Pre-tensioned product and method of manufacturing the same

Abstract

The present application relates to pre-tensioned articles and methods of making the same. A pre-tensioned article and method of making an article of footwear includes pre-tensioning a sole structure during manufacture. In some embodiments, the sole structure may include a plurality of holes that provide an auxetic effect. In other embodiments, the upper may also be pre-tensioned in a similar manner to the sole structure.

Description

[0001] This application is a divisional application of an application with an application date of May 21, 2018, application number 201880034332.8, and invention name “Pre-tensioned product and its manufacturing method”.

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS

[0003] This application claims priority to and the benefit of U.S. Patent Application No. 15 / 604,870, filed on May 25, 2017. Technical Field

[0004] The present disclosure relates generally to articles of footwear, and in particular to articles of footwear having an upper and a sole structure. Background Art

[0005] Articles of footwear generally include two main elements: an upper and a sole structure. The upper may be formed of a variety of materials that are stitched or adhesively bonded together to form a space inside the footwear for comfortably and securely accommodating the foot. The sole structure is secured to a lower portion of the upper and is generally positioned between the foot and the ground. In many articles of footwear, including those of the athletic footwear type, the sole structure generally includes an insole, a midsole, and an outsole. Summary of the invention

[0006] This application provides the following:

[0007] 1). A method for manufacturing a footwear product, comprising:

[0008] providing a sole structure in a relaxed state comprising a plurality of apertures, wherein the plurality of apertures are arranged in an auxetic configuration;

[0009] placing the sole structure under tension such that the sole structure undergoes auxetic expansion; and

[0010] An upper is attached to the sole structure while the sole structure is under the tension.

[0011] 2). The method according to 1) further comprises releasing the tension from the sole structure so that the sole structure returns to the relaxed state.

[0012] 3). The method according to any one of 1) or 2), further comprising:

[0013] Provide shoe lasts;

[0014] wherein the shoe last has a lower shoe last surface, and the lower shoe last surface has a lower shoe last surface area;

[0015] wherein the sole structure has a last contacting surface, the last contacting surface having an interior surface area; and

[0016] When the sole structure is in the relaxed state, the lower last surface area is greater than the inner surface area of ​​the last contact surface.

[0017] 4). The method according to 3), wherein when the sole structure is tensioned, the inner surface area of ​​the last contact surface is equal to the lower last surface area.

[0018] 5). The method according to 3) further includes attaching the upper to the sole structure when the sole structure is tensioned to form an article, wherein the article defines a cavity having a tensioned volume when the sole structure is tensioned.

[0019] 6). The method according to 5) further includes removing the product from the last so that the sole structure returns to the relaxed state, wherein when the sole structure is in the relaxed state, the cavity has a relaxed volume, and the relaxed volume is smaller than the tensioned volume.

[0020] 7). The method according to any one of 1)-6), wherein placing the sole structure under the tension comprises applying the tension laterally on the sole structure, and the laterally applied tension causes the sole structure to expand laterally and longitudinally.

[0021] 8). The method according to any one of 1) to 7), wherein the sole structure has a first length and a first width in the relaxed state, and the sole structure has a second length and a second width in the tensioned state, the second width is greater than the first width, and the second length is greater than the first length.

[0022] 9). A method for manufacturing a footwear product, comprising:

[0023] forming a sole structure having a plurality of apertures, wherein the plurality of apertures are spaced apart in an auxetic configuration and the sole structure has a first sole length and a first sole width;

[0024] Providing a shoe last having a lower surface, the shoe last comprising a shoe last length and a shoe last width, wherein the first sole length is smaller than the shoe last length, and the first sole width is smaller than the shoe last width;

[0025] laterally tensioning the sole structure so that the sole structure expands both laterally and longitudinally, wherein the tensioned sole structure has a second sole length and a second sole width, the second sole length being greater than the first sole length, and the second sole width being greater than the first sole width;

[0026] placing the tensioned sole structure on the lower surface of the last; and

[0027] An upper is attached to the tensioned sole structure.

[0028] 10) The method according to 9) further comprises removing the upper and the sole structure from the last, wherein the sole structure is restored to have the first sole length and the first sole width after being removed from the last.

[0029] 11). The method according to any one of 9) to 10), wherein the sole structure is formed of foam.

[0030] 12). The method according to any one of 9)-11), wherein the upper comprises a plurality of holes, and the plurality of holes are arranged in an auxetic configuration.

[0031] 13). The method according to 11), wherein, when the sole structure is tensioned, the size of the plurality of holes of the sole structure is substantially the same as the size of the plurality of holes of the upper when the upper is tensioned.

[0032] 14) The method according to 11), wherein, when the sole structure is tensioned, the plurality of holes of the sole structure are larger than the plurality of holes of the upper when the upper is tensioned.

[0033] 15). A method according to any one of 11) to 13), wherein the upper is attached to the sole structure to form an article located on the last, the article having a cavity, and when the article is on the last, the cavity has a tensioned volume.

[0034] 16). The method according to 15) further includes removing the product from the last so that the sole structure returns to the first sole width and the first sole length, wherein the cavity has a relaxed volume, and the relaxed volume is smaller than the tensioned volume.

[0035] 17). A footwear product, comprising:

[0036] vamp;

[0037] a sole structure attached to the upper;

[0038] wherein each of the upper and the sole structure defines a plurality of apertures arranged in an auxetic configuration; and

[0039] Therein, when worn by a user, the sole structure is configured to expand auxetically, and the upper is also configured to expand auxetically.

[0040] 18). The footwear article as described in 17), wherein, when the sole structure is in a neutral state, the sole structure has a first thickness, and when the sole structure is subjected to a lateral force, the sole structure has a second thickness, and the first thickness and the second thickness are substantially similar.

[0041] 19) The article of footwear as described in 17), wherein when the upper and the sole structure are subjected to the same magnitude of force, both the upper and the sole structure are configured to expand at substantially similar rates.

[0042] 20) The footwear article as described in 1), wherein when the upper and the sole structure are subjected to the same magnitude of force, the upper expands at a rate greater than the expansion rate of the sole structure. BRIEF DESCRIPTION OF THE DRAWINGS

[0043] The embodiments can be better understood by referring to the following drawings and descriptions. The components in the drawings are not necessarily drawn to scale, but the emphasis is placed on illustrating the principles of the embodiments. In addition, in the drawings, the same reference numerals always represent corresponding parts in different views.

[0044] Figure 1 is a schematic diagram of an embodiment of a sole structure with expansion holes in a relaxed state;

[0045] Figure 2 yes Figure 1 A schematic diagram of an embodiment of a sole structure of a shoe in a tensioned state;

[0046] Figure 3 is a schematic diagram of an embodiment of a sole structure and a shoe last;

[0047] Figure 4 is a schematic diagram of an embodiment of a sole structure positioned adjacent to a last;

[0048] Figure 5 is a schematic diagram of an embodiment of a tensioned sole structure positioned adjacent to a last;

[0049] Figure 6 is a schematic diagram of an embodiment of an article of footwear removed from a last;

[0050] Figure 7 is a schematic diagram of an embodiment of an article of footwear separated from a last;

[0051] Figure 8 is an isometric view of an embodiment of an article of footwear in a relaxed state;

[0052] Fig. 9 yes Figure 8 A bottom view of the footwear article in a relaxed state;

[0053] Fig.10 yes Figure 8 An isometric cross-sectional view of the article of footwear in a relaxed state;

[0054] Fig.11 It is foot insertion Figure 8 A schematic diagram of a footwear article;

[0055] Fig.12 is an isometric view of a foot inserted into an article of footwear;

[0056] Fig.13 yes Fig.12 a bottom view of the illustrated article of footwear;

[0057] Fig.14 yes Fig.12 An isometric cross-sectional view of a footwear article;

[0058] Fig.15 is a schematic diagram of an embodiment of a sole structure with expansion holes in a relaxed state;

[0059] Fig.16 is a schematic diagram of an embodiment of a shoe upper with expansion holes in a relaxed state;

[0060] Fig.17 yes Fig.15 A schematic diagram of a sole structure in a tensioned state;

[0061] Fig.18 yes Fig.16 A schematic diagram showing a shoe upper in a tensioned state;

[0062] Fig.19 is a schematic diagram of an embodiment of a relaxed upper, a relaxed sole structure and a shoe last;

[0063] Fig. 20 It is a schematic diagram of the upper being wrapped around the last;

[0064] Fig.21 is a schematic diagram of a shoe upper fixed to a shoe last;

[0065] Fig. 22 is a schematic diagram of a sole structure positioned adjacent to a shoe last;

[0066] Fig.23 is a schematic diagram of a tensioned sole structure;

[0067] Fig.24 is a schematic diagram of an embodiment of an article of footwear removed from a last;

[0068] Fig.25 is a schematic diagram of an article of footwear completely removed from a last;

[0069] Fig.26is an isometric view of an embodiment of an article of footwear in a relaxed state;

[0070] Fig. 27 yes Fig.26 An isometric cross-sectional view of an article of footwear in a relaxed state;

[0071] Fig.28 yes Fig.26 An alternative isometric cross-sectional view of an article of footwear in a relaxed state;

[0072] Fig.29 It is foot insertion Fig.26 A schematic diagram of a footwear article;

[0073] Fig.30 is an isometric view of a foot inserted into an article of footwear;

[0074] Fig.31 yes Fig.30 An isometric cross-sectional view of a footwear article;

[0075] Fig.32 yes Fig.30 Alternative isometric cutaway views of articles of footwear;

[0076] Fig.33 is an isometric view of an embodiment of an article of footwear on a foot;

[0077] Fig.34 is a schematic diagram of a set of embodiments of an upper and a sole structure; and

[0078] Fig.35 is a schematic diagram of another embodiment of a set of upper and sole structures. DETAILED DESCRIPTION

[0079] For the sake of clarity, certain exemplary embodiments are described in detail herein, but the disclosure herein can be applied to any footwear article including certain features described herein and recited in the claims. In particular, although the following detailed description discusses exemplary embodiments in the form of footwear such as running shoes, jogging shoes, tennis, squash or short-handle basketball shoes, basketball shoes, sandals and fins, the disclosure herein can be applied to a wide range of footwear or possibly other types of articles.

[0080] For consistency and convenience, directional adjectives are used throughout the detailed description corresponding to the illustrated embodiments. The term "longitudinal direction" used throughout the detailed description and in the claims refers to the direction extending from the heel to the toe, which can be associated with the length or longest dimension of a footwear article such as a sports shoe or a casual shoe. In addition, the term "lateral direction" used throughout the detailed description and in the claims refers to the direction extending from one side to the other side (outer side and inner side) or the width of the footwear article. The transverse direction may be approximately perpendicular to the longitudinal direction. The term "vertical direction" used throughout the detailed description and in the claims with respect to the footwear article refers to the direction perpendicular to the sole plane of the footwear article. In addition, the vertical direction may be approximately perpendicular to both the longitudinal direction and the transverse direction.

[0081] The present disclosure describes an article of footwear and a method of manufacturing the same. The manufacturing method disclosed herein allows for adjustment of the fit and cushioning of the article of footwear. In certain embodiments, the method includes (a) providing a sole structure in a relaxed state including holes, wherein the holes are arranged in an auxetic configuration; (b) placing the sole structure under tension such that the sole structure undergoes auxetic expansion; and (c) attaching an upper to the sole structure while the sole structure is under tension. The sole structure having the auxetic configuration compresses the upper after the upper is attached. Thus, when the foot is inserted into the article of footwear, the upper expands, and the sole structure does a better job of conforming to the contours of the foot during expansion than if the upper were merely suspended. Thus, the article of footwear promotes better fit, feel, and more fully engages the auxetic properties of the sole structure than other articles of footwear. The method may also include releasing tension from the sole structure such that the sole structure returns to a relaxed state. The method may also include providing a last. The last has a lower last surface having a lower last surface area, and the sole structure has a last contact surface having an inner surface area. When the sole structure is in a relaxed state, the lower last surface area of ​​the last may be greater than the inner surface area of ​​the last contact surface of the sole structure. When the sole structure is tensioned, the inner surface area of ​​the last contact surface may be equal to the lower last surface area.

[0082] The method may also include attaching the upper to the sole structure while the sole structure is tensioned to form the article. When the sole structure is tensioned, the article may define a cavity having a tensioned volume. The method may also include removing the article from the last so that the sole structure returns to a relaxed state. When the sole structure is in a relaxed state, the cavity has a relaxed volume, and the relaxed volume may be less than the tensioned volume. Placing the sole structure under tension may include applying tension laterally across the sole structure. The laterally applied tension may cause the sole structure to expand both laterally and longitudinally. The sole structure has a first length and a first width in the relaxed state. The sole structure has a second length and a second width in the tensioned state.

[0083] The second width may be greater than the first width, and the second length may be greater than the first length.

[0084] In some embodiments, a method of manufacturing an article of footwear includes: (1) forming a sole structure having holes, wherein the holes are spaced apart in an auxetic configuration, and the sole structure has a first sole length and a first sole width; (b) providing a last having a lower surface, the last including a last length and a last width, wherein the first sole length is less than the last length, and the first sole width is less than the last width; (c) laterally tensioning the sole structure so that the sole structure is expanded both laterally and longitudinally, wherein the tensioned sole structure has a second sole length and a second sole width, the second sole length being greater than the first sole length, and the second sole width being greater than the first sole width; (d) placing the tensioned sole structure on the lower surface of the last; and (e) attaching an upper to the tensioned sole structure. The method may also include removing the upper and the sole structure from the last. The sole structure returns to having the first sole length and the first sole width after being removed from the last. The sole structure may be formed of foam. The upper includes holes, and the holes are arranged in an auxetic configuration. When the sole structure is tensioned, the holes of the sole structure may have substantially the same size as the holes of the upper when the upper is tensioned. When the sole structure is tensioned, the holes of the sole structure may be larger than the holes of the upper when the upper is tensioned. The upper attached to the sole structure may form an article located on a last. The article has a cavity, and when the article is on the last, the cavity has a tensioned volume. The method may also include removing the article from the last so that the sole structure returns to a first sole width and a first sole length. The cavity has a relaxed volume, and the relaxed volume may be less than the tensioned volume.

[0085] The present disclosure also describes an article of footwear. In some embodiments, the article includes an upper and a sole structure attached to the upper. Each of the upper and the sole structure defines a plurality of holes arranged in an auxetic configuration. When worn by a user, the sole structure is configured to expand in an auxetic manner, and the upper is also configured to expand in an auxetic manner. When the sole structure is in a neutral state, the sole structure has a first thickness. When the sole structure is subjected to a lateral force, the sole structure has a second thickness, and the first thickness and the second thickness may be substantially similar. When the upper and the sole structure are subjected to the same magnitude of force, both the upper and the sole structure may be configured to expand at a substantially similar rate. When the upper and the sole structure are subjected to the same magnitude of force, the upper may expand at a rate greater than the rate of expansion of the sole structure.

[0086] Figure 11 is a bottom view of the sole structure 100. In some embodiments, the sole structure 100 can be configured to provide traction for the footwear. In addition to providing traction, the sole structure 100 can reduce ground reaction forces when it is compressed between the foot and the ground during walking, running or other ambulatory activities. The configuration of the sole structure 100 can vary significantly in different embodiments. In some cases, the configuration of the sole structure 100 can be configured according to one or more types of ground surfaces (on which the sole structure 100 can be used). Examples of ground surfaces include, but are not limited to, natural turf, synthetic turf, soil, hardwood floors, and other surfaces.

[0087] The sole structure 100 may include at least one layer made of an auxetic structure. This layer may be referred to as an "auxetic layer" (or "reactive layer"). When a person wearing an article of footwear including the sole structure 100 engages in an activity that places the auxetic layer under increased longitudinal or lateral tension, such as running, turning, jumping, or accelerating, the length and width of the auxetic layer increases and, thus, provides improved traction. This expansion of the auxetic material may also help absorb some of the impact with the playing surface. Although the following description discusses only a limited number of footwear types, embodiments may be applicable to many sports and recreational activities, including tennis and other racket sports, walking, jogging, running, hiking, handball, training, running or walking on a treadmill, and team sports such as basketball, volleyball, lacrosse, hockey, and soccer.

[0088] In some embodiments, the sole structure 100 may include features that facilitate expansion and / or adaptability of the sole structure during dynamic motion. In some embodiments, the sole structure may be configured with auxetic features. In particular, one or more components of the sole structure may be capable of undergoing auxetic motion (e.g., expansion and / or contraction). Figure 1 and Figure 2 The sole structure 100 specifically shown in FIG. 1 and described in further detail below has an auxetic structure or construction. Sole structures incorporating auxetic structures are described in Cross' U.S. Patent Application Publication No. 2015 / 0075033, published on March 19, 2015, and entitled "Auxetic Structure and Footwear Having a Sole with an Auxetic Structure" ("Auxetic Structure Application"), the entire contents of which are incorporated herein by reference.

[0089] As described in the Auxetic Structure Application, auxetic materials have a negative Poisson's ratio, such that when they are placed under tension in a first direction, their dimensions increase in the first direction and in a second direction orthogonal or perpendicular to the first direction. This property of auxetic materials or structures is Figure 1 and Figure 2 Shown in.

[0090] like Figure 1As shown, the sole structure 100 may include a plurality of holes. The plurality of holes 102 may be configured to provide an auxetic effect or an auxetic action. That is, when the sole structure 100 is subjected to a lateral force, the sole structure 100 may extend laterally as well as longitudinally. Figure 2 As shown, the sole structure 100 is subjected to a lateral force 104. When subjected to the lateral force 104, the sole structure 100 extends a lateral distance 106 and a longitudinal distance 108. Due to the geometric configuration of the plurality of holes 102, the sole structure 100 extends along an axis parallel to the lateral force 104 and along an axis perpendicular to the lateral force 104. As shown, each hole in the plurality of holes 102 expands laterally and longitudinally. The expansion of the holes, in turn, causes the sole structure 100 to also expand laterally and longitudinally. This effect may be referred to as auxetic expansion. It should be appreciated that the opposite auxetic contraction is also possible. That is, during auxetic contraction, when the sole structure 100 is subjected to a compressive lateral force, the lateral distance 106 and the longitudinal distance 108 may decrease. As a non-limiting example, one or more holes 102 may have a simple isoxalic star polygon shape.

[0091] In some embodiments, a sole structure may be designed to have a first size when at rest and a second size when subjected to a force. In some embodiments, varying the size of the holes within the sole structure may help determine or set the amount of stretch the sole structure will experience when subjected to a force. That is, by varying the size of the holes, the percentage change in cross-sectional area enclosed by the sole structure when subjected to a tensile force may be varied. Figure 1 As shown, the plurality of holes 102 may be narrow or small. In some embodiments, for example Figure 1 As depicted in , the plurality of apertures 102 may be slits in the sole structure 100. The narrower apertures may be configured to stretch to a greater degree than the larger apertures. This is because the percentage difference in cross-sectional area between the narrow apertures in an untensioned or relaxed state and the narrow apertures in a tensioned state is greater than the percentage difference in cross-sectional area between the larger apertures in an untensioned or neutral state and the larger apertures in a tensioned state.

[0092] In some embodiments, the plurality of holes 102 may be specifically sized in the relaxed state so that when subjected to a force, the stretched sole structure 100 will be a second specific size. For example, in some embodiments, the size of each hole in the plurality of holes 102 may be designed so that when pulled or stretched a specific distance, the plurality of holes 102 may be a specific size. More specifically, for example, when the sole structure 100 is stretched a quarter inch, the plurality of holes 102 may have a cross-sectional area of ​​approximately a quarter square inch. By changing the size of the plurality of holes 102 in the relaxed state, the size of the plurality of holes 102 in the tensioned state may be changed. Therefore, the desired size of each hole in the plurality of holes 102 when tensioned may be used to determine the size of the plurality of holes 102 in the relaxed state. In addition, using holes of a smaller size or a larger size in the relaxed state will also affect the size of the holes in the tensioned state.

[0093] In some embodiments, the size and shape of multiple holes 102 can be specially formed to realize various characteristics in the sole structure. In some embodiments, the size of multiple holes 102 can be designed so that when the footwear article utilizing the sole structure 100 is worn on the foot of the user, multiple holes 102 can be relatively large. That is, in some embodiments, when the sole structure 100 is stretched by the user, multiple holes 102 can surround a large percentage of the sole structure 100. In such embodiments, the sole structure 100 can be bent or twisted to a greater extent than in the embodiment with smaller holes. This is because the sole structure with less material can be bent to a greater extent than the sole structure with a larger amount of the same material. When stretched, the material of the sole structure 100 of the same amount is expanded on a larger cross section compared to the sole structure 100 in a tensioned state. In other embodiments, multiple holes 102 can be designed so that when worn by the user, a smaller percentage of the sole structure 100 is occupied by the holes. In such embodiments, the sole structure 100 can resist bending or twisting to a greater extent than in the embodiment with a larger area occupied by the holes. Embodiments may utilize designs having a smaller percentage of sole structure 100 occupied by apertures to allow for support and stability while also including a sole structure having auxetic properties.

[0094] The embodiments described herein may utilize any of the devices or structures described in U.S. Patent Application Publication No. 2015 / 0075033 to Cross, published on March 19, 2015, and entitled "Auxetic Structure and Footwear Having a Sole with an Auxetic Structure". In Cross et al., many different auxetic structures are discussed, having varying thicknesses, material compositions, and geometries associated with the sole structure. In addition, the embodiments described herein may also utilize the devices or structures described in U.S. Patent Application Serial No. 13 / 774,186 to Hull, U.S. Patent Application Publication No. 2014 / 0237850, the entire contents of which are incorporated herein by reference. In the Hull patent, an auxetic material is used in combination with a non-elastic material in the formation of the band.

[0095] Reference now Figure 3-Figure 6 , which describes a method of forming an article of footwear. With particular reference to Figure 3 , the sole structure 100 and the last contact surface 103 are spaced apart from the last 110 (e.g., the last of the shoe). In the depicted embodiment, the upper 112 can be positioned around a portion of the last 110. The upper 112 can be formed of various materials, including knitted materials, woven or non-woven materials, and foam, polyurethane materials, and other materials. In some embodiments, the upper 112 can be prepared to receive the sole structure 100. For example, in some embodiments, the upper 112 can include an adhesive applied along the edge of the upper 112. In other embodiments, the upper 112 can extend completely around the lower surface 114 of the last 110. In such an embodiment, the upper 112 can be sock-shaped. In an embodiment where the upper 112 extends along the lower surface 114 of the last 110, an adhesive such as glue can be applied along the portion of the upper 112 covering the lower surface 114 of the last 110.

[0096] In some embodiments, the flexibility and / or stretchability of the upper 112 can vary. In some embodiments, the upper 112 can be designed to have a small stretch, while in other embodiments, the upper 112 can be designed to have a significant stretch, so that in one or more directions, the dimension along the direction can increase its unstretched length by several or more percentages. The properties of the upper 112 can be changed or selected based on the expected fit of the article. For example, in an embodiment including a flexible sole structure, the upper 112 can also be flexible to complement the properties of the sole structure. In addition, the upper 112 can be rigid or less flexible to provide stability to the footwear article.

[0097] Reference now Figure 4, the sole structure 100 is shown positioned along the lower surface 114 of the last 110. For example, the sole structure 100 can be placed directly on the lower surface 114 of the last 110. As shown, the sole structure 100 is in a relaxed, neutral, or untensioned state, such that the plurality of apertures 102 are closed or contracted compared to the tensioned state. In this state, as can be seen, the sole structure 100 does not extend laterally or inwardly to the edge 116 of the upper 112. That is, the sole structure 100 is smaller or shorter than the last 110 in the longitudinal and transverse directions. Therefore, the area of ​​the last contacting surface of the sole structure 100 can be smaller than the area of ​​the lower surface 114 of the last 110. In some embodiments, in an untensioned or relaxed state, sole structure 100 may approximate the full width and full length of last 110, while in other embodiments, in an untensioned state, sole structure 100 may be 10% to 60% shorter or smaller in the transverse and / or longitudinal direction than last 110. In other embodiments, in an untensioned state, sole structure 100 may be 1% to 10% shorter or smaller in the transverse and / or longitudinal direction than last 110.

[0098] Reference now Figure 5 , the sole structure 100 can withstand the tensile force 118. As shown in the figure, when the sole structure 100 is subjected to the tensile force 118, the plurality of holes 102 expand. Because the plurality of holes 102 expand, the size of the sole structure 100 may also expand. Figure 5 As shown, when subjected to lateral forces, sole structure 100 can undergo auxetic expansion and extend laterally and longitudinally. In the illustrated configuration, sole structure 100 is now aligned with edge 116 of upper 112 along the medial and lateral sides and along the heel and forefoot portions of upper 112. As shown, sole structure 100 now occupies a greater percentage of the surface area of ​​lower surface 114. It should be appreciated that when stretched, the material forming sole structure 100 can stretch; however, auxetic expansion accounts for the majority of the change in surface area occupied by sole structure 100 in the tensioned configuration.

[0099] In some embodiments, when sole structure 100 is tensioned, the interior area of ​​sole structure 100 may be changed. As discussed herein, "interior area" refers to the area within the boundaries of a given article that defines the overall shape of the article. For example, perimeter 101 defines the boundaries of sole structure 100. Figure 4 The sole structure 100 shown may have a Figure 5 The sole structure 100 shown has a smaller interior area because the perimeter 101 surrounds less area in the untensioned or relaxed state than in the tensioned state. Therefore, the last contact surface 103 can surround a smaller interior area in the untensioned state than in the tensioned state.

[0100] In some embodiments, upper 112 can be secured to sole structure 100 while sole structure 100 is tensioned. Upper 112 can be secured to sole structure 100 using an adhesive, or upper 112 can be secured using other techniques. For example, in some embodiments, upper 112 can be stitched or sewn to sole structure 100, while in other embodiments, upper 112 can be secured to sole structure 100 using needles, pins, tacks, or other devices. Once sole structure 100 is secured to upper 112, article of footwear 120 can be formed.

[0101] Reference now Figure 6 , the article of footwear 120, also referred to simply as article 120, may be removed from the last 110. In some embodiments, the sole structure 100 may be specifically designed to accommodate additional stretching when the article 120 is removed from the last 110. When the article 120 is removed, additional tension may be applied to the sole structure 100, thereby further stretching the sole structure 100 and assisting in removing the article 120 from the last 110. By designing additional stretching accommodations into the sole structure 100, the article 120 may be more easily removed from the last 110 than an article of footwear that does not include additional stretching accommodations in the sole structure. When the article 120 is removed, various portions of the sole structure 100 may be compressed to a relaxed or neutral state. For example, the heel region 14 of the sole structure 100 may include fully closed pores, while the forefoot region 10 of the sole structure 100 may include nearly fully extended pores. Additionally, the midfoot region 12 may include partially enclosed pores. When the article 120 is removed from the last 110, the force or tension provided to the sole structure 100 by the last 110 can be removed, thereby allowing the sole structure 100 to return to a relaxed state. The article of footwear can be tuned using auxetic structures. Using auxetic structures, the ride, fit, and cushioning on the sole structure can be customized. Such customization is generally not possible when using a monolithic rubber or foam sole. The heel region 14 is configured to absorb energy while providing lateral stability. The midfoot region 12 can be stiffer and / or non-auxetic than the heel region 14 because the foot exerts very little contact pressure on the midfoot portion 12 compared to the heel region 14, and the forefoot region 10 has sufficient stiffness and structure to enable a good / firm push-off without the need to dig out a porous liner.

[0102] Reference now Figure 7, article 120 has been removed from last 110. As shown, length 122 of sole structure 100 is shorter than length 124 of last 110. Because forces have been released from sole structure 100, plurality of apertures 102 of sole structure 100 collapse or close in the relaxed state of sole structure 100, resulting in that the length of sole structure 100 may be reduced. Additionally, width 126 of sole structure 100 is less than width 128 of last 110. Because plurality of apertures 102 are arranged in an auxetic configuration, as the length of sole structure 100 is reduced, the width of sole structure 100 may also be reduced. Once article 120 is removed from last 110, last 110 no longer restricts sole structure 100 from returning to the relaxed form of sole structure 100.

[0103] Reference now Figure 8-Figure 14 , showing various views of an article of footwear in a relaxed state and when worn or used by a user. With particular reference to Figure 8-Figure 10 , depicting various views of article 120 in a static or relaxed state. Fig. 9 Sole structure 100 is depicted in a relaxed or untensioned state. While sole structure 100 is attached to upper 112, sole structure 100 may return to a shape and size similar to the shape and size of sole structure 100 before sole structure 100 was attached to upper 112. In other embodiments, upper 112 may be harder or more rigid such that upper 112 may resist or restrain sole structure 100 such that sole structure 100 is unable to return to a fully relaxed configuration.

[0104] Reference now Fig.10 , depicting a cross-sectional view of article 120. As shown, the plurality of apertures 102 of sole structure 100 are narrow, which in turn causes sole structure 100 to have a width 126 that is also narrow. Because upper 112 is bonded to sole structure 100 when sole structure 100 is under tension from last 110, upper 112 may include excess material when tension is removed. Thus, in some embodiments, upper 112 may form a bulbous structure when article 120 is in a relaxed state. This figure is representative and does not necessarily depict the amount of additional material that may be present.

[0105] Figure 11-Figure 14The article 120 is depicted with a user's foot 130 inserted into the article 120. As the foot 130 is inserted into the article 120, the sole structure 100 may auxetically stretch to accommodate the foot 130. In some embodiments, the foot 130 may be longitudinally longer than the sole structure 100. In such embodiments, the sole structure 100 may expand longitudinally to accommodate the length of the foot 130. Similarly, in some embodiments, the foot 130 may be laterally wider than the sole structure 100. In such embodiments, the sole structure 100 may expand laterally to accommodate the width of the foot 130.

[0106] Special References Fig.13 and Fig.14 , the changes in width and length of sole structure 100 are clearly depicted. Fig.13 The dashed line shown in FIG. 1 represents the sole structure 100 when the sole structure 100 is not subjected to a force (eg, Fig. 9 ). Fig.13 In the embodiment, the sole structure 100 has been stretched by the foot 130, so that the sole structure 100 is extended laterally and longitudinally. Fig.14 As shown, the width 132 of the sole structure 100 may be greater than Fig.10 Width 126 is shown. When foot 130 presses against upper 112 of article 120, upper 112 can pull sole structure 100. This pulling or tensioning of sole structure 100 can cause plurality of apertures 102 within sole structure 100 to expand, thereby causing sole structure 100 to expand.

[0107] In some embodiments, the design of sole structure 100 can increase the comfort or fit of article 120. Because sole structure 100 can expand to accommodate the foot, the fit of article 120 can be more comfortable or more precise when compared to other embodiments without sole structure 100. When the foot is pressed against upper 112, sole structure 100 expands to accommodate the shape or size of foot 130. Upper 112 can fit closely to foot 130 because sole structure 100 accommodates the size of foot 130.

[0108] In other embodiments, the sole structure may be designed so that it is compressed before being attached to the upper. That is, in some embodiments, the sole structure may be larger when in a relaxed state and compressed before being attached to the upper. In such embodiments, the holes may be larger in the relaxed state than those depicted in the previous embodiments. Once compressed, the sole structure will reduce in size in the lateral and longitudinal directions in order to align with the upper around the last. This technique will provide a larger sole structure in the relaxed state.

[0109] Reference now Figure 15-18 , depicting an alternative embodiment of a portion of an article of footwear. Fig.15 The sole structure 200 is depicted in an untensioned or relaxed state. In some embodiments, the sole structure 200 may have a composition similar to that of the previously described sole structure 100. In other embodiments, the sole structure 200 may be formed of a different material, thickness, size, or shape. The sole structure 200 may include a plurality of holes 202. In some embodiments, the plurality of holes 202 may have an auxetic shape or may be arranged in an auxetic configuration as previously discussed with respect to the sole structure 100. That is, the plurality of holes 202 may be shaped such that when the sole structure 200 is laterally subjected to tension, the sole structure 200 may extend laterally and longitudinally. Additionally, when the sole structure 200 is laterally compressed, the sole structure 200 may decrease in width as well as length. For example, one or more holes 202 may have a simple isoxalic star polygon shape.

[0110] like Fig.16 As shown, the upper 212 is depicted as including a plurality of holes 242. In some embodiments, the upper 212 can be formed of the same material as the sole structure 200. In other embodiments, the upper 212 can be formed of various other materials. For example, in some embodiments, the upper 212 can be formed of a textile material, a non-textile material, or a knitted material. In other embodiments, the upper 212 can be formed of a polyurethane material or foam, among other materials.

[0111] Reference now Fig.17 and Fig.18 , sole structure 200 is subjected to tension 218, while upper 212 is subjected to tension 248. In a manner similar to sole structure 100, sole structure 200 and upper 212 can expand. When subjected to tension 218 along the transverse axis, sole structure 200 can expand laterally as well as longitudinally. In a similar manner, when subjected to tension 248 along the transverse axis, upper 212 can expand or extend laterally as well as longitudinally. As previously discussed, because upper 212 and sole structure 200 include pores arranged in an auxetic configuration, both upper 212 and sole structure 200 can extend in a direction parallel to the direction of the tension as well as in a direction perpendicular to the direction of the tension. The pores of sole structure 200 and upper 212 can expand in a manner as previously discussed with reference to sole structure 100. That is, plurality of pores 202 and plurality of pores 242 can expand in an auxetic manner.

[0112] Reference now Fig.19, depicting sole structure 200, upper 212, and last 210. In this view, sole structure 200 and upper 212 are in a relaxed or untensioned state. Thus, as shown, multiple holes 202 and multiple holes 242 are in a closed or relaxed state. As previously discussed with reference to sole structure 100, multiple holes 202 and multiple holes 242 can be of various shapes and sizes. That is, although depicted as slits or narrow holes, multiple holes 202 and multiple holes 242 can be larger than Fig.19 By varying the size of plurality of apertures 202 and plurality of apertures 242 in the relaxed state, as depicted in FIG, the flexibility and fit of an article utilizing sole structure 200 and upper 212 may be varied.

[0113] In some embodiments, the dimensions of the upper may be designed so that the upper needs to be stretched when wrapped around the last. Fig.19 As shown, the size of the upper 212 can be designed so that in order to wrap the upper 212 around the shoe last 210, it may be necessary to stretch the upper 212 so that the plurality of holes 242 expand. That is, in some embodiments, in a relaxed or untensioned state, the upper 212 can be smaller than the size required to wrap the shoe last 210 and form a footwear article. In some embodiments, the upper 212 can be specifically sized so that when stretched, the upper 212 can extend vertically, laterally, and longitudinally to specific areas along the shoe last 210.

[0114] Reference now Fig. 20 , the upper 212 is shown wrapped around the last 210. As the upper 212 is wrapped around the last 210, various portions of the upper 212 may begin to stretch. As shown, for example, the plurality of holes 242 in the forefoot region 10 may stretch to a greater degree than the plurality of holes 242 toward the midfoot region 12. As the upper 212 is pressed, pulled, and stretched around the last 210, the plurality of holes 242 may expand, thereby increasing the size of the upper 212.

[0115] Reference now Fig.21 , the upper 212 can be fixed around the shoe last 210. As shown, the plurality of holes 242 can be expanded in an auxetic manner. Because the upper 212 can be folded or twisted when wrapped around the shoe last 210, the upper 212 can be in a three-dimensional orientation. This orientation can allow the upper 212 to extend vertically (e.g., along the ankle area 16 of the shoe last 210) as well as laterally and longitudinally. The position and orientation of the upper 212 can be specifically designed to stretch a specific amount laterally, longitudinally, and vertically. By specifically arranging the holes and specifically setting the size of the holes, the position and size of the upper 212 on the shoe last 210 can be specifically located.

[0116] Reference now Fig. 22, the sole structure 200 can be placed along the shoe last 210. As shown, the sole structure 200 may not extend to the edge 216 of the upper 212. The sole structure 200 can be designed so that when stretched (such as Fig.23 ), the sole structure 200 may be aligned with the edge 216. That is, the sole structure 200 may be designed so that when tensioned, the sole structure 200 will be aligned with the edge 216 from the heel area 14 to the forefoot area 10 and from the medial side 18 to the lateral side 20, so that Fig. 22 As shown, the plurality of holes 202 can be closed or collapsed when not being tensioned. This design can allow the sole structure 200 to be able to stretch a greater amount and be attached to the upper 212 with a specific tension on the upper 212.

[0117] Special References Fig.23 , sole structure 200 may be tensioned such that the perimeter of sole structure 200 is aligned with edge 216. In a similar manner as described with reference to the alternative embodiment, upper 212 may be secured to sole structure 200 in this configuration. While stretched, sole structure 200 may be glued, stitched, fastened, or otherwise secured to upper 212.

[0118] like Fig.23 As shown, the footwear article 220 or simply the article 220 can be formed by fixing the sole structure 200 to the upper 212. In some embodiments, the sole structure 200 and the upper 212 can be stretched to the same or similar tension. Therefore, in some embodiments, the size of the plurality of holes 242 and the plurality of holes 202 is as follows: Fig.23 212 may be substantially the same when tensioned. In other embodiments, various portions of sole structure 200 and upper 212 may have similar or substantially the same tension levels. By matching the tension of upper 212 and sole structure 200, article of footwear 220 formed with both upper 212 and sole structure 200 may be stretched in a substantially uniform manner.

[0119] Reference now Fig.24, depicting article 220 being removed from last 210. Because both upper 212 and sole structure 200 include plurality of holes 242 and plurality of holes 202, upper 212 and sole structure 200 may stretch during removal. By arranging plurality of holes 202 in an auxetic configuration, article 220 may be more easily removed from last 210 when compared to other articles that do not include holes arranged in an auxetic configuration. The arrangement of holes in article 220 allows article 220 to expand in multiple directions when subjected to tension, compared to other embodiments that may utilize holes that are not arranged in an auxetic configuration. For example, by laterally tensioning sole structure 200, sole structure 200 will expand laterally as well as longitudinally. In other embodiments without holes in an auxetic configuration, laterally tensioning sole structure 200 will longitudinally reduce the length of sole structure 200. Reducing the length of sole structure 200 may inhibit removal of article 220 from last 210. Thus, the arrangement of the apertures of the auxetic construction may facilitate removal of the article 220 from the last 210 .

[0120] Reference now Fig.25 , depicting article 220 removed from last 210. As shown, article 220 is smaller in the lateral, longitudinal, and vertical directions than when article 220 is mounted on last 210. As previously discussed, because upper 212 and sole structure 200 are tensioned or stretched around last 210 during assembly, the tensioning can be released when removed from last 210. As shown, multiple holes 242 of upper 212 and multiple holes 202 of sole structure 200 can be closed or of reduced cross-sectional area. The reduction in size can result in a reduction in the overall size of upper 212 and sole structure 200, thereby reducing the size of article 220.

[0121] See now Figure 26 to Figure 28 , various views of an article 220 are shown. In these figures, the article 220 is depicted in a relaxed or untensioned state. Fig.26 is an isometric view of article 220. Fig.26 As shown, the plurality of apertures 242 of the upper 212 are in a closed or relaxed state. Fig. 27 Included is a depiction of a transverse cross-section of article 220 through sole structure 200 and upper 212 . Fig.28 A depiction of article 220 including a longitudinal cross-section through sole structure 200 and upper 212 .

[0122] like Fig. 27As shown, the sole structure 200 has an untensioned width 300. Because the plurality of apertures 202 of the sole structure 200 are narrow or closed, the width of the sole structure 200 can be narrower than when the sole structure 200 is tensioned. Similarly, the apertures 242 of the upper 212 can also be narrow or closed. Because the plurality of apertures 242 are narrow or closed, when the upper 212 is stretched, the untensioned lateral perimeter 304 can be shorter or smaller than the perimeter of the upper 212. The untensioned lateral perimeter 304 can refer to the cross-sectional perimeter of the upper 212 from the medial side 18 to the lateral side 20 of the article 220. By changing the perimeter of the upper 212, the cross-sectional area of ​​the cavity 306 can also be changed or varied. As shown in FIG. Fig. 27 As shown, transverse cross-sectional area 308 of cavity 306 can be smaller than the transverse cross-sectional area when upper 212 is tensioned. Additionally, tensioning sole structure 200 can also help to expand transverse cross-sectional area 308. Because both sole structure 200 and upper 212 define cavity 306, when the length of either or both of sole structure 200 and upper 212 changes, the volume of cavity 306 can change, and the cross-sectional areas of various portions of article 220 can also change.

[0123] In some embodiments, the upper and sole structures of the article of footwear may have various thicknesses. Fig. 27 As shown, upper 212 has a thickness 250 and sole structure 200 has a thickness 252. In some embodiments, thickness 250 of upper 212 can be similar to thickness 252 of sole structure 200. In other embodiments, thickness 250 can be greater than thickness 252. In still other embodiments, thickness 250 can be less than thickness 252. The thickness of various components of article 220 can be varied to change the amount of cushioning, support, or other properties.

[0124] See now Fig.28 , which depicts a longitudinal cross-section of the article 220. As shown, the plurality of holes 202 of the sole structure 200 and the plurality of holes 242 of the upper 212 can be narrow or closed in a relaxed state. In this configuration, the sole structure 200 has an untensioned length 310. Because the plurality of holes 202 are closed or narrow in the untensioned configuration, the untensioned length 310 can be less than the length in embodiments where the sole structure 200 is subjected to tension. In addition, as shown in FIG. Fig.28 As shown, upper 212 includes an untensioned longitudinal perimeter 312. Untensioned longitudinal perimeter 312 may extend from a toe edge of sole structure 200 to a heel edge of sole structure 200. In this configuration, untensioned longitudinal perimeter 312 may be smaller than the longitudinal perimeter when article 220 is tensioned.

[0125] In the illustrated configuration, the cavity 306 can have a relatively small volume when compared to the tensioned article 220. Thus, as shown, the article 220 can occupy a smaller space or volume when compared to other embodiments that do not include pre-stretched or pre-tensioned auxetic features. Because the article 220 can be smaller than other articles, the packaging and storage of the article 220 can be smaller than other embodiments that do not utilize auxetic holes in the upper and sole structures. By reducing the amount of space required to store the article 220, the amount of money required to form boxes or other containers and storage costs can be reduced.

[0126] Reference now Figure 29-Figure 32 , the foot can be inserted into the article 220. Fig.29 As shown, the foot 400 is inserted through the ankle opening 402 of the article 220. As shown, the plurality of apertures 242 of the upper 212 can be expanded to assist in inserting the foot 400 into the article 220.

[0127] Reference now Figure 30-Figure 32 , depicts various views of an article 220 having a foot 400. Fig.30 As shown, when foot 400 is inserted into article 220, plurality of apertures 242 may expand. Although plurality of apertures 242 are shown as expanding to the same extent, it should be appreciated that each aperture in plurality of apertures 242 may expand at a different rate or to a different size, depending on the amount of force received by each area of ​​upper 212. For example, in some embodiments, foot 400 may be wider in forefoot region 10 than in heel region 14, and therefore, in some embodiments, plurality of apertures 242 in forefoot region 10 may not expand to the same extent or the same amount as plurality of apertures 242 in heel region 14.

[0128] See also Fig.31 , depicting a transverse cross-section of article 220. As shown, foot 400 presses against upper 212 and causes plurality of apertures 242 to expand. Additionally, foot 400 may also expand plurality of apertures 202. By expanding upper 212 and sole structure 200, foot 400 may also increase the volume of cavity 306.

[0129] like Fig.31As shown, as the plurality of apertures 202 expand, the width of the sole structure 200 increases to a tensioned width 404. In this embodiment, the tensioned width 404 may be greater than the untensioned width 300. The ability of the sole structure 200 to conform and respond to the size and shape of the foot 400 may increase comfort and feel compared to embodiments that do not include apertures arranged in an auxetic configuration. Additionally, the tensioned lateral perimeter 406 may be greater than the untensioned lateral perimeter 304. Because the tensioned lateral perimeter 406 and the tensioned width 404 of the article 220 may be greater than the article 220 in the untensioned state, the transverse cross-sectional area of ​​the article 220 may be greater than the transverse cross-sectional area 308 of the untensioned article 220. The larger cross-sectional area of ​​the tensioned article 220 may allow the article 220 to accommodate feet of various sizes in a comfortable manner. By including various apertures having an auxetic configuration, pressure points along the foot 400 may be reduced.

[0130] In some embodiments, upper 212 and sole structure 200 can be pressed against foot 400 so that article 220 closely or closely conforms to the shape and size of foot 400. This close fit can mimic the barefoot feel of the user. Additionally, because article 220 can expand by different amounts based on different levels of tension, users with differently shaped feet can be able to have a comfortable and form-fitting article of footwear with the same article of footwear. That is, a single article of footwear can comfortably fit on feet of different shapes.

[0131] In some embodiments, the thickness of various components of the article can remain substantially consistent when stretched. Fig.31 2, the thickness 250 of the upper 212 remains substantially unchanged in the stretched configuration. Additionally, the thickness 252 of the sole structure 200 also remains substantially unchanged in the stretched configuration. The thickness 250 may remain substantially the same between the upper 212 when untensioned and the upper 212 when tensioned because the plurality of holes 242 are opened or expanded when the upper 212 is stretched. Similarly, the plurality of holes 202 of the sole structure 200 are opened or expanded when stretched. Because the plurality of holes are able to be opened or expanded, the amount of stress on the material forming the upper 212 and the sole structure 200 may be reduced. Thus, the material forming the upper 212 and the sole structure 200 may not be stretched to the same extent as an upper or sole structure that does not include auxetic holes. For example, a sole structure that does not include holes may be stretched both laterally and longitudinally; however, the thickness of the sole structure will also be reduced when stretched both laterally and longitudinally. This is because, without the apertures, the material forming the sole structure itself would stretch, as compared to the present embodiment which utilizes the mechanical structure of sole structure 200 and upper 212 to expand.

[0132] See now Fig.32, depicting a longitudinal cross-section of the article 220. As shown, the plurality of apertures 242 and the plurality of apertures 202 have been expanded, and thus the longitudinal perimeter and length of the article 220 have been expanded. For example, the tensioned longitudinal perimeter 410 may be greater than or longer than the untensioned longitudinal perimeter 312. Additionally, the tensioned length 408 may be longer or greater than the untensioned length 310. The expansion of the length, width, and perimeter of the article 220 may allow for insertion of feet of various shapes into the article 220. Additionally, the article 220 may conform to the foot 400 as the portions stretch when subjected to a force.

[0133] Reference now Fig.33 , depicts an alternative article of footwear. As shown, article 502 includes a plurality of apertures 504. The plurality of apertures 504 may be arranged in an auxetic configuration as previously discussed with respect to other embodiments. A foot 500 may be inserted into article 502 and cause various portions of article 502 to stretch relative to other portions. Because foot 500 may not have a uniform shape or size, various portions of article 502 may stretch to different degrees relative to each other. For example, forefoot apertures 506 in forefoot region 10 may stretch to a greater degree than midfoot apertures 508 in midfoot region 12. Additionally, heel apertures 510 in heel region 14 may stretch to a greater degree than midfoot apertures 508.

[0134] In some embodiments, the size of the plurality of holes 504 may vary in a pre-stretched form. That is, before forming the article 502, the plurality of holes 504 may be specifically sized for a desired effect. For example, in a pre-stretched configuration, the mid-foot hole 508 may be smaller than the forefoot hole 506. When worn by a user, in some embodiments, the mid-foot hole 508 and the forefoot hole 506 may have approximately the same size. By determining where various pressure points may be located on the article 502, the article 502 may be designed to have approximately the same size holes when worn by a user. This may give the user a uniform feel throughout the article 502 around the foot 500.

[0135] In some embodiments, the sole structure and the upper may be designed to have different stretch properties. For example, Fig.34 The sole structure 600 and upper 602 shown in FIG. 6 can have holes of substantially similar sizes. In such an embodiment, when assembled, the footwear article can have holes of similar shapes. Such a constructed article may require the same amount of force to stretch the upper 602 and the sole structure 600. That is, when subjected to forces of substantially similar magnitude, the holes of the upper 602 and the sole structure 600 can expand at substantially similar rates. In other embodiments, for example, Fig.35As shown, the upper and sole structure may have holes of different shapes. For example, the plurality of holes 704 of the upper 702 may be larger than the plurality of holes 706 of the sole structure 700. The article may be designed in this way so as to limit the stretching in various areas. The plurality of holes 704 may have a small amount that allows them to stretch. In contrast, the plurality of holes 706 of the sole structure 700 are shown as slits. This configuration may allow the plurality of holes 706 to stretch to a greater extent than the plurality of holes 704. Both the plurality of holes 704 and the plurality of holes 706 may generally be expanded into a triangle. However, the plurality of holes 706 may be further away from the triangular shape than the plurality of holes 704. That is, the plurality of holes 706 have a larger chamber or expansion capacity than the plurality of holes 704. Due to this difference, the sole structure 700 may increase the amount of greater length and width or increase at a greater rate than the upper 702 when subjected to tension. By changing the geometry of the plurality of holes in the sole structure or the upper, the amount of stretching may therefore be limited, increased or otherwise customized.

[0136] Although various embodiments have been described, the description is intended to be exemplary rather than limiting, and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations within the scope of the embodiments are possible. Unless otherwise specified, any feature of any embodiment may be used in combination with or replace any other feature or element in any other embodiment. Therefore, the embodiments are not limited except in accordance with the appended claims and their equivalents. Moreover, various modifications and changes may be made within the scope of the appended claims.

Claims

1. A footwear product comprising: vamp; Sole structure; wherein each of said upper and said sole structure defines a plurality of apertures arranged in an auxetic configuration; wherein, when the article of footwear is formed, the area of ​​the last-contacting surface of the sole structure is less than the area of ​​the lower surface of the last, and when the sole structure is subjected to a lateral force, the sole structure undergoes auxetic expansion and extends laterally and longitudinally such that a perimeter of the sole structure is aligned with an edge of the upper, and the upper is secured to the sole structure when the sole structure is tensioned; Therein, when worn by a user, the sole structure is configured to expand auxetically, and the upper is also configured to expand auxetically.

2. The footwear article according to claim 1, wherein: The sole structure has a first thickness when the sole structure is in a neutral state and has a second thickness when the sole structure is subjected to a lateral force, and the first thickness and the second thickness are substantially similar.

3. The article of footwear according to claim 1, wherein: When the upper and the sole structure are subjected to the same magnitude of force, both the upper and the sole structure are configured to expand at substantially similar rates.

4. The article of footwear according to claim 1, wherein: When the upper and the sole structure are subjected to the same magnitude of force, the upper expands at a rate greater than a rate at which the sole structure expands.

5. The article of footwear according to claim 1, wherein: The sole structure is formed from foam.

6. The article of footwear according to claim 1, wherein: When the sole structure is tensioned, the plurality of apertures of the sole structure are substantially the same size as the plurality of apertures of the upper when the upper is tensioned.

7. The article of footwear according to claim 1, wherein: When the sole structure is tensioned, the plurality of apertures of the sole structure are larger than the plurality of apertures of the upper when the upper is tensioned.

8. The article of footwear according to claim 1, wherein: The sole structure includes a forefoot area, a heel area, and a midfoot area arranged between the heel area and the forefoot area, the multiple holes of the sole structure in the heel area are completely closed, the multiple holes of the sole structure in the forefoot area are almost completely extended, and the multiple holes of the sole structure in the midfoot area are partially closed.

9. The article of footwear according to claim 1, wherein: The upper has a first thickness, the sole structure has a second thickness, and the first thickness is less than the second thickness.

10. The article of footwear according to claim 1, wherein: The plurality of apertures of the upper are larger than the plurality of apertures of the sole structure.

11. The article of footwear according to claim 1, wherein: The plurality of apertures of the upper and the plurality of apertures of the sole structure expand at substantially similar rates when subjected to forces of substantially similar magnitudes.

12. A footwear article comprising: vamp; a sole structure attached to the upper, wherein the sole structure includes a forefoot region, a heel region, and a midfoot region disposed between the heel region and the forefoot region, wherein, when forming the article of footwear, the area of ​​the last contacting surface of the sole structure is less than the area of ​​the lower surface of the last, and when the sole structure is subjected to a lateral force, the sole structure undergoes auxetic expansion and extends laterally and longitudinally such that a perimeter of the sole structure is aligned with an edge of the upper, and the upper is secured to the sole structure when the sole structure is tensioned; wherein the article of footwear is in a worn state when a wearer's foot is positioned within a space defined between the upper and the sole structure, and wherein the article of footwear is in an unworn state when a foot is not present within the space; wherein each of the upper and the sole structure defines a plurality of apertures arranged in an auxetic configuration; wherein, when in the unworn state, the plurality of holes of the sole structure in the heel region are completely closed, the plurality of holes of the sole structure in the forefoot region are almost fully extended, and the plurality of holes of the sole structure in the midfoot region are partially closed; and Wherein, when a foot is inserted into the void to transition the article of footwear from the unworn state to the worn state, the sole structure is configured to expand auxetically and the upper is also configured to expand auxetically.

13. The article of footwear according to claim 12, wherein: The sole structure has a first thickness when the sole structure is in a neutral state and has a second thickness when the sole structure is subjected to a lateral force, and the first thickness and the second thickness are substantially similar.

14. The article of footwear according to claim 12, wherein: When the upper and the sole structure are subjected to the same magnitude of force, both the upper and the sole structure are configured to expand at substantially similar rates.

15. The article of footwear according to claim 12, wherein: When the upper and the sole structure are subjected to the same magnitude of force, the upper expands at a rate greater than a rate at which the sole structure expands.

16. The article of footwear according to claim 12, wherein: The sole structure is formed from foam.

17. The article of footwear according to claim 12, wherein: When the sole structure is tensioned, the plurality of apertures of the sole structure are substantially the same size as the plurality of apertures of the upper when the upper is tensioned.

18. The article of footwear according to claim 12, wherein: When the sole structure is tensioned, the plurality of apertures of the sole structure are larger than the plurality of apertures of the upper when the upper is tensioned.

19. The article of footwear according to claim 12, wherein: The upper has a first thickness, the sole structure has a second thickness, and the first thickness is less than the second thickness.

Images