Patent Description:
Footwear typically includes a sole configured to be located under a wearer's foot to space the foot away from the ground or floor surface. Soles can be designed to provide a desired level of cushioning. A sole may be an assembly that includes a midsole and an outsole. Athletic footwear in particular sometimes utilizes a polyurethane or ethylene-vinyl acetate foam or other resilient materials in the sole to provide cushioning. In some configurations, the sole may further include one or more fluid filled chambers to alter the cushioning performance.

<CIT> describes a method of manufacturing an article that comprises etching an etched feature on a surface of a first polymeric sheet, and forming a fluid-filled bladder element from the first polymeric sheet, with the fluid-filled bladder element having a sealable internal cavity that retains fluid. The method includes assembling the bladder element in the article so that a first portion of the bladder element having the etched feature is exposed to view, and a second portion of the bladder element is blocked from view by the article. An article includes the bladder element with the etched feature.

<CIT> describes a method displaying a self-authenticating indicia on footwear. In one embodiment, a first segment of the indicia is displayed on the upper of the shoe, and a second segment is displayed on the sidewall. Alternately, the indicia may be in three segments which are displayed on the upper, sidewall and bottom of the sole. In each embodiment the segments are aligned to form the full indicia when the shoe is manufactured.

The claimed invention is defined by the independent claims. Additional embodiments are defined in the dependent claims-.

The claimed invention generally relates to a manner of altering the visual and/or tactile characteristics of an article of footwear after the article has been fully assembled. In doing so, graphics or tactile textures may be extended continuously across multiple adjacent components, which my otherwise be extremely difficult to properly execute if the graphics or textures were applied prior to assembly.

Referring to <FIG>, an article of footwear <NUM> includes an upper <NUM> and sole structure <NUM>. The article of footwear <NUM> is divided into one or more regions. The regions include a forefoot region <NUM>, a mid-foot region <NUM>, and a heel region <NUM>. The mid-foot region <NUM> may correspond with an arch area of the foot, and the heel region <NUM> may correspond with rear portions of the foot, including a calcaneus bone. The footwear <NUM> may further include an anterior end <NUM> associated with a forward-most point of the forefoot region <NUM>, and a posterior end <NUM> corresponding to a rearward-most point of the heel region <NUM>. A longitudinal axis of the footwear <NUM> generally extends along a length of the footwear <NUM> from the anterior end <NUM> to the posterior end <NUM>, and generally divides the footwear <NUM> into a lateral side and a medial side. Accordingly, the lateral side and the medial side respectively correspond with opposite sides of the footwear <NUM> and extend through the regions <NUM>, <NUM>, <NUM>.

The upper <NUM> includes interior surfaces that define an interior void <NUM> configured to receive and secure a foot for support on sole structure <NUM>. The upper <NUM> may be formed from one or more materials that are stitched or adhesively bonded together to form the interior void <NUM>. Suitable materials of the upper may include, but are not limited to, mesh, textiles, foam, leather, and synthetic leather. The materials may be selected and located to impart properties of durability, air-permeability, wear-resistance, flexibility, and comfort.

With reference to <FIG>, in some examples the upper <NUM> includes a strobel <NUM> having a bottom surface opposing the sole structure <NUM> and an opposing top surface defining a footbed of the interior void <NUM>. Stitching or adhesives may secure the strobel to the upper <NUM>. The footbed may be contoured to conform to a profile of the bottom surface (e.g., plantar) of the foot. Optionally, the upper <NUM> may also incorporate additional layers such as an insole or sockliner that may be disposed upon the strobel <NUM> and reside within the interior void <NUM> of the upper <NUM> to receive a plantar surface of the foot to enhance the comfort of the article of footwear <NUM>. An ankle opening <NUM> in the heel region <NUM> may provide access to the interior void <NUM>. For example, the ankle opening <NUM> may receive a foot to secure the foot within the void <NUM> and to facilitate entry and removal of the foot from and to the interior void <NUM>.

In some examples, one or more fasteners <NUM> extend along the upper <NUM> to adjust a fit of the upper <NUM> around the foot and to accommodate entry and removal of the foot therefrom. The upper <NUM> may include apertures <NUM> such as eyelets and/or other engagement features such as fabric or mesh loops that receive the fasteners <NUM>. The fasteners <NUM> may include laces, straps, cords, hook-and-loop, or any other suitable type of fastener. The upper <NUM> may include a tongue portion <NUM> that extends between the interior void <NUM> and the fasteners.

With continued reference to <FIG>, the sole structure <NUM> includes a cushioning component <NUM> that defines a portion of the outer periphery of the sole structure <NUM> within the heel region <NUM>. The cushioning component <NUM> may include a fluid-filled bladder <NUM> and an outsole portion <NUM>. In some configurations, the outsole portion <NUM> may be integrally coupled with the fluid-filled bladder <NUM>, such as via an overmolding process, or else by integrally molding the outsole portion <NUM> when forming a wall of the bladder <NUM>. The outsole portion <NUM> extends along a ground-facing side of the fluid-filled bladder <NUM> and may define a first portion of a ground-engaging surface <NUM> of the sole structure <NUM>.

The sole structure <NUM> further includes a forward midsole component <NUM> in the forefoot region <NUM> and the mid-foot region <NUM>. The forward midsole component <NUM> may be formed from an energy absorbing material such as, for example, a polymeric foam. Forming the forward midsole component <NUM> from an energy-absorbing material such as a polymeric foam allows the forward midsole component <NUM> to attenuate ground-reaction forces caused by movement of the article of footwear <NUM> over ground during use.

With reference to <FIG>, the fluid-filled bladder <NUM> may be formed from a plurality of polymeric sheets (e.g., first and second polymeric sheets 212a, 212b) that are fused together at a peripheral flange or seam <NUM> to define an internal volume between the respective sheets 212a, 212b. This internal volume is adapted to receive a pressurized fluid (e.g. air), which may provide a cushioning quality to the sole structure. In some embodiments, the seam <NUM> may extend around some or all of the periphery of the fluid-filled bladder <NUM>, though may preferably be concealed by the outsole portion <NUM>. Although the seam <NUM> is illustrated as forming a relatively pronounced flange protruding outwardly from the fluid-filled bladder <NUM>, in some embodiments, the seam <NUM> may be a flat seam such that the upper polymeric sheet 212a and the lower polymeric sheet 212b are substantially continuous with each other. In some embodiments, additional polymeric sheets may be provided between the first and second polymeric sheets 212a, 212b to define one or more additional volumes within the fluid-filled bladder <NUM>.

The first and second polymeric sheets 212a, 212b may each be formed from one or more layers of a substantially transparent, thermoplastic material, such as a thermoplastic polyurethane (TPU). Examples of other suitable polymeric materials that may be used to form the fluid-filled bladder <NUM> include thermoplastic polyurethane, polyester, polyester polyurethane, and polyether polyurethane. Moreover, each of the polymeric sheets 212a, 212b forming the fluid-filled bladder <NUM> can include layers of different materials. In one embodiment, the polymeric sheets 212a, 212b may be formed from a plurality alternating thin films comprising one or more thermoplastic polyurethane (TPU) layers and one or more barrier layers comprising a copolymer of ethylene and vinyl alcohol (EVOH). In use, the EVOH layers may be configured such that they are impermeable to the pressurized fluid contained therein. Such constructions are further disclosed in <CIT>.

In some embodiments, the polymeric sheets 212a, 212b may also be formed from a material that includes alternating layers of thermoplastic polyurethane and ethylene-vinyl alcohol copolymer, as disclosed in <CIT> and <CIT>Alternatively, the layers may include ethylene-vinyl alcohol copolymer, thermoplastic polyurethane, and a regrind material of the ethylene-vinyl alcohol copolymer and thermoplastic polyurethane. The polymeric sheets 212a, 212b of the fluid-filled bladder <NUM> may also be flexible microlayer membranes that include alternating layers of a gas barrier material and an elastomeric material, as disclosed in <CIT> and <CIT> Additional suitable materials for the fluid-filled bladder <NUM> are disclosed in <CIT> and <CIT>. Further suitable materials for the fluid-filled bladder <NUM> include thermoplastic films containing a crystalline material, as disclosed in <CIT> and <CIT>, and polyurethane including a polyester polyol, as disclosed in <CIT><CIT>, and <CIT>.

In selecting materials for the fluid-filled bladder <NUM>, engineering properties such as tensile strength, stretch properties, fatigue characteristics, dynamic modulus, and loss tangent can be considered. The thicknesses of polymeric sheets 212a, 212b used to form the fluid-filled bladder <NUM> can be selected to provide these characteristics. The fluid-filled bladder <NUM> is resilient and provides cushioning and flexibility that can be tuned such as by selecting a level of pressurization. Optionally, tensile members and/or reinforcing structures can be integrated with the fluid-filled bladder <NUM> to provide desired responsiveness, such as disclosed in <CIT>, and <CIT>.

In some implementations, the outsole portion <NUM> extends over a portion of the bladder <NUM> to provide increased durability and resiliency for the bladder <NUM>. Accordingly, the outsole portion <NUM> may be formed of a different material than the bladder <NUM>, and includes at least one of a different thickness, a different hardness, and a different abrasion resistance than the second/lower polymeric sheet 212b. In some examples, the outsole portion <NUM> may be formed integrally with the second polymeric sheet 212b of the bladder <NUM> using an over-molding process. In other examples the outsole portion <NUM> may be formed separately from the second polymeric sheet 212b and may be adhesively bonded to the second barrier layer 212b through a subsequent process.

With continued reference to <FIG>, the fluid-filled bladder may be continuously exposed along an outer periphery of the heel region <NUM> from a distal end <NUM> on the lateral side to a similar distal end on the medial side. For example, the first barrier layer 212a may be continuously exposed along the outer periphery of the sole structure <NUM> between the upper <NUM> and the outsole portion <NUM>, such that the transparent first polymeric sheet 212a is exposed around the periphery of the heel region <NUM>.

The sole structure <NUM> may further include a heel counter <NUM> that may be formed of the same transparent TPU material as the first polymeric sheet 212a and may further extend over a portion of the forward midsole component <NUM>. As shown, the heel counter <NUM> extends from the first distal end <NUM> of the bladder <NUM>, around the posterior end <NUM>, and to the distal end of the bladder <NUM> on the opposite side of the sole structure <NUM>.

In general, the fluid-filled bladder <NUM> and the forward midsole component <NUM> may cooperate to define at least a portion of the overall midsole of the article of footwear. The midsole generally has an outward facing midsole sidewall that is at least partially formed from a fluid-filled bladder sidewall and a forward midsole component sidewall. The midsole sidewall may generally extend upward from the ground-engaging surface <NUM> toward the upper and may form at least a portion of the overall side profile of the article of footwear <NUM>.

In one embodiment, an article of footwear <NUM>, and in particular, the sole structure <NUM> of the article of footwear may have its visual and/or tactile appearance customized through the use of an etching process. In particular, a laser etching system <NUM>, such as shown in <FIG>, may be used to scribe one or more designs into the midsole sidewall, where the designs may extend across one or both of the fluid-filled bladder sidewall and the forward midsole component sidewall. The system <NUM> may generally include a laser head <NUM>, a workpiece holder <NUM> configured to hold and/or move a workpiece <NUM>, a movement system <NUM> configured to provide motion between the laser head <NUM> and the workpiece, and a computer numerical controller <NUM> configured to control the movement between the laser head <NUM> and the workpiece. The laser head <NUM> may emit an intense beam of light at a particular wavelength, and may be driven by a laser oscillator <NUM>, which is in turn powered by a transformer <NUM>.

The laser etching system <NUM> may include any suitable type of laser cutting machine for cutting away sole material. For example, the laser etching system <NUM> may include a pulse fiber laser, continuous wave carbon dioxide laser, ultraviolet solid state laser, yttrium lithium fluoride laser, or excimer (exciplex) laser cutting machine, e.g., the <NUM>-axis computer numerical controlled laser cutting machine ML1515VZ20 that is manufactured by Mitsubishi Corporation. In another example, Sumitomo Heavy Industries, Ltd. makes laser cutting machines, such as the KrF excimer laser INDEX-<NUM> having a wavelength of <NUM>.

The wavelength of the laser light may vary depending upon the nature of material to be cut and the desired effect. In some embodiments, the wavelength may be in the ultraviolet portion of the spectrum, i.e., from about <NUM> to about <NUM>. In other embodiments, a specific portion of the ultraviolet spectrum may be selected, such as from about <NUM> to about <NUM>. For example, for many polymers, <NUM> light may be effective for cutting/etching. In other embodiments, other portions of the electromagnetic spectrum may be selected for the laser. Infrared light may also be selected, e.g., carbon dioxide lasers in the <NUM>-<NUM> wavelength range may be desirable for certain materials/effects. In other embodiments, lasers operating at <NUM>, <NUM>, and <NUM> may be desirable. When used with thermoplastics, IR (e.g. ><NUM>) lasers may tend to thermally transform/melt the polymer (i.e., a "hot" process), while UV lasers (e.g., <<NUM>) may break molecular bonds at the surface layer in a "cold" photo-ablation process that can produce features with smoother edges. Similarly to the selection of wavelength, the power of the laser and/or the duration of any laser pulses or exposure to laser beams may be selected depending upon such factors as the wavelength, the power source, the type of material desired to be cut/etched, and the type of cutting/etching effect desired.

The laser head <NUM> may be connected to the laser oscillator <NUM> and may be configured to focus the laser produced by the laser oscillator <NUM>. The laser head <NUM> may include a laser nozzle <NUM> disposed on the bottom of the laser head <NUM>. The laser nozzle <NUM> may be configured to further focus the laser and emit a laser beam, and may be adjustable to increase and/or decrease the focus of the laser beam. In some embodiments, the laser nozzle <NUM> may be adjusted by a local processing device <NUM>. The local processing device <NUM> is discussed in more detail below. The type of laser head <NUM> and/or laser nozzle <NUM> may be selected based on a variety of factors. For example, the type of laser head and laser nozzle may be selected based on the type of the laser cutting machine used and/or the desired depth and shape of the etching pattern.

A workpiece holder <NUM> may include any suitable type of holder that is operative to hold an article of footwear. For example, as shown in <FIG> the workpiece holder <NUM> may include a workpiece table <NUM>. In other embodiments, the workpiece holder <NUM> may include a last upon which the article of footwear is mounted.

The laser etching system <NUM> of <FIG> may include a movement system <NUM> providing motion between the laser head <NUM> and the workpiece, e.g., the ML1515VZ20 from Mitsubishi Corporation as noted above. In one configuration, the laser etching system <NUM> may include a <NUM>-axis cutting machine configured to move the laser head <NUM> in three directions and the workpiece in two directions. In some embodiments, the laser etching system <NUM> may include a <NUM>-axis cutting machine configured to move the laser head <NUM> in two directions and the workpiece in three directions. The laser etching system <NUM> may alternatively include a <NUM>-axis cutting machine configured to move the laser head <NUM> in three directions and the workpiece in three directions. Providing multiple directions of movement between the laser head <NUM> and the workpiece holder <NUM> may provide many etching pattern possibilities.

When used to etch a visual pattern in the sole structure <NUM>, the laser beam emitted from the laser head <NUM> may be adjusted to leave the surface of the sole structure <NUM> smooth after cutting, though may alter a visual appearance of the polymer. In some embodiments, the laser beam emitted from the laser head <NUM> may be adjusted to leave marks in the wake of the laser beam. The marks resulting from laser cutting may be so subtle and uniform that the roughness of the resulting surface of the sole structure <NUM> may be extremely low or relatively unchanged from a pre-etched state. In some embodiments, the laser etching system <NUM> of <FIG> may be used to cut fine lines and/or other repeated patterns that may add texture to the surface of the sole structure <NUM>.

As discussed above, the laser etching system <NUM> may include a computer numerical controller <NUM> configured to control the movement between the laser head <NUM> and the workpiece. For example, as mentioned above, Mitsubishi Corporation makes <NUM>-axis computer numerical controlled laser cutting machines, such as the ML1515VZ20. In some embodiments, the computer numerical controller <NUM> may be configured to control the focus of the laser beam emitted from the laser head <NUM>. The computer numerical controller <NUM> may include any suitable type of computer numerical controller. The type of computer numerical controller may be selected based on a variety of factors. For instance, the type of computer numerical controller may be selected based on the type of laser head and/or type of workpiece table used.

The laser etching system <NUM> of <FIG> may include a local processing device <NUM> operative to control the laser head <NUM> and/or the computer numerical controller <NUM>. In some embodiments, the local processing device includes a local user interface that is operative to configure the system <NUM>. The local processing device <NUM> may include one or more dedicated processors, or one or more computing devices in local communication with the computer numerical controller <NUM>. For example, in some embodiments, the local processing device <NUM> may include a desktop or laptop computer, a tablet computer, or a suitable portable computing device in wired or direct wireless communication with the computer numerical controller <NUM>.

In some embodiments, the local processing device <NUM> may be in communication with one or more networked user interfaces <NUM> over a digital computer network, local area network, wide area network, or through point-to-point RF communications such as using a BLUETOOTH protocol. The networked user interface <NUM> may be displayed or provided on any suitable portable computing device, such as a smartphone, tablet, laptop, or the like and may enable a user to provide one or more designs <NUM> that are desired to be etched into the sole structure <NUM>. In some embodiments, the networked user interface <NUM> may include a dedicated application operating on the user's device or may include an internet-based web application that is viewable through a suitable internet browser.

As shown in <FIG>, a user may access the networked user interface <NUM> via a display screen or other human-machine interface device to respond to a set of user prompts. For instance, the display screen may be a touch screen and the user prompts may be one or more icons and/or text-based prompts requesting entry of a desired surface feature or design, such as a customized depth, pattern, or effect that may be etched into the sole structure <NUM>. Alternatively, the user prompts may request entry of a desired logo on the outer surface of the sole structure <NUM>, with the term "logo" as used herein referring to any image, letters, characters, or the like which would effectively form a custom watermark or etched image.

As noted above, in one embodiment, the article of footwear <NUM>, and in particular, the sole structure <NUM> of the article of footwear may have its visual appearance customized via the laser etching system <NUM>. In particular, the laser etching system <NUM> may be configured to controllably apply laser energy to an outer surface of the article of footwear <NUM> for the purpose altering a visual characteristic of the material used to form the article and/or altering a physical characteristic of the article itself.

<FIG> schematically illustrates one embodiment of an article of footwear <NUM> having an etched pattern <NUM> imprinted into an outer surface <NUM>. As generally illustrated, the etched pattern <NUM> may extend continuously across multiple components without interruption. In one particular embodiment, this continuous aspect of the etched pattern <NUM> may be formed by controlling the movement system <NUM>, computer numerical controller <NUM> and/or workpiece holder <NUM> such that the laser beam emanating from the laser head <NUM> is approximately orthogonal to the outer surface <NUM> at the point where the beam impacts the outer surface.

<FIG> schematically illustrates an embodiment of a method <NUM> for laser etching an article of footwear. As shown, the method <NUM> may include providing (or receiving) an article of footwear <NUM> on a workpiece holder <NUM> (at <NUM>) and identifying the silhouette or outer surface profile of the article of footwear (at <NUM>), followed by identifying an etchable workspace on the outer surface of the article (at <NUM>). Identifying the silhouette may occur either manually, such as by receiving, from the user interface, an indication of the model and size of the article of footwear, or automatically, such as by scanning the outer surface of the article, for example, with a laser. In one embodiment, the identified etchable workspace extends continuously over multiple components, such as a polymeric foam midsole (e.g., the forward midsole component <NUM> shown in <FIG>), a polymeric fluid filled chamber (e.g., fluid-filled chamber <NUM> shown in <FIG>), and/or a heel counter (e.g., the heel counter <NUM> shown in <FIG>).

The method <NUM> further includes receiving a design (at <NUM>) from a user via the local processing device <NUM> and/or the networked user interface <NUM>. In one configuration, the design may comprise a repeating pattern of discrete graphical primitives, such as repeating check pattern or a repeating herringbone design. In another configuration, the design may comprise a more complex graphic, such as a logo, picture, or other creative work.

Following receipt of the design at <NUM>, the local processing device <NUM> may apply/project the design onto the etchable workspace (at <NUM>), and then construct a series of numerical codes (at <NUM>) that may be used to instruct the movement system <NUM> and/or computer numerical controller <NUM> to move the laser head <NUM> such that the laser beam traces the design onto the article (at <NUM>). In one embodiment, the local processing device <NUM> may utilize the dimensional geometry of the outer surface of the article to construct numerical codes that maintain the laser beam in an approximately orthogonal orientation to the surface on which it's shining. Following the creation of the numerical codes, the local processing device may instruct the movement system <NUM> and/or computer numerical controller <NUM> to move the laser head <NUM> while modulating the laser oscillator <NUM> and/or power of the laser to etch the prescribed design into the article.

Applying the design in this manner may result in a completed article with at least one etched line, formed by the laser, that extends continuously across a boundary between two components. In one embodiment, the laser may cut or locally melt the outer surface of the one or more components to result in a channel having a depth, measured from one or more directly adjacent land areas, of between about <NUM> and about <NUM>, or between about <NUM> and about <NUM>, or between about <NUM> and about <NUM>, or even between about <NUM> and about <NUM>.

In one embodiment, at least one of the midsole (e.g., the forward midsole component <NUM> shown in <FIG>), polymeric fluid filled chamber (e.g., fluid-filled chamber <NUM> shown in <FIG>), and/or heel counter (e.g., the heel counter <NUM> shown in <FIG>) may have an outer skin or outer material construction that is comprised of a plurality of layers. One or more of the layers may have a substantially constant thickness, and at least two of the layers may be formed from materials having different pigmentation. In such an embodiment, the depth of the laser etching may be greater than <NUM>% of the thickness of the outer-most layer such that the second layer (i.e., the layer immediately below the outer-most layer) may be at least partially visible through the etched channel and/or remaining material of the outer layer. In one embodiment, the depth of the laser etching may be greater than or equal to the thickness of the outer-most layer such that the second layer is at least partially exposed within the channel formed via the etching. In some configurations, the second layer may be a different color than the outer-most layer, and further may only be visible through the etched channel.

In another embodiment, the etching process may alter one or more of the pigments of the outer surface of the sole structure <NUM> or may alter the light transmissibility of the polymer, such as in a barrier layer 212a of the fluid-filled chamber <NUM>. The alteration in the pigmentation and/or transmissibility of the polymer may occur, for example, by altering the polymer chain structure, or by initiating a hyperlocalized chemical reaction that results in a visible change.

The etchable workspace may include various portions of the article of footwear, including the toe bumper, sidewall of the sole structure, ground facing surface, heel counter, fluid filled chamber, and/or upper.

In some configurations, the processes and systems described herein may be used to apply a texture to an outer surface of the article of footwear and across multiple discrete components. This texture may enable non-visual differentiation between a right shoe and a left shoe, which may be beneficial for individuals with visual impairments. For example, in one configuration, the texture may be applied to only one shoe in a respective pair of shoes. In another configuration, similar textures may be applied to each shoe, however, the texture may only be applied to one of the lateral or medial side of each article (though consistent between the two - i.e., both lateral or both medial). In yet another configuration, a first texture may be applied to a first article in the respective pair while a second texture, differentiable from the first texture, may be applied to the second article in the pair. In these embodiments, the applied texture may generally include a debossed or etched surface profile that has sufficient roughness or surface geometry to be perceivable and identifiable by human touch.

Claim 1:
A sole structure (<NUM>) for an article of footwear (<NUM>) comprising:
a midsole comprising a bladder (<NUM>) and a foam midsole component (<NUM>), wherein the bladder (<NUM>) defines a fluid-filled chamber (<NUM>), the foam midsole component (<NUM>) having a ground facing surface and a sidewall, and wherein the bladder (<NUM>) forms a visible portion of the sidewall, and wherein the bladder (<NUM>) meets the foam midsole component (<NUM>) to define a component boundary on the sidewall;
an etched channel extending into both the foam midsole component (<NUM>) and the bladder (<NUM>), the etched channel having a depth into the sidewall of between about <NUM> and about <NUM>, and wherein the etched channel continuously extends across the component boundary,
wherein the etched channel is formed by a laser after the article of footwear (<NUM>) has been fully assembled.