM>. The mask magnet <NUM> is oriented to have a magnetic attraction with the top platen <NUM>. The top platen <NUM>, in this example, includes a top magnet <NUM> that is oriented to have a magnetic attraction to the mask magnet <NUM>. The top magnet may be integrated (e.g., embedded) and secured into the top platen <NUM>. The magnetic attraction between at least the top magnet <NUM> and the mask magnet <NUM> provides a securing force to maintain the mask <NUM> and associated insert <NUM> in connection with the top platen during a positioning process of a direct attach operation. It is understood that any number of magnetic elements may be implemented in the mask <NUM> and/or the top platen <NUM>.

Further, it is contemplated that the positioning of the mask magnet <NUM> relative to the mask <NUM> is effective to position and align the mask <NUM> with a corresponding portion of the top platen <NUM>. The positioning, alignment, and orientation that is guided by the magnetic attraction is consequently effective to align, position, and orient the insert <NUM> relative to the top platen <NUM>, which as a result align the insert <NUM> with the mold <NUM> as a whole. Further, it is contemplated that one or more features (e.g., recesses, protrusions) are formed in the top platen <NUM> that correspond with features of the insert <NUM> that are to be positioned adjacent thereto. These features of the top platen may aid in alignment, positioning, and orientation of the insert <NUM> relative to the top platen <NUM>.

The mask <NUM> is effective to serve as a gasket, seal, or other barrier to prevent the spread of the polymeric foam composition or polymeric composition around the insert proximate the molding surfaces of the mold <NUM>. The mask <NUM> is effective to mask a surface of the insert <NUM> from injected materials. The mask <NUM> is effective to contain injected materials from extending between the insert <NUM> and a molding surface of the mold <NUM>. For example, to form a visible insert on the article of footwear sole sidewall, the mask <NUM> is positioned on the insert <NUM> prior to injecting the polymeric foam composition. After the curing (or at least partial curing) of the polymeric foam composition to form a portion of the sole, the mask <NUM> is removed from the insert <NUM> to expose the insert <NUM> as forming a portion of the sole sidewall without the polymeric composition obscuring the insert <NUM> at the sole sidewall. The mask <NUM> is therefore an effective tooling component to protect a surface of the insert <NUM> from injected material and to potentially prevent migration of the injected material between the insert <NUM> and the molding surface to limit cross-contamination between different injected materials.

The mask <NUM> may be formed from any material. The mask <NUM> may be formed from a polymer-based material. Further, it is contemplated that the mask <NUM> is compliant and resilient in nature. For example, the mask <NUM> may be sized to compress a portion of the insert <NUM>, such as to compress the surfaces masked by the mask <NUM>. This scaled sizing allows for a mechanical compression securement between the insert <NUM> and the mask <NUM>. To apply and remove the mask <NUM> from the insert <NUM>, the mask may comply (e.g., distort) to fit around/on the insert. Additionally or alternatively, the insert itself may comply with the mask to create a removable mechanical compression securement there between. In a specific example, the insert is an airbag for a shoe sole, where the airbag forms about <NUM> degrees of the heel end sole sidewall. A mask is formed from a polymer material to mask the surface of the insert forming the about <NUM> degrees of sidewall. The mask is sized to cover the surface of the insert while creating a compressive force on the insert. Following injection of a midsole forming polymeric foam composition, the mask is removed to expose the insert forming about <NUM> of the sole sidewall. Without the mask, the injected polymeric foam composition may obscure the insert and prevent the insert from forming the sole sidewall, at least in part. As such, the shape and size of the mask will change to accommodate the insert and/or the intended sole.

Further, the mask <NUM> is illustrated as extending below a bottom surface of the insert <NUM> for illustration purposes. However, in practice, a mask, such as the mask <NUM> may not extend above and/or below the insert being masked. Further, it is contemplated that a portion of the insert sidewall immediately adjacent a top surface and/or a bottom surface is not masked by the mask to allow for a coverage of injected polymeric foam composition. As previously discussed, the tooling is illustrated in simplistic form for purposes of the present disclosure and ease of comprehension, but in use, the tooling may have non-planar surfaces that accommodate and fit to the elements inserted into the mold cavity, such as the insert and/or the mask. For example, instead of the depicted mask <NUM> extending below a bottom surface of the insert <NUM>, the mask <NUM> may terminate at or before the bottom surface of the insert <NUM>. A raised portion of the bottom plate <NUM>, such as on the first molding surface <NUM>, may protrude to serve as a physical barrier to the injected outsole polymeric composition from extending past a heel end of the insert <NUM>. Stated differently, in practice, the mask exclusively covers a portion of the insert sidewall without extending beyond a top surface or bottom surface of the insert. The first molding surface <NUM> may instead limit the outsole material from extending in a heelward direction past the heel end of the insert. Similarly, if the insert is positioned in other location of the article of footwear, the mask and the molding surface may work in any combination to control and limit the distribution of the injected materials to intended locations.

While the mask is depicted as a U-shaped element, it is understood that the mask may have any shape to serve as an effective mask for a portion to be masked. For example, the mask may be linear, curved, dimensional, planar, or the like. Further, the mask may be configured to self-secure to a component or the mask may be configured to be secured to other tooling (e.g., mold), or secure to the component through additional securements (e.g., clips, pins, adhesive, mechanical engagement). Therefore, the mask may be any size, shape, and configuration.

<FIG> depicts the mold <NUM> with the top platen <NUM> positioning the insert <NUM> in the mold cavity to be received by the injected polymeric composition <NUM> forming the outsole <NUM>, in accordance with aspects of the method according to the claimed invention. As previously discussed, the top platen <NUM> may be positioned by a robotic element, a portion of the molding machine, and/or manually positioned by an operator. The positioning of the top platen <NUM> in the mold <NUM> positions the insert <NUM> along the second molding surface <NUM> allowing for the insert <NUM> to form a portion of a sidewall of the formed shoe. When stated herein that the insert contacts a molding surface (e.g., second molding surface) that one or more intermediate materials not specific to the insert <NUM> may be positioned between the insert <NUM> and the molding surface. For example, the material may be a mold release agent, a securing mechanism, a spacer, a gasket, and the like. For example, the mask <NUM> may extend between the insert <NUM> and the second molding surface <NUM>, but it is still considered that the insert <NUM> contacts the second molding surface <NUM> as other materials to be molded will not contact the portion of the second molding surface <NUM> adjacent the mask <NUM>. Stated differently, the insert <NUM> forms an exterior surface of the sole when it "contacts" the molding surface. Therefore, physical connection between the molding surface and the insert is not necessary for the insert to contact the molding surface so long as the insert is positioned in the mold to form an externally visible portion of the footwear sole sidewall.

In the examples of <FIG>, an outsole is formed in the mold <NUM> as part of the direct last process; however, it is contemplated that the outsole is separately formed and attached to the polymeric foam composition responsible for the direct attach coupling at a later time or during the direct attach process. As depicted in <FIG>, the polymeric composition <NUM> is injected into the mold cavity <NUM> through the first runner port <NUM>. The polymeric composition <NUM>, as previously described, may be any polymer-based composition. While the polymeric composition <NUM> is depicted in a liquid-like state (e.g., flowing condition), it is contemplated that the polymeric composition could be in any state, such as pellets, powder, formed, and the like. It is contemplated that the polymeric composition <NUM> is a foamed composition or a non-foamed composition. The polymeric composition <NUM> when cured may be flexible (e.g., rubber-like outsole) or at least partially rigid (e.g., cleat-like structure).

The polymeric composition <NUM> is injected into the mold cavity <NUM> and contacts the first molding surface <NUM> of the bottom plate <NUM>. The first molding surface, while depicted in a planar configuration for illustrative purposes, is contemplated to have a complex surface suitable for forming elements of an outsole. For example, the first molding surface may have indentations that form a tread structure (e.g., lugs) that will serve as a ground-contacting surface for the formed shoe. Additionally, while the outsole <NUM> is depicted as extending across the entire bottom plate <NUM>, it is contemplated that the polymeric composition <NUM> may only be deposited (e.g., injected) onto portion of the first molding surface <NUM>. For example, the polymeric composition <NUM> may form an outsole structure at the heel end and/or the toe end. Alternatively, the polymeric composition <NUM> may only form an outsole in the toe and as the insert <NUM> may serve as a ground-contacting surface in the heel end. The insert <NUM>, as previously discussed, may be positioned at any location of the article of footwear sole and therefore may serve as a ground-contacting portion of the sole at any location of the sole. In this example, the polymeric composition <NUM> may be deposited onto the first molding surface <NUM> in locations other than where the insert <NUM> is positioned opposite. The selective placement of the polymeric composition <NUM> may be accomplished through intentional structures formed with the first molding surface <NUM> to direct and collect the polymeric composition <NUM> for curing as a selectively formed outsole portion.

<FIG> depicts the bottom plate <NUM> moving in a vertical direction within the mold to position that allows for physical interaction between the polymeric composition <NUM> and the insert <NUM>. The positioning of the bottom plate <NUM> and the associated first molding surface <NUM> may be accomplished through the movement of the bottom plate <NUM> and/or the movement of the top platen having the insert <NUM> secured thereto. In an aspect, the bottom plate <NUM> moves such that at least the first molding surface <NUM> moves past the first runner port <NUM>, as depicted in <FIG>. The positioning of the first molding surface above (from a position originally below) the first runner port <NUM> allows for the severing of material from the first runner port <NUM> following the injection of the polymeric composition <NUM>. This severing of the material limits tooling marks as the material cures.

The positioning of the polymeric composition <NUM> in contact with the insert <NUM> occurs while the polymeric composition <NUM> is capable of forming a bond with the insert <NUM> to couple the polymeric composition <NUM> with the insert <NUM>. For example, prior to the polymeric composition <NUM> achieving a full cure, the polymeric composition <NUM> and the insert contact one another to form a coupling as the polymeric composition achieves a cure. The insert <NUM>, as previously discussed, may be formed from a material to which the polymeric composition <NUM> has an affinity for forming a bond. For example, if the polymeric composition <NUM> is a PU-based material, the insert <NUM> may be a TPU-based material, at least in part. In this example, PU and TPU have a relatively strong affinity for forming a coupling there between.

The positioning of the bottom plate <NUM> in proximity of the insert <NUM> also allows for the mask magnet <NUM> to be attracted to a bottom plate magnet <NUM>. This attraction of the mask magnet <NUM> and the bottom plate magnet <NUM> allows for the release of the mask <NUM> from the top platen <NUM>. The release occurs, in this example, through an offsetting magnetic attraction between the mask magnet <NUM> and the bottom plate magnet <NUM> relative to the magnetic attraction between the mask magnet and the top magnet <NUM>. Further, an adhesive effect the polymeric composition <NUM> has on the contacted insert <NUM> overcomes the maintaining force of the insert <NUM> to the top platen <NUM>, as will be depicted in <FIG> hereinafter.

The top platen <NUM> may remain in the mold for a prescribed period of time to serve as a molding surface for the outsole <NUM> as the material cures. Further, the top platen may remain in the mold for a prescribed period of time until a sufficient coupling occurs between the insert <NUM> and the outsole <NUM>. In the alternative, the top platen <NUM> may be removed from the mold immediately after the insert <NUM> contacts the outsole <NUM> and is transferred to the outsole <NUM>.

<FIG> depicts the top platen <NUM> being removed from the mold <NUM> after depositing the insert <NUM> to be coupled with the outsole <NUM>, in accordance with aspects of the method according to the claimed invention. Additionally, the bottom plate is depicted as being positioned such that the insert <NUM> is below the second runner port; however, it is contemplated that the removal of the top platen <NUM> and the positioning of the bottom plate may be decoupled and independent operations.

<FIG> depicts the upper <NUM> on a last <NUM> being positioned in the mold and the polymeric foam composition <NUM> being injected into the mold, in accordance with aspects of the method according to the claimed invention. In this example, the polymeric foam composition is injected into the mold between the lasted upper <NUM> and the insert <NUM>. However, it is contemplated that the relative positioning may be different for alternative implementations. Having the polymeric foam composition <NUM> inserted into the mold at a position between the insert <NUM> and the plantar region <NUM> of the upper <NUM> allows for the polymeric foam composition to be positioned between the outsole <NUM> and the upper <NUM> to serve as a direct attach material for the shoe. Additionally, by positioning the insert <NUM> below the injection location, the insert <NUM> does not interfere with the injection of the material, in at least this example. A prescribed amount of the polymeric foam composition is injected into the mold, such that after the foaming processes completes and the polymeric foam composition is cured, the intended density, fill, and molded characteristics are achieved by the polymeric foam composition.

<FIG> depicts the sole being positioned relative to the upper <NUM> so that the polymeric foam composition130 mechanically engages with the upper <NUM>. The mechanical engagement may occur through the positioning and/or through an expansion of the polymeric foam composition <NUM> as a foaming reaction occurs. As the polymeric foam composition <NUM> cures while in contact with the upper <NUM>, the direct attach process couples the sole and the upper <NUM> without additional adhesives. The mechanical engagement between the polymeric foam composition <NUM> and the upper <NUM> provides a mechanical coupling and/or chemical coupling to join the sole and the upper <NUM>. The movement of the bottom plate <NUM> additionally allows for the severing of material extending from the second runner used to inject the polymeric foam composition <NUM>. The severing of the material aids in limiting tooling marks on the cured article, in an example aspect.

The polymeric foam composition <NUM> extends along the entire upper plantar region <NUM> of the upper <NUM>. In this arrangement, the polymeric foam composition serves as both a binder of sole elements (e.g., insert <NUM>, outsole <NUM>) to the upper <NUM> and as an impact attenuating layer of the sole. Specifically, the polymeric foam composition <NUM> extends between the insert <NUM> and the plantar region <NUM> to couple the insert <NUM> and the upper <NUM>. In alternative examples, it is contemplated that the insert <NUM> includes an adhesive or other bonding agent to directly couple to the upper <NUM> in the absence of the polymeric foam composition <NUM>.

As seen in the toe end of <FIG>, the bottom plate <NUM> could include contouring that provides a traditional molding surface to form a traditional sole profile. However, for illustrative purposes, the elements of <FIG> have been simplified.

Following the mechanical engagement of polymeric foam composition <NUM> and the upper <NUM>, the polymeric foam composition <NUM> may be allowed to cure for a prescribed time. The curing of the material allows for the molded surfaces to be maintained while also ensuring a coupling between elements is sufficient to prevent a decoupling from occurring. Following the prescribed curing time, the article may be removed from the mold <NUM> as a formed article of footwear having a direct attached sole with a visible insert formed in the sole.

<FIG> depict a more illustrative perspective of the previously discussed steps of <FIG>. Specifically, <FIG> depicts the top platen <NUM> having the insert <NUM> secured thereon by way of the mask <NUM>, in accordance with aspects of the method according to the claimed invention. The robotic element <NUM> is effective to position the top platen <NUM> in the mold <NUM>, as depicted in <FIG>. As seen in <FIG>, it is contemplated that the mold <NUM> is a ring mold that splits along the cross section depicted in <FIG>. The ring mold separates to allow for the positioning of the top platen <NUM> having the insert <NUM> and the mask <NUM>, as seen in <FIG> and for receiving the upper <NUM> on the last <NUM>, as seen in <FIG>. As the ring mold closes around the inserted elements, a seal may be formed between a portion of the inserted elements (e.g., the mask <NUM>, the insert <NUM>, the top platen <NUM>, the upper <NUM>, and/or the last <NUM>). Forming a seal contains an injected material to a portion of the mold cavity for which it is intended. For example, the mold <NUM> closing around the top platen <NUM> and the mask <NUM> in <FIG> prevents blow past of the polymeric composition during the forming of an outsole. Blow past is the unintended spreading of the polymeric composition around the insert <NUM>. Similarly, the closing of the mold <NUM> around the upper <NUM> in <FIG> while the insert and the mask are contained in the mold may also prevent a blow past as the polymeric foam composition is injected. The prevented blow past in <FIG> prevent the injected polymeric foam composition from obscuring the insert <NUM> on the sole sidewalls being formed.

As the rings close to form the mold <NUM> of <FIG>, the outsole material may be injected into the mold <NUM> and formed, at least in part, to couple with the insert <NUM>. <FIG> depicts the upper <NUM> on the last <NUM>. The last <NUM> may be connected, at least temporarily, to a robotic element to position the last <NUM>. The robotic element may be the same or similar to the robotic element <NUM> of <FIG>. <FIG> depicts the upper being positioned in the mold <NUM>. Rings of the mold <NUM> may close to secure the upper for an injection of polymeric foam composition to form a direct attached sole thereon. <FIG> depicts the mold <NUM> secured around the upper <NUM> with an injector <NUM> injection a polymeric composition into the mold <NUM>, in accordance with aspects of the method according to the claimed invention. The injector <NUM> aligns with a runner (e.g., the first runner <NUM> of <FIG>) to insert polymeric material into the mold <NUM>.

While specific tooling is depicted in <FIG>, it is understood that is exemplary in nature and not limiting. Alternative configurations are contemplated and may be implemented.

<FIG> depicts a flow diagram <NUM> representing a method of making an article of footwear having an insert forming a portion of a sole sidewall, in accordance with the claimed invention. At a block <NUM>, an insert is positioned in a mold cavity. The insert is positioned such that it ultimately forms a portion of an external sidewall of the sole that will be direct attached to an upper. An exemplary positioning that achieves the insert as a portion of a sole sidewall includes contacting the insert with a molding surface that ultimately forms the sole sidewall. The insert may be the insert <NUM> of <FIG>, for example. The insert may be an airbag. The inert may be positioned by a top platen having the insert secured thereto being positioned such that the insert is provided into the mold cavity. A block <NUM> represents injecting a polymeric foam composition into the mold cavity. The polymeric foam composition creates, at least a portion, of the sole direct attached with an upper. The formation of the article of footwear may include a prior formation of an outsole within the mold cavity or separately. The prior formed outsole may then be coupled with the injected polymeric foam composition of the block <NUM>. A block <NUM> provides for positioning a footwear upper at the mold cavity such that the polymeric foam composition mechanically engages with the footwear upper.

<FIG> depicts a flow diagram <NUM> representing another exemplary method of making an article of footwear having an insert forming a portion of a sole sidewall whose disclosure is useful for understanding the claimed invention. At a block <NUM>, a platen is positioned in a mold cavity. For example the, top platen <NUM> of <FIG> is positioned in a mold cavity of the mold <NUM>. It is contemplated that the platen positioned in the mold cavity of the block <NUM> has secured thereto an insert, such as the insert <NUM> of <FIG>. The platen may also have contours and surfaces effective to form an upper-facing surface of a to-be molded outsole portion. In this example, the platen may have a portion configured to receive the insert, such as a recesses sized to maintain and position the insert at an appropriate location relative to the upper-facing molding surface of the platen.

At a block <NUM>, a first polymeric composition is injected into the mold cavity. The first polymeric composition may be any composition in any state, such as a to-be-cured polymeric composition, a polymeric composition above a glass transition temperature, a polymeric composition that is activate for forming bonding by subsequent processing (e.g., heat treatment, pressure treatment). The first polymeric composition, may be a PU or EVA, however additional/alternative polymeric compositions are contemplated. The first polymeric composition is injected, in this example, through a runner of the mold. The runner may be a specific runner for injecting only the first polymeric composition or it may be a runner that is used or injecting additional/alternative polymeric compositions (e.g., polymeric foam composition).

At a block <NUM>, a first molding surface is moved to contact the first polymeric composition with the insert. The first molding surface is a ground-contacting molding surface of a bottom plate, such as the bottom plate <NUM> of <FIG>, in this example. The bottom plate may be moved through an actuator, such as a pneumatic actuator, a hydraulic actuator, an electric actuator, a cam assembly, and the like. The first molding surface forms the ground-contacting surface of the outsole being formed at the block <NUM>. Therefore, the first molding surface may include one or more features that form an appropriate structure (e.g., treads, lugs, cleats) within the ground-contacting surface of the outsole. An adhesion is formed between the first polymeric composition and the insert through the contact between the two. This adhesion allows for the insert to remain in contact with the first polymeric composition for coupling there between.

At a block <NUM>, the platen is removed from the mold cavity. In this example, the platen is removed, such as through a robotic mechanism, while the insert previously coupled thereto is maintained by the previously injected first polymeric composition. In this way, the first platen served as a positioning tooling for appropriately placing the insert within the mold and providing a reactive force against the movement of the first molding surface allowing for sufficient contact between the insert and the first polymeric composition to form an adhesion there between. The platen also may serve as an upper-facing molding surface for the first polymeric composition to form a prescribed surface of the outsole.

At a block <NUM>, a footwear upper is positioned at the molding cavity. The upper may be a lasted upper, such as the upper <NUM> having the last <NUM> of <FIG>. By placing the upper at the mold cavity, the upper serves as a molding surface of the mold cavity. However, unlike a traditional molding surface where there is an expectation of a release from the molding surface, the upper that contact a polymeric foam composition is intended to form a coupling there between to direct attach the formed sole with the upper. In reality, a portion of the upper extends into the mold cavity when the upper is positioned at the mold cavity. The upper extends into the mold cavity as there is, in an example, an expectation that the polymeric foam composition infiltrates at least a portion of the upper material(s) to create a mechanical engagement between the upper and the polymeric foam composition. For example, a plantar portion of the upper may extend into the mold cavity while other portions of the upper (e.g., throat, ankle collar, or vamp) are maintained outside of the mold cavity.

At a block <NUM>, a polymeric foam composition is injected into the mold cavity. The polymeric foam composition may in in a pre-foamed state during the injection. A foaming operation may occur subsequent to the injection. The polymeric foam composition may be any polymeric composition, such as a PU, EVA, and other polymer-based materials. The injection of the polymeric foam composition may occur through a runner that is different from a runner used to previously inject the polymeric composition of the block <NUM>. Alternatively, a common runner may be used to inject both the polymeric composition and the polymeric foam composition. An amount of polymeric foam composition to be injected into the cavity may be prescribed for the size, style, and model of the shoe to be formed.

At a block <NUM>, the first molding surface is moved such that the polymeric foam composition mechanically engages with the footwear upper. The movement of the first molding surface results in the movement of the previously formed combination of the outsole and the insert as well. As such, the first molding surface movement to cause a mechanical engagement between the polymeric foam composition and the upper positioning the whole sole in closer proximity to the upper. It is contemplated that the bottom plate forming the first molding surface may stop moving into proximity of the upper prior to the contact of the polymeric foam material and the upper. In this situation, an expansion of the polymeric foam composition closes the remaining gap to allow for the eventual mechanical engagement between the polymeric foam composition and the upper. This mechanical engagement results in a coupling between the sole and the upper as a direct attach. The coupling may be chemical and/or mechanical. The polymeric foam composition, in an example, is allowed to cure, at least partially, prior to the formed article of footwear being removed from the mold cavity.

<FIG> depicts a view of the insert <NUM> having the mask <NUM> attached thereto. The mask <NUM> surrounds the sidewall-forming surfaces of the insert <NUM> to prevent one or more injected materials into a mold (e.g., such as the mold <NUM> of <FIG>) from covering the sidewall forming surfaces of the insert <NUM>. It is contemplated that the mask may be sized to compress a portion of the insert to maintain attached thereto. Further, it is contemplated that the mask may be shaped to expose portions of the insert to allow for interaction and bonding between the insert <NUM> and an injected material, such as a polymeric foam composition that is injected into a mold containing the insert <NUM>. For example, toeward portion of the medial and lateral sidewalls of the insert may not be masked by the mask allowing for a foam transition to occur along the insert <NUM> sidewalls up until a toeward end of the mask when positioned on the insert <NUM>, in the depicted example. Further, it is contemplated that the mask serves as a molding edge or surface for an injected polymeric foam composition such that the mask is capable of forming a molded shape, contour, element, and/or edge at the insert <NUM>.

Claim 1:
A method of making an article of footwear (<NUM>) having a direct attach sole, the method comprising:
positioning an insert (<NUM>) in a mold cavity (<NUM>) of a mold (<NUM>) having a first molding surface (<NUM>) forming a ground-contacting surface of a footwear sole (<NUM>), and a second molding surface (<NUM>) forming a sidewall of the footwear sole (<NUM>), wherein a mask (<NUM>) contacts both the insert (<NUM>) and the second molding surface (<NUM>), wherein positioning the insert (<NUM>) comprises mechanically engaging the mask (<NUM>) to the insert (<NUM>) and magnetically coupling the mask (<NUM>) with a platen (<NUM>);
injecting a polymeric foam composition (<NUM>) into the mold cavity (<NUM>) containing the insert (<NUM>); and
positioning a footwear upper (<NUM>) at the mold cavity (<NUM>), wherein the footwear upper (<NUM>) is positioned such that the polymeric foam composition (<NUM>) engages with the footwear upper (<NUM>) to form the article of footwear (<NUM>) having the insert (<NUM>) forming a portion of the footwear sole sidewall.