Article of footwear and method of manufacturing an article of footwear

Abstract

The present application relates to an article of footwear and a method of manufacturing an article of footwear. The article of footwear includes a sole structure and a guide secured to an interior surface of the sole structure. An exterior surface of a bottom of an upper is secured to the interior surface of the sole structure, the upper and the guide forming a channel. A tensioning member extends along the guide in the channel and out of the channel at a medial side and / or a lateral side of the upper. An increase in tension in the tensioning member causes the sole structure to flexingly conform to a foot disposed in the upper. The method of manufacturing the article of footwear includes placing the upper on a last, applying an adhesive on the interior surface of the sole structure, placing the guide on the adhesive, placing the tensioning member on the guide, and abutting the interior surface of the sole structure against the exterior surface of the upper.

Description

[0001] This application is a divisional application of the application filed on November 11, 2019, with application number 201980086539.4 and invention title "Footwear Articles and Method of Manufacturing Footwear Articles".

[0002] Cross-references to related applications

[0003] This application claims the benefit of priority to U.S. Provisional Application No. 62 / 785,438, filed December 27, 2018, which is incorporated herein by reference in its entirety. Technical Field

[0004] This disclosure generally relates to footwear articles and methods of manufacturing footwear articles. background

[0005] Footwear typically includes a sole structure that is configured to lie beneath the wearer's foot to separate the foot from the ground. The sole structure can generally be configured to provide one or more of cushioning, motion control, and rebound. Brief description of the attached diagram

[0006] The accompanying drawings described herein are for illustrative purposes only, are schematic in nature, and are intended to be exemplary and not to limit the scope of this disclosure.

[0007] Figure 1 It is an external view of footwear, including the sole structure and the upper.

[0008] Figure 2 yes Figure 1 A top view of footwear, in which the tensioning components are shown as being untensioned.

[0009] Figure 3 yes Figure 1 A top view of footwear, in which the tensioning components are shown as being in a fixed state.

[0010] Figure 4 Is Figure 3 The line 4-4 was cut off. Figure 3 A cross-sectional view of footwear, where the increased tension in the tensioning component is shown in dashed lines.

[0011] Figure 5 Is Figure 3 The line 5-5 was cut off. Figure 3 A cross-sectional view of footwear, where the increased tension in the tensioning component is shown in dashed lines.

[0012] Figure 6It is a cross-sectional view of a footwear article with an alternative sole structure, and the state of increased tension in the tensioning component is shown in dashed lines.

[0013] Figure 7 yes Figure 6 Another cross-sectional view of the footwear, showing the state of increased tension in the tensioning component in dashed lines.

[0014] Figure 8 yes Figure 1 A top view of the sole structure before it is attached to the upper.

[0015] Figure 9 yes Figure 8 A top view of the shoe sole structure, with markings for placing the upper, guide, and tensioning components.

[0016] Figure 10 yes Figure 8 A top view of the sole structure, in which adhesive is applied to the proximal inner surface.

[0017] Figure 11 yes Figure 10 A top view of the sole structure, with guides placed on the adhesive.

[0018] Figure 12 yes Figure 11 A top view of the sole structure, in which the tensioning element is placed on the guide and has an end extending to the adhesive.

[0019] Figure 13 yes Figure 12 A top view of the sole structure, in which the lasted upper is placed on the sole structure above the adhesive, guides and tensioning components.

[0020] Figure 14 It is a partial cross-sectional view of an assembly drawing used for applying adhesive and heating a pre-formed sole structure in a fixture shown in cross-section.

[0021] Figure 15 This is a medial side view of the upper during the process of being placed on the sole structure above the adhesive, guides, and tensioning components.

[0022] Figure 16 yes Figure 15 An inner side view of the upper and sole structure of the last, wherein the sole structure is formed into the upper.

[0023] Figure 17 This is a lateral view of footwear.

[0024] Figure 18 This is a bottom view of the shoe sole components.

[0025] Figure 19 yes Figure 18 A top view of the shoe sole structure.

[0026] Figure 20 This is a top view of the components of the sole structure, including guides and tensioning parts.

[0027] Figure 21 This is a top view of the components of the sole structure, including guides and tensioning parts.

[0028] Figure 22 This is a top view of the components of the sole structure, including guides and tensioning parts.

[0029] Figure 23 It is a flowchart of a method for manufacturing footwear articles having a sole structure formed on the upper.

[0030] describe

[0031] This disclosure generally relates to footwear articles and a method of manufacturing footwear articles having a sole structure adapted to conform to a foot disposed in the upper by tensioning a tensioning member disposed between the upper and the sole structure. By including a guide between the sole structure and the upper, the tensioning member is movable relative to the sole structure and the upper along the guide to conform the sole structure around the upper and the foot disposed in the upper. The sole structure, in its pre-formed state (before it is formed onto the upper), may have a relatively planar inner surface, allowing for a relatively easy process of rolling an adhesive along the planar surface, enabling the sole structure to adhere to the upper.

[0032] In conventional footwear construction, the sole structure is molded into its final shape through processes such as compression molding or injection molding. Subsequently, the sole structure can be adhered to the upper, for example by applying an adhesive to both the final sole structure and the strobel (midsole fabric) portion of the upper, thus securing these components together. In this disclosure, the sole structure has an intermediate shape (which may be referred to as an intermediate sole structure or a pre-formed sole structure), and the sole structure is then thermoformed to the upper to become the final shape. The sole structure has an intermediate molded shape prior to thermoforming. This process overcomes the design limitations present when relying on molding to achieve the final shape of the sole structure, as designs with undercuts can be difficult to remove from the mold. Furthermore, sole structures comprising multiple layers of materials are difficult or impossible to form using conventional molding because molding multi-material geometries can be difficult or impossible to control if the various materials are layered, for example, within protrusions or other isolating features.

[0033] In the example, footwear may include a sole structure having an inner surface. A guide may be attached to the inner surface of the sole structure. The outer surface of the bottom of the upper may be attached to the inner surface of the sole structure around the guide, wherein the guide is located between the bottom of the upper and the sole structure, and the upper and the guide form a channel. A tensioning member may extend along the guide in the channel and may extend out of the channel at at least on the inner or outer side of the upper. In response to an increase in tension in the tensioning member, the tensioning member may be movable relative to the upper and the guide in the channel to allow the sole structure to flexibly conform to the foot disposed in the upper. Thus, in addition to the degrees of freedom in geometry and other benefits of the sole structure thermoformed to the upper, the guide and tensioning member enable a further adaptation of the fit to the wearer.

[0034] In one or more embodiments, the outer surface of the guide may adhere to a first portion of the inner surface of the sole structure, and the outer surface of the upper may adhere to a second portion of the inner surface of the sole structure, and not adhere to the inner surface of the guide at the channel.

[0035] In one or more configurations, the sole structure may have a base portion, an inner sidewall portion extending upward from the base portion along the inner side of the upper at the inner side of the base portion, and an outer sidewall portion extending upward from the base portion along the outer side of the upper at the outer side of the base portion. A guide may extend along the inner surface of the sole structure at the base portion and at least at one of the inner or outer sidewall portions.

[0036] In one aspect of this disclosure, the upper can be configured as a strobel-less bootie or sock. In another aspect, an adhesive layer can be disposed on the inner surface of the sole structure, and the guide and the upper can be secured to the inner surface of the sole structure.

[0037] The sole structure can be siped to further enhance its ability to be adjusted to conform to the foot positioned within the upper. For example, in one or more configurations, the sole structure may have multiple sipes extending partially through the outer surface of the sole structure, and these sipes may be adapted to further open when the tensioning element is tensioned. In another aspect, the sole structure may include multiple sipes extending partially through the inner surface of the sole structure. The sipes on the inner surface of the sole structure may deviate from and alternate with the sipes on the outer surface of the sole structure. Furthermore, the sipes on the inner surface of the sole structure may be adapted to at least partially close when the tensioning element is tensioned. In other words, when the tensioning element is tightened, the sipes allow the sole structure to more easily tighten around the foot positioned within the upper.

[0038] In various configurations, one or more guides may be used, and one or more tensioning components may have fixed ends that are attached to the sole structure, or may simply extend through the channel across the sole structure without being attached to it.

[0039] For example, in one or more embodiments, the guide may define an X shape, and two intersecting channels may be formed between the guide and the bottom of the upper. A first tensioning member may be disposed in one of the two intersecting channels, and a second tensioning member may extend along the guide in the other of the two intersecting channels and may extend beyond the first tensioning member.

[0040] In one or more configurations, the guide may be a first guide, the channel may be a first channel, and the tensioning member may be a first tensioning member having a fixed end attached to the inner surface of the sole structure. The first tensioning member may extend from the fixed end along the first guide in the first channel and may extend out of the channel at the inner side of the upper. A second guide may be attached to the inner surface of the sole structure, and the upper and the second guide may form a second channel. The second tensioning member may have a fixed end attached to the inner surface of the sole structure. The second tensioning member may extend from the fixed end along the second guide in the second channel and may extend out of the channel at the outer side of the upper. By placing the fixed end of the tensioning member closer to the side opposite to the side from which the tensioning member extends out of the channel and is pulled to increase tension, the force on the sole structure at the fixed end is at a greater distance from the side where the tensioning member is pulled, making it easier for the tensioning member to tighten a larger portion of the sole structure.

[0041] In one aspect of this disclosure, the tensioning member can be positioned to balance this tightening effect. For example, the fixed end of the first tensioning member can be fixed to the sole structure closer to the outer edge of the sole structure than to the inner edge of the sole structure, and the fixed end of the second tensioning member can be fixed to the sole structure closer to the inner edge than to the outer edge of the sole structure.

[0042] In another embodiment, the tensioning components can be arranged to provide a balanced and maximized tightening effect on the sole structure. First and second guides can be spaced apart from each other along the longitudinal direction of the sole structure on the inner surface of the sole structure. In one or more configurations, the first guide can be one of a plurality of medial guides, and the second guide can be one of a plurality of lateral guides, each guide being fixed to the inner surface of the sole structure, and each guide forming a channel together with the upper. The medial guides can be arranged in an alternating sequence with the lateral guides. The first tensioning component can be one of a plurality of medial tensioning components, each medial tensioning component having a fixed end fixed to the sole structure closer to the lateral edge of the sole structure than the medial edge of the sole structure, and each medial tensioning component extending from the fixed end along one of the medial guides in a channel, extending from the medial side of the upper out of that channel. The second tensioning component may be one of a plurality of outer tensioning components, each outer tensioning component having a fixed end fixed to the sole structure closer to the inner edge of the sole structure than the outer edge of the sole structure, and each outer tensioning component extending from the fixed end along one of the outer guides in a channel, and extending the channel at the outer side of the upper.

[0043] When multiple guides are used, these guides can be configured to also function as supports on the medial and lateral sides of the upper. For example, in one or more configurations, the medial guide can extend onto the medial side support on the medial side of the upper and can be constructed together with the medial side support as a unitary, one-piece component. Similarly, the lateral guide can extend onto the lateral side support on the lateral side of the upper and can be constructed together with the lateral side support as a unitary, one-piece component.

[0044] This disclosure also provides a method of manufacturing a footwear article having one or more guides and one or more tensioning members to conform a sole structure to a foot disposed in a described upper. In an example, the method may include placing the upper onto a last. The method may also include applying an adhesive to the inner surface of the sole structure and placing the guides on the adhesive. The method may further include placing the tensioning members on the guides and then placing the inner surface of the sole structure against the outer surface of the upper to secure the sole structure to the upper using the adhesive, channels formed by the upper and the guides, and tensioning members within the channels.

[0045] In one or more embodiments, when the adhesive is placed on the inner surface of the sole structure, the inner surface of the sole structure can be substantially planar, and the adhesive can be placed on the inner surface of the sole structure by rolling the adhesive onto the inner surface of the sole structure. The planar configuration of the preformed sole structure allows for the use of a relatively simple and rapid rolling technique to apply the adhesive to the sole structure.

[0046] In one aspect of this disclosure, placing the guide on an adhesive on the inner surface of the sole structure may include aligning the guide with positioning features on the inner surface of the sole structure.

[0047] In one or more configurations, the method may further include heating the sole structure before placing the inner surface of the sole structure against the outer surface of the upper, and forming the sole structure onto the outer surface of the upper, wherein the sole structure partially wraps around and conforms to the upper at the inner and outer sides of the upper, such that the inner surface of the sole structure is non-planar.

[0048] In one aspect, the method may further include cutting grooves in the outer surface of the sole structure before forming the sole structure onto the outer surface of the upper. The grooves are adapted to open when the sole structure is formed onto the upper, and are adapted to further open in response to an increase in tension in the tensioning member. The method may further include cutting grooves in the inner surface of the sole structure before forming the sole structure onto the outer surface of the upper. The grooves in the inner surface of the sole structure are adapted to partially close when the sole structure is formed onto the upper, and are adapted to further close in response to an increase in tension in the tensioning member.

[0049] In one or more configurations, the tensioning member may be a first tensioning member, and the method may further include placing a second tensioning member on a guide before placing the inner surface of the sole structure against the outer surface of the upper, wherein the second tensioning member passes over the first tensioning member.

[0050] In one or more embodiments, placing the tensioning member on the guide may include positioning the tensioning member such that an end of the tensioning member extends out of the guide and into the inner surface of the sole structure, the end being secured to the sole structure by an adhesive, and the tensioning member extending from the end along the guide and extending a channel at the inner or outer side of the upper.

[0051] In one aspect of this disclosure, the guide may be a first guide, the channel may be a first channel, the tensioning member may be a first tensioning member extending from the first channel at the inner side of the upper, and the method may further include placing a second guide on an adhesive before placing the inner surface of the sole structure against the outer surface of the upper. The method may further include placing a second tensioning member on a second guide, the upper and the second guide forming a second channel, and the second tensioning member extending from the second guide to an end on the inner surface of the sole structure. This end of the second tensioning member is secured to the sole structure by an adhesive, and the second tensioning member extends along the second guide from the fixed end and extends into the second channel at the outer side of the upper.

[0052] In one or more configurations, the first guide may be one of a plurality of medial guides, each medial guide being fixed to the inner surface of the sole structure and extending along the inner surface to form a channel with the upper. The second guide may be one of a plurality of lateral guides, each lateral guide being fixed to the inner surface of the sole structure and extending along the inner surface of the sole structure to form a channel with the upper. The method may further include placing the medial and lateral guides on the inner surface of the sole structure such that the medial and lateral guides are arranged in an alternating sequence.

[0053] The above features and advantages, as well as other features and advantages, of this teaching will become apparent when understood in conjunction with the accompanying drawings and in the following detailed description of the mode of implementing this teaching.

[0054] Figure 1 A footwear article 10 is shown, comprising a sole structure 12 attached to an upper 14. The footwear article 10 includes a forefoot region 16, a midfoot region 18, and a heel region 20. The forefoot region 16 generally comprises the portion of the footwear article 10 corresponding to the metatarsophalangeal joint (which may be referred to as the MPT joint or MPJ ​​joint) connecting the toes and the metatarsals and proximal phalanges of the toes to the foot. The midfoot region 18 generally comprises the portion of the footwear article 10 corresponding to the arch and instep of the foot, and the heel region 20 corresponds to the posterior portion of the foot, including the calcaneus. The forefoot region 16, midfoot region 18, and heel region 20 are not intended to delineate precise areas of the footwear article 10, but rather are intended to represent general areas of the footwear article 10 to facilitate the discussion below.

[0055] The sole structure 12 may be slotted to further enhance its ability to be adjusted to conform to the foot disposed in the upper 14. In other words, when the tensioning element is tightened, the slots allow the sole structure 12 to be more easily fastened around the foot 40 disposed in the upper 14, as discussed further herein.

[0056] For example, the sole structure 12 may have a plurality of grooves 21A, 21B extending partially through the sole structure at the outer surface 23 of the sole structure. Groove 21A extends generally along the longitudinal direction of the sole structure 12, and groove 21B extends generally along the lateral direction of the sole structure 12. As used herein, a sipe, multiple sipes, and siping are intended to refer to thin cuts in the surface of the sole structure 12. Grooves are typically formed via secondary processing after the sole structure 12 is initially molded into its preformed state, but before the sole structure 12 is formed (e.g., thermoformed) to the upper 14 as described herein. In some embodiments, grooves 21A, 21B and grooves (if present) at the inner surface can be formed by cutting the preformed sole structure 12 to a controlled depth (e.g., using a hot knife or laser). Generally, the width of the cut is limited by the width of the tool used to make the cut. For example, multiple grooves 21A, 21B can be cut using a blade, which can be heated to assist in creating smooth cuts with an acceptable surface finish on the sidewalls of the grooves. In another embodiment, one or more of the multiple grooves 21A, 21B can be laser-cut into the foam to a controlled depth. In some embodiments, each of the multiple grooves can be cut to a different depth depending on the sole thickness, cushioning design goals, and desired final sole appearance. In some embodiments, the stiffness and / or cushioning properties of any one or more protrusions (or the sole in that local area) defined by the grooves can be varied by changing the depth of adjacent grooves (i.e., where deeper grooves can provide a less stiff sole structure with increased cushioning) to meet different design goals. In some embodiments, when the inner surface of the sole structure 12 has a substantially planar configuration, the grooves 21A, 21B can be cut entirely orthogonally to the inner surface of the sole structure 12.

[0057] In one embodiment, the grooves can be cut such that they all extend from a common direction into the outer surface 23 of the sole structure 12. Such a design improves manufacturing efficiency by eliminating the need for reorienting cutting tools for each groove or section of a groove. In embodiments where the inner surface of the sole structure 12 is substantially flat / planar when preformed, this common cutting direction can be orthogonal to the inner surface. In another embodiment, one or more of the grooves 21A, 21B can be angled relative to the inner surface 15. Creating such angled cuts allows for the production of unique geometries when the sole structure is subsequently thermoformed to the upper.

[0058] The sole structure 12 defines a plurality of protrusions 25 that are separated from each other by a plurality of grooves 21A, 21B. Figure 1 Only some protrusions 25 are marked in the text. For example... Figure 1 As further illustrated, when the sole structure 12 is thermoformed to the upper 14, some or all of the plurality of grooves 21A, 21B may partially open due to the bending that occurs in the sole structure 12. In the embodiment described below, where the flat inner surface of the sole structure is thermoformed to the substantially wavy / curved upper 14 on the last, most of the grooves 21A, 21B may experience a degree of opening during the thermoforming process, such that the grooves 21A, 21B are partially open even when the tensioning member described herein is not tensioned. When the tensioning member is further tensioned, the grooves 21A, 21B then open further. Thus, the grooves 21A, 21B help increase the flexibility of the sole structure 12 and facilitate the conformation of the sole structure to the foot disposed in the upper 14 when the tensioning member is tensioned.

[0059] Additionally, the sole structure 12 may include multiple layers, with the innermost layer at the inner surface and the outermost layer at the outer surface 23. Grooves may extend only into the outermost layer, terminate at the boundary between the outermost layer and the next inner layer, or they may extend partially into the innermost layer. When the grooves 21A and 21B are open, the presence of the various layers may be visible on the sides of the protrusion 25.

[0060] The upper 14 can be made of various materials, such as leather, textiles, polymers, cotton, foam, composites, etc. For example, the upper 14 can be a polymeric material that provides elasticity and can have a braided construction, a knitted (e.g., warp-knitted) construction, or a woven construction. In some embodiments, the upper 14 can be secured to a strombel at a lower extent to form a foot-receiving cavity 22 that receives a foot inserted through an opening 24 (such as an ankle opening) in the upper 14. In the illustrated embodiment, the upper 14 is alternatively an insole-like or insole-like construction that includes a bottom portion such that the upper 14 is strombel-free, as shown herein. An insole (not shown) may be placed in the foot-receiving cavity 22, or there may be no insole. The upper 14 can be tightened around the foot by using tensioning elements described herein and / or by laces, straps, or other tightening mechanisms.

[0061] Guide components 30A and 30B (in) Figure 1 (Indicated only by dashed lines) are fixed to the inner surface of the sole structure 12 at their respective outer surfaces, as further disclosed herein. The upper 14 has a bottom, and the outer surface of the bottom is fixed to the inner surface of the sole structure 12 around the guides 30A, 30B, wherein the guides 30A, 30B are located between the bottom of the upper 14 and the sole structure 12. For example, as further discussed herein, an adhesive layer may be provided on the inner surface of the sole structure 12, and the guides 30A, 30B and the upper 14 may be fixed to the inner surface of the sole structure 12. The sole structure 12 has a base portion 12A, an outer sidewall portion 12B extending upward from the base portion 12A along the outer sidewall 14A of the upper 14 at the outer side of the base portion 12A, and an inner sidewall portion extending upward from the base portion on the inner side of the upper (in Figure 1 (Not visible in the middle). Guides 30A and 30B extend along the base portion 12A of the sole structure 12 and along the outer sidewall portion 12B of the sole structure 12 at the inner surface of the sole structure 12.

[0062] The outer surface of the bottom of the upper 14, together with the guide 30A, forms channel 34A, and the outer surface of the bottom of the upper 14, together with the guide 30B, forms another channel 34B. Channels 34A and 34B are... Figure 1The channels 34A and 34B are indicated as hidden because they are located between the outer surface of the upper 14 and the inner surfaces of the guides 30A and 30B, since these surfaces are not adhered to each other. Tensioning members 32A and 32B are adhered to the inner surface of the sole structure 12 at their fixed ends, and extend longitudinally along the guides 30A and 30B in the channels 34A and 34B, and extend out of the channels 34A and 34B at the outer surface 14A of the upper 14.

[0063] Figure 2 The footwear article 10 is shown in top view. Channels 34A and 34B formed between the upper 14 and the sole structure 12 are visible at their ends on the outer surface 14A of the upper 14 (where tensioning members 32A and 32B depart). The outer surface tensioning members 32A and 32B are shown in an untensioned state. The tensioning members 32A and 32B have fixed ends 35A and 35B that adhere to the inner surface of the sole structure 12. Although the ends 35A and 35B are fixed, the tensioning members 32A and 32B can move relative to the upper 14 and guides 30A and 30B in the corresponding channels 34A and 34B in response to an increase in tension in the tensioning members 32A and 32B, so that the sole structure 12 flexibly conforms to the foot disposed in the upper 14.

[0064] The footwear article 10 also includes additional guides 30C, 30D, and 30E, which are fixed at their respective outer surfaces to the inner surface 15 of the sole structure 12, as further disclosed herein. Guides 30A and 30B may be referred to as lateral guides, and guides 30C, 30D, and 30E may be referred to as medial guides. The medial guides 30C, 30D, and 30E are arranged in an alternating sequence with the lateral guides 30A and 30B in the longitudinal direction of the sole structure 12. In addition to the lateral sidewall portion 12B, the sole structure 12 also has an inner sidewall portion 12C at the inner surface of the base portion 12A, which extends upward from the base portion 12A along the inner surface 14B of the upper 14. Guides 30C, 30D, and 30E extend along the base portion 12A and the medial sidewall portion 12C of the sole structure 12 on the inner surface of the sole structure 12. The bottom of the upper 14 forms a channel 34C together with guide 30C, another channel 34D together with guide 30D, and yet another channel 34E together with guide 30E. Channels 34C, 34D, and 34E are located between the outer surface of the upper 14 at the bottom of the upper and the inner surfaces of guides 30C, 30D, and 30E, respectively, because these surfaces are not adhered to each other.

[0065] The inner tensioning components 32C, 32D, and 32E are adhered to the inner surface 15 of the sole structure 12 at their fixed ends 35C, 35D, and 35E, respectively. The inner tensioning components 32C, 32D, and 32E extend longitudinally along the guides 30C, 30D, and 30E in channels, and extend out of the channels at the inner surface 14B of the upper 14. The channels 34C, 34D, and 34E are visible at their ends at the inner surface 14B of the upper 14 (where the tensioning components 32C, 32D, and 32E depart). Although the ends 35C, 35D, and 35E are fixed, the tensioning members 32C, 32D, and 32E can move relative to the upper 14 and the guides 30C, 30D, and 30E in the corresponding channels 34C, 34D, and 34E in response to an increase in tension in the tensioning members 32C, 32D, and 32E, so that the sole structure 12 flexibly conforms to the foot disposed in the upper 14.

[0066] The outer surface of the bottom of the upper 14 is fixed to the inner surface 15 of the sole structure 12 around the guides 30C, 30D, and 30E, wherein the guides 30C, 30D, and 30E are located between the bottom of the upper 14 and the sole structure 12. For example, in Figure 2 In this configuration, the inner surface 15 of the sole structure 12 and the bottom surface of the upper 14 are adhered to each other in all areas outside the hidden lines of the guides 30A-30E. However, the outer surface of the upper 14 is not adhered to the top or inner (i.e., proximal) surface of the guides 30A-30E, allowing the upper to be lifted away by the tensioning members 32A-32E. The tensioning members 32A-32E are also not fixed to the guides, thus allowing the tensioning members 32A-32E to move slightly relative to the upper 14 and the sole structure 12 within the corresponding channels 34A-34E when pulled. However, because the bottom surface of the upper 14 adheres to the inner surface 15 of the sole structure 12 anywhere else around the guides 30A-30E, this tightening of the tensioning members 32A-32E causes the sole structure 12 to tighten around the foot disposed in the upper 14, including by pulling the outer sidewall portion 12B and the inner sidewall portion 12C inward and / or upward, and by fastening the base portion 12A of the sole structure 12.

[0067] For the purposes of discussion, any of the guides 30C, 30D, and 30E may be referred to as the first guide, any of the channels 34C, 34D, and 34E may be referred to as the first channel, and any of the tensioning members 32C, 32D, and 32E may be referred to as the first tensioning member. Any of the guides 30A and 30B may be referred to as the second guide, any of the channels 34A and 34B may be referred to as the second channel, and any of the tensioning members 32A and 32B may be referred to as the second tensioning member. The fixing ends 35C, 35D, and 35E of the first tensioning members 32C, 32D, and 32E are configured to be closer to the outer edge (e.g., the outer side edge) of the preformed sole structure 12 than to the inner edge (e.g., the outer side edge). In contrast, the fixing ends 35A and 35B of the second tensioning members 32A and 32B are fixed to the sole structure 12 closer to the inner edge than to the outer edge. By placing the fixed end closer to the side opposite to the side where the tensioning member extends out of the channel and is pulled to increase tension, the force on the sole structure 12 at the fixed end is at a greater distance from the side where the tensioning member is pulled, and the tensioning member tightens a larger portion of the sole structure 12 between the fixed end and the pulled side. The inner guides 30C, 30D, and 30E are arranged in an alternating sequence with the outer guides 30A and 30B. By alternating the first tensioning members 32C, 32D, and 32E with the second tensioning members 32A and 32B in the longitudinal direction of the sole structure 12, and similarly alternating the inner guides 30C, 30D, and 30E with the outer guides 30A and 30B, the overall tightening effect of the tensioning member on the sole structure 12 is maximized and balanced around the longitudinal centerline of the sole structure. For example, as a result of tension, the outer and inner side portions are pulled inward and / or upward, while the center of the base portion 12A does not shift significantly toward the sidewall portions 12B or 12C.

[0068] from Figure 2 As can be seen, the inner tensioning members 32D and 32E in the midfoot region 18 and heel region 20 are connected together by the female portion 36 of a buckle. The male portion 38 of the buckle is fixed to the outer tensioning member 32B extending from the midfoot region 18. The inner tensioning member 32C in the forefoot region 16 is fixed to another female portion 36 of a buckle. The male portion 38 of the buckle is fixed to the outer tensioning member 32A extending from the forefoot region 16. Although shown as a buckle, other tightening and / or securing methods for the tensioning members, such as shoelaces, snaps, hook and loop fasteners, etc., can be used.

[0069] refer to Figure 3Tensioning members 32A-32E are shown as being fixed to each other on the top of the outer surface of the upper 14. The female portion 36 of the buckle on tensioning members 32D and 32E is fastened to the male portion 38 of the buckle fixed to the outer side tensioning member 32B. The female portion 36 of the buckle fixed to the inner side tensioning member 32C is fastened to the male portion 38 of the buckle fixed to the outer side tensioning member 32A. Figure 3 In this configuration, the tensioning components are fixed, but only partially tensioned. A more customized fit between the sole structure 12 and the foot can be achieved by adjusting the position of the female portion 36 and / or male portion 38 of the buckles on the tensioning components so that when these buckles are fastened, they create a tighter fit of the tensioning components around the upper 14 and provide greater fastening force on the sole structure 12. Unlike conventional straps, because the tensioning components 32A-32E have fixed ends 35A-35E to the sole structure 12 near the side opposite to the side from which the tensioning components extend, and because the tensioning components 32A-32E can move relative to the sole structure 12 and the upper 14 in channels 34A-34E, and because the sole structure 12 has an outer sidewall portion 12B and an inner sidewall portion 12C extending from the base portion 12A as described herein, the sole structure 12 is easily fastened and partially wraps around the foot.

[0070] Figure 4 The illustration illustrates how tensioning of the tensioning member 32C can achieve a more customized fit between the sole structure 12 and the foot 40 by bending and flexibly conforming the sole structure 12 around the foot 40. For example, when a force F is applied to the free end of the tensioning member 32C, the tensioning member can move (e.g., slide) relative to the upper 14 in the channel 34C, causing the free end to move to a new position 32C1. The fixed end 35C remains fixed in place. This may cause the inner surface 14B of the upper 14 to move inward against the foot 40; however, this is not shown for clarity. Furthermore, because the outer surface of the upper 14 adheres to the inner surface of the sole structure 12 around the guide member 30C (e.g., the front and rear portions of the guide member 30C), the sole structure 12 moves (e.g., flexibly conforms), as indicated by the dashed lines, showing the new positions 12C1 of the sidewall portions 12C and 12B1 of the sidewall portions 12B that have moved higher and / or inward around the foot 40. The base portion 12A also tightens against the bottom of the foot 40. Figure 4 As indicated by the dashed lines, the grooves 21A (only some of which are marked) further open when the tensioning member 32C is further tensioned. The outer surface 42C of the guide 30C is shown as adhering to the inner surface 15 of the sole structure 12. The fixing end 35C is also shown as adhering to the inner surface 15.

[0071] Figure 5 The illustration illustrates how tensioning of the tensioning member 32A can achieve a more customized fit between the sole structure 12 and the foot 40 by bending and flexibly conforming the sole structure 12 around the foot 40. For example, when a force F is applied to the free end of the tensioning member 32A, the tensioning member can move relative to the upper 14 in the channel 34A, causing the free end to move to a new position 32A1. The fixed end 35A remains fixed in place. This may cause the outer surface of the upper 14 to move inward against the foot 40, however, this is not shown for clarity. Furthermore, since the outer surface of the upper 14 adheres to the inner surface of the sole structure 12 around the guide member 30A (e.g., the front and rear portions of the guide member 30A), the sole structure 12 moves (e.g., flexibly conforms), as indicated by the dashed lines, showing the new positions 12C1 of the sidewall portions 12C and 12B1 of the sidewall portions 12B that have moved higher and / or inward around the foot 40. The base portion 12A will also tighten against the bottom of the foot portion 40. (If...) Figure 5 As indicated by the dashed lines, the grooves 21A (only some of which are marked) further open when the tensioning member 32A is further tensioned. The outer surface 42A of the guide 30A is shown as adhering to the inner surface 15 of the sole structure 12. The fixing end 35A is also shown as adhering to the inner surface 15. Although Figure 4 and Figure 5 The tensioning effect of tensioning members 32A and 32C is shown, but the sole structure 12 responds in a similar manner to any or all of the increased tension of tensioning members 32B, 32D and 32E.

[0072] Figure 6 Another aspect is shown, wherein the sole structure 12 may include a plurality of grooves 21C that partially extend through the sole structure at the inner surface 15 of the sole structure. Figure 6 Intended to show with Figure 4 The cross-section is at the same location, but the sole structure 12 is provided with grooves 21C. Grooves 21C extend generally in the longitudinal direction of the sole structure 12 and are adapted to close at least partially in response to increased tension in any or all tensioning components. Grooves 21C at the inner surface 15 of the sole structure 12 may deviate from and alternate with grooves 21A at the outer surface 23 of the sole structure 12 in the lateral direction of the sole structure 12 (e.g., from the inner sidewall portion 12C to the outer sidewall portion 12B of the sole structure 12). Figure 6 As indicated in the document. (As per the instructions) Figure 6As illustrated by the dashed lines, when a force F is applied to the free end of the tensioning member 32C, thereby increasing the tension in the tensioning member 32C, the groove 21C at the inner surface 15 of the sole structure 12 at least partially closes. In other words, when the tensioning member 32C is tightened, the groove 21C allows the sole structure 12 to be more easily fastened around the foot 40 disposed in the upper 14. Therefore, when the groove 21C is at least partially closed, the groove 21A further opens. The groove 21C thus further allows the inner surface of the sole structure 12 to conform to the foot 40. Because the grooves 21A and 21C are offset from each other, this configuration further allows the sole structure 12 to flexibly conform to the shape of the foot 40.

[0073] Figure 7 Intended to show with Figure 5 The cross-section is at the same location, but the sole structure 12 has grooves 21C. (As shown by...) Figure 7 As illustrated by the dashed lines, when a force F is applied to the free end of the tensioning member 32A, thereby increasing the tension in the tensioning member 32A, the groove 21C at the inner surface 15 of the sole structure 12 at least partially closes. In other words, when the tensioning member 32A is tightened, the groove 21C allows the sole structure 12 to be more easily fastened around the foot 40 disposed in the upper 14. Therefore, when the groove 21C is at least partially closed, the groove 21A further opens.

[0074] Figure 8 The sole structure 12 is shown after it has been molded into its preformed state but before it has been thermoformed into the upper 14. In this state, the sole structure 12 may be referred to as the preformed sole structure 12 or the intermediate sole structure 12. The inner surface 15 of the sole structure 12 is shown. Grooves 21C are not shown, but these grooves 21C can cut into the inner surface 15. If the sole structure 12 is molded with multiple layers in the vertical direction, the portion of the sole structure exposed at the inner surface 15 is the innermost layer. If the sole structure 12 is molded with inner and outer layers, the dashed line B represents the outer boundary of the outer layer of the sole structure 12 (in...). Figure 8 (The middle is located below the innermost layer).

[0075] Figure 9Positioning features are shown, which may be marks applied to the inner surface 15 of the sole structure 12 to serve as visual aids when placing the guides 30A-30E, the fixed ends 35A-35E of the tensioning members 32A-32E, and the upper 14 onto the sole structure 12, so that the guides 30A-30E, the fixed ends 35A-35E of the tensioning members 32A-32E, and the upper 14 adhere to the inner surface 15 in the correct relative positions. Positioning features 50A, 50B, 50C, 50D, and 50E are marks having a shape substantially the same as the guides and are respectively configured to position the guides 30A, 30B, 30C, 30D, and 30E. Positioning features 52A, 52B, 52C, 52D, and 52E are respectively configured to position the fixed ends 35A, 35B, 35C, 35D, and 35E. Positioning feature 54 is configured to position the bottom of the upper 14.

[0076] Figure 10 An adhesive 56 is shown placed on the entire inner surface 15 of the sole structure 12. The adhesive 56 may also be referred to as an adhesive layer. Because the inner surface 15 of the intermediate sole structure 12 is substantially planar, the adhesive layer 56 is relatively easy to apply via a roller, as discussed further herein. The portion 58 of the inner surface 15 of the sole structure 12 surrounded by the markings 50A, 50B, 50C, 50D, and 50E may be referred to as the first portion of the inner surface 15 and is the location where the outer surfaces of the guides 30A-30E adhere to the sole structure 12.

[0077] Figure 11 The sole structure 12 is shown, in which guides 30A-30E are placed Figure 9 At the corresponding positioning features 50A-50E, the outer surface of the guide 30A-30E adheres to the inner surface 15 of the sole structure 12. Placing the guide 30A-30E on the inner surface 15 may include aligning the guide 30A-30E with the positioning features 50A-50E, such as by... Figure 10 and Figure 11 The alignment of the guides 30A-30E and their placement on the inner surface 15 of the sole structure 12 can be done manually or automatically by a robot. The inner guides 30C, 30D, and 30E are arranged in an alternating sequence with the outer guides 30A and 30B in the longitudinal direction of the sole structure 12.

[0078] Figure 12 This shows the situation after the guides 30A-30E and tensioning members 32A-32E are positioned on the inner surface 15. Figure 12The inner surface 15 of the shoe has a large portion 60 with the adhesive 56 still exposed. This portion can be referred to as the second part of the inner surface 15 of the sole structure 12 and is the part to which the outer surface of the upper 14 is adhered. Because... Figure 12 As shown, there is no adhesive on the inner surface of the guides 30A-30E or the inner surface of the tensioning members 32A-32E, so the bottom surface of the upper 14 will not be fixed to these surfaces, and a channel 34A-34E will be formed between the upper 14 and the guides 30A-30E on the inner surface of the guides 30A-30E.

[0079] Figure 12 It is shown that when tensioning members 32A-32E are placed on the corresponding guides 30A-30E, the tensioning members 32A-32E are positioned such that the ends 35A-35E of the tensioning members extend out of the guides and into the inner surface 15 of the sole structure 12 and are fixed to the sole structure 12 by adhesive 56.

[0080] Figure 13 The illustration shows an upper 14 placed on a last 62 such that the upper 14 extends around the last 62 and has the three-dimensional foot shape of the last 62. In some embodiments, the upper 14 may first be heated, and then the last 62 may be moved against the sole structure with the guides 30A-30E and tensioning members 32A-32E already placed on the sole structure, and a second portion 60 of the inner surface 15 of the sole structure 12 is placed against the outer surface of the upper 14 to secure the sole structure 12 to the upper 14 using an adhesive 56, channels 34A-34E formed between the upper 14 and the guides 30A-30E, and tensioning members 32A-32E in the channels 34A-34E.

[0081] Figure 14 The diagram illustrates that after the pre-formed sole structure 12 and the plurality of grooves 21A, 21B are cut into the outer surface 23 (and in some embodiments the grooves are also cut into the inner surface), adhesive 56 can be applied to the inner surface 15 of the sole structure 12. Adhesive 56 can be applied from a supply source 68, for example using a brush, sprayer, or roller applicator. To minimize any desired complexity, a roller applicator is likely best suited for applications where the inner surface 15 is substantially planar or, in other words, substantially flat. In such a configuration, the roller applicator can be a single roller 70 with a constant cylindrical cross-section, such as... Figure 14 As shown, the sole structure 12 can be supported within a fixing device 72 (shown in cross-section), which can function as a radiator and may be referred to as a radiator. As an additional benefit of rolling, if any grooves are cut into the inner surface 15, such as... Figure 6As shown, the roller applicator can then be most easily controlled to avoid applying adhesive within the inner / upper grooves and without the need for separate masking of the grooves. In such an embodiment, the unadhesive inner grooves 21C can allow each groove to function as an expansion gap, which can allow stretching and / or flexing within the pure plane of the sole structure 12. When combined with a non-Stronbel upper 14, such stretching or flexing response can be even further unrestricted (i.e., where the relatively inelastic Stronbel is generally more restrictive than a non-Stronbel all-knit upper).

[0082] After the adhesive 56 is applied, the sole structure 12 can continue to undergo a thermoforming process on the conveyor 74 to obtain its final shape and positioning on the upper 14. Generally, the thermoforming process involves heating at least a portion of the sole structure 12, forming it onto a surface (e.g., via vacuum forming), and then cooling the sole structure to hold it in a deformed state. However, the sole structure has the flexibility to elastically deform by selectively increasing the tension in the tensioning components, such that the sole structure 12 conforms to the foot as described herein. For example, the sole structure 12 may include thermoplastic portions or layers near the inner surface 15 that are easily deformable upon heating. Therefore, the sole structure 12 is first heated to soften the sole structure, and in particular, to soften at least any thermoplastic portions or layers of the sole structure 12. Figure 14 As further shown in the figure, in an embodiment, heating can be performed by a radiant heating element 76 or a convection heating nozzle (not shown), which applies heat only to the inner surface 15 of the sole structure 12. Since the outer surface 23 has been grooved, the primary purpose of heating is only to soften the sole structure 12 at the inner surface 15 to a degree that it can be thermoformed into the upper 14. If the sole structure 12 is heated too much, it may lose some structural integrity and / or its properties may change to an undesirable extent. Thus, in an embodiment, a temperature gradient should exist between the inner surface 15 and the outer surface 23. In one configuration, the fixing device 72 on which the sole structure 12 rests can function as a radiator to cool the sole structure 12 at the outer surface 23 while the sole structure 12 is heated at the inner surface 15. This ensures that the sole structure 12 does not deform at the outer surface 23 in any unintended way during thermoforming. The guides 30A-30E and tensioning components 32A-32E can be placed on the adhesive 56 before or after the sole structure 12 is heated at the inner surface 15.

[0083] refer to Figure 15 Once the sole structure 12 has softened to a degree that allows it to be thermoformed, the sole structure can then be positioned adjacent to the outer surface 78 of the upper 14 disposed on the last 62. This is achieved by... Figure 15 The directional arrow A is illustrated in the diagram. However, the sole structure 12 can alternatively or additionally move towards the upper 14. The outer surface 78 of the upper 14 covers portions of the guides 30A-30E (such as...). Figure 15 Parts 78A, 78B, and 78C will not adhere to the sole structure 12 because there is no adhesive on the inner surface of the guide or on the tensioning parts of the guide. However, the portion of the outer surface 78 surrounding the guide will directly contact the adhesive 56 and will thus be fixed to the sole structure 12.

[0084] refer to Figure 16 Once the outer surface 78 of the upper 14 is adjacent to the inner surface 15 of the sole structure 12, the sole structure 12 can be pushed into contact with the upper 14 (e.g., by vacuum forming), where it can then be cooled to maintain its shaped form. For example, the softened sole structure 12 can be pulled into contact with the lasted upper 14, such as by using any or all of positive external pressure PP, negative internal pressure NP, compliant fixation, or similar methods. In vacuum forming, the lasted upper 14 and sole structure 12 can be placed under a compliant polymer sheet 80, shown in cross-sectional view, in their predefined arrangement. Once in place, a vacuum can be created using negative pressure NP, causing the sheet 80 to apply force to the sole structure 12, forcing it into contact with the upper 14. In doing so, adhesive 56 can be pulled to contact the outer surface 78 of the upper 14, and portions of the pre-formed sole structure 12 can be bent to contact the inner and outer sides of the upper 14, as well as around the rear of the upper in the heel area and around the front of the upper in the forefoot area, such as... Figure 16 The inner surface 14B is shown. Once thermoformed, the inner surface 15 is therefore no longer, for example, as shown... Figure 4 The shape shown is essentially planar. Then, the bending caused by vacuum forming results in multiple grooves 21A, 21B partially opening to, for example... Figure 4 The position is indicated by the solid line. When one or more of the tensioning components 32A-32E are subsequently selectively tightened, the grooves 21A, 21B will further open to, for example... Figure 4 The location is indicated by the dashed line. For example, if groove 21C is provided at the inner surface 15, the bending caused by vacuum forming will then cause multiple grooves 21C to partially close to, for example... Figure 6 The position is indicated by the solid line. For example, when one or more of the tensioning components 32A-32E are subsequently selectively tightened, the groove 21C will further close to, for example... Figure 6 The position indicated by the dashed line.

[0085] Figure 17Another embodiment of footwear article 110 is shown, which is similar to footwear article 10 in all respects, except that footwear article 110 includes additional lateral guides 30F fixed to sole structure 12 and three lateral tensioning members 132A, 132B, 132F, which have fixed ends fixed to the inner surface of sole structure 12 and extend upward through guide channel 182 on one side of upper 14 to annular free ends 184A, 184B, 184C. Shoelace 186 extends through the annular free ends. Shoelace 186 also extends through similar tensioning members that extend from a channel formed by the inner guides between the upper and sole structure on the inner surface of upper 14. Tightening shoelace 186 pulls the tensioning members to conform sole structure 12 to the foot disposed in upper 14.

[0086] Figure 18 A bottom view schematically illustrates another embodiment of the sole structure 212. This design generally includes a plurality of grooves 221B, each extending between the outer edge 35 and the inner edge 37 of the sole structure 212. Each groove 221B may include a longitudinal deflection member 204 within a central region 206 of the groove 221B, which is shaped to varying degrees resembling a “U” or a “V”. Such a design provides increased edge stability by omitting any longitudinal grooves (or grooves with a primary longitudinal member) near the outer edge 35 and the inner edge 37. Instead, the longitudinal deflection member 204 within the central region 206 allows for foot roll and / or lateral extension of the foot due to ground impact.

[0087] In some embodiments, the flexibility of the sole structure 212 can be further increased by including or cutting into the inner surface 15 of the sole structure 212 with one or more grooves 221C, such as... Figure 19 As shown in the diagram. To ensure that the sole structure 212 remains waterproof and / or provides sufficient protection against foreign objects on the ground, preferably, any grooves 221C cut into the inner surface 15 do not intersect with any grooves 221B cut into the outer surface 23. Doing so would result in any possible holes or openings extending completely through the sole structure 212. Figures 18-19 As shown, in one configuration, the grooves 221C cut into the inner surface 15 can be staggered along the longitudinal axis relative to the grooves 221B cut into the outer surface 23.

[0088] Although Figure 1 and Figure 18Two possible groove patterns are illustrated, but other patterns and unique geometries are similarly possible. For example, in one embodiment, the sole structure 212 may include multiple grooves, all extending in a substantially longitudinal direction. In another embodiment, the grooves may extend diagonally from each of the inner and outer edges. In a variation, the grooves may terminate before reaching the opposite edges.

[0089] Figure 20 A sole structure 12 with multiple inner guides 30C, 30D, 30E and multiple outer guides 30A, 30B in its preformed state is shown. The multiple inner guides 30C, 30D, 30E are each fixed to the inner surface 15 of the sole structure 12, and the multiple outer guides 30A, 30B are each fixed to the inner surface 15 of the sole structure 12, arranged in an alternating order as previously described. The inner guides 30C, 30D, 30E are configured to be more... Figure 2 The outer guides 30A and 30B are further extended outwards to the inner side support 31A and are constructed together as a single piece. Similarly, the outer guides 30A and 30B are constructed to be more... Figure 2 The middle extends further outward to the outer side support 31B and together with the outer side support 31B, forms an integral one-piece component. When Figure 2 When the outer surface of the upper 14 is fixed to the sole structure 12 during thermoforming, the inner side support 31A extends along and abuts the inner side 14B of the upper 14 to also serve as a support at the inner side of the upper 14, and the outer side support 31B extends along and abuts the outer side 14A of the upper 14 to also serve as a support at the outer side of the upper 14.

[0090] Figure 21 A pre-formed sole structure 12 is shown, having only a single guide 30G. This guide 30G adheres to and extends completely across the inner surface 15 of the sole structure 12, extending beyond the outer edge 35 and the inner edge 37. A single tensioning member 32F is positioned on the inner surface of the guide 30G and extends along the inner and outer sides of the upper 14 in a channel formed between the outer surface of the upper 14 and the inner surface of the guide 30G. The portion of the guide 30G extending beyond the edges 35, 37 can be secured to the upper 14, but only around the tensioning member to maintain the channel of tensioning between the guide and the upper. The tensioning member 32F has no fixed ends because no part of it adheres to the inner surface 15. Two side supports 88A and 88B are adhered to the inner surface 15 near the inner and outer sides in the heel area 20, and the two side supports 88A and 88B can be adhered to the upper 14 when the sole structure is thermoformed to the upper 14.

[0091] Figure 22 A multi-piece sole structure 312 is shown, comprising sole structure portions 312A, 312B, and 312C in their pre-formed state. The sole structure portions 312A, 312B, and 312C together include an inner surface 15 that can be fixed to the upper 14 using an adhesive. A tensioning member 32G is directly fixed to portion 312A by an adhesive layer 56 disposed thereon during manufacturing, and therefore does not slide or move relative to the sole structure 312. A guide 30H is adhered to the inner surface 15 of portion 312C in the midfoot region 18. The guide 30H has two portions 30H1 and 30H2 defining an X-shape. Because the adhesive is only placed on the inner surface 15 and not on the upper 14 or the inner surface of the guide 30H, two intersecting channels are formed between the upper 14 and the two intersecting portions 30H1 and 30H2 of the guide 30H. When the sole structure 312 is fixed to the upper 14, the first tensioning member 32H is positioned on one of the portions 30H1 and extends along the portion 30H1 and is disposed in one of the two intersecting channels. When the sole structure 312 is fixed to the upper 14, the second tensioning member 32I is positioned on the other portion 30H2, extending beyond the first tensioning member 32H and along the portion 30H2, such that the second tensioning member 32I is disposed in the other of the two intersecting channels. A plurality of supports 288A, 288B, 288C are adhered to or otherwise fixed to the inner surface 15 of portion 312C on the inner and outer sides and near the rear in the heel area 20, and the plurality of supports 288A, 288B, 288C can be adhered to the upper 14 when the sole structure 312 is thermoformed to the upper 14.

[0092] Figure 23 This is a flowchart illustrating the steps of a method 400 for manufacturing footwear articles having various sole structures and other components disclosed herein. For discussion purposes, method 400 will refer to sole structure 12 where applicable, but is also applicable to other sole structures disclosed herein. The method begins at step 402, in which the pre-formed sole structure 12 is received in its pre-formed state or molded to achieve its pre-formed state. If the sole structure 12 is a multi-material sole structure as described herein, molding the pre-formed sole structure 12 to achieve its pre-formed shape may include molding a first pre-formed part and a second pre-formed part, each pre-formed part corresponding to a different one of the first material and the second material, such as for... Figure 8 The two layers are indicated by boundary B, and the pre-molded sole structure 12 to achieve its pre-molded shape can be produced, for example, by injection molding or compression molding.

[0093] The first and second preforms can then be placed together in an intermediate mold, with the first preform in contact with the second preform. Heat is then supplied to the mold for a predetermined period of time. In one embodiment, the mold may be heated at approximately 130°C for approximately 15-20 minutes. This heating may cause the first and second preforms to partially expand and fill the internal mold cavity, overflowing into any associated mold overflow chamber. It should be understood that the specific temperature and time period used to form the sole structure preform in the mold can vary in a known manner depending on the specific ethylene-vinyl acetate (EVA) or other materials used. After this heating step is completed, the mold is opened, and the sole structure preform can expand further in a known manner after its removal from the mold.

[0094] After the sole structure preform has stabilized and cooled to ambient temperature, it can then undergo a subsequent compression molding step in a second mold. This second mold can have an internal volume smaller than that of the cooled sole structure preform. Therefore, when the preform is compression molded, it can be physically compressed to a smaller volume when the mold is closed. The second mold can then be heated for a predetermined period of time. In some embodiments, the second mold can be heated to approximately 140°C for approximately 15 minutes to form a preformed sole structure of the desired size / shape. The specific temperature and duration of heating the second mold can vary in a known manner depending on the specific EVA or other materials used.

[0095] While the second mold remains closed, it is cooled to allow the sole structure to fully solidify and stabilize. In some embodiments, the second mold is cooled in the closed state for approximately 15 minutes, until its temperature drops below approximately 35°C. Afterward, the mold can be opened and the sole structure removed.

[0096] After receiving the pre-formed sole structure 12 in its pre-formed state or molding the pre-formed sole structure to achieve its pre-formed state as described in step 402, method 400 proceeds to step 404, in which grooves 21A, 21B may be inserted into the outer surface 23 of the pre-formed sole structure 12. In some embodiments, such as for Figure 6 In step 406, grooves 21C are cut into the inner surface 15 of the sole structure 12. Next, in step 408, adhesive 56 can be applied to the inner surface 15. In step 410, at least a first guide (such as guide 30C) is placed on the adhesive 56 at the inner surface 15. This may include a sub-step 412, aligning the first guide with a positioning feature 50C on the surface, as shown in reference... Figure 9As described above. In some embodiments, only a single guide is used. In other embodiments, method 400 further includes step 414, placing a second guide, such as guide 30A, on the adhesive 56 at the inner surface 15.

[0097] Next, in step 416, a tensioning component is placed on the guide. This includes placing a first tensioning component, such as... Figure 12 A tensioning member 32C is placed on the guide 30C. In some embodiments, step 416 may include a sub-step 418, placing a second tensioning member on the first guide, the second tensioning member being, for example, in addition to... Figure 22 In addition to the first tensioning member 32H, a second tensioning member 32I is placed on the guide 30H. Alternatively or additionally, method 400 may include step 420 of placing a second tensioning member on a second guide, such as a second tensioning member 32A placed on the second guide 30A.

[0098] Before or after stacking the components onto the sole structure as described in steps 410-420, the sole structure may be heated in step 422 to soften it sufficiently for thermoforming. In step 424, the upper 14 is received or constructed in a pre-constructed state. Then, in step 426, the upper 14 is placed on the last 62. In step 428, the sole structure 12 is then placed against the outer surface of the bottom portion of the upper 14, thereby forming a channel between each guide and the upper, as described herein, in which tensioning components can move, as described herein. In step 430, the sole structure 12 is then formed onto the upper 14, such as by vacuum forming and using methods such as... Figure 16 The sheet 80 described herein is used to achieve this.

[0099] Therefore, before forming the sole structure onto the upper, a guide and tensioning member are included between the pre-formed sole structure and the upper. The tensioning member can move along the guide relative to the sole structure and the upper to allow the sole structure to conform to the upper and the foot positioned within the upper. The advantages of the pre-formed sole structure, such as the ability to laminate materials, ease of grooving, and the ability to roll adhesive onto the inner surfaces of opposing planes, allow for a combination of relative manufacturing processes and adjustable conforming fit of the sole structure.

[0100] The following terms provide exemplary configurations of the footwear articles and manufacturing methods disclosed herein.

[0101] Clause 1: A footwear article comprising: a sole structure having an inner surface; a guide fixed to the inner surface of the sole structure; an upper having a bottom, the outer surface of the bottom being fixed to the inner surface of the sole structure around the guide, wherein the guide is located between the bottom of the upper and the sole structure, the upper and the guide forming a channel; and a tensioning member extending along the guide in the channel and extending from the channel at at least one of an inner or outer side of the upper, the tensioning member being movable in the channel relative to the upper and the guide in response to an increase in tension in the tensioning member, such that the sole structure flexibly conforms to a foot disposed in the upper.

[0102] Clause 2: Footwear articles according to Clause 1, wherein the outer surface of the guide is adhered to a first portion of the inner surface of the sole structure, and the outer surface of the upper is adhered to a second portion of the inner surface of the sole structure and is not adhered to the inner surface of the guide at the channel.

[0103] Clause 3: Footwear articles according to Clause 1 or Clause 2, wherein: the sole structure has a base portion, an inner sidewall portion extending upward from the base portion along the inner side of the upper at the inner side of the base portion, and an outer sidewall portion extending upward from the base portion along the outer side of the upper at the outer side of the base portion; and the guide extends along the inner surface of the sole structure at the base portion and at least one of the inner sidewall portion or the outer sidewall portion.

[0104] Clause 4: Footwear articles according to any one of Clauses 1-3, wherein the upper is configured as a non-Stronbel insole or insole lining.

[0105] Clause 5: Footwear articles according to any one of Clauses 1-4 further include: an adhesive layer disposed on the inner surface of the sole structure and securing the guide and the upper to the inner surface of the sole structure.

[0106] Clause 6: A footwear article according to any one of Clauses 1-5, wherein the guide defines an X-shape, two intersecting channels are formed between the guide and the bottom of the upper, the tensioning member is a first tensioning member disposed in one of the two intersecting channels, and the footwear article further comprises: a second tensioning member extending along the guide and over the first tensioning member in the other of the two intersecting channels.

[0107] Clause 7: Footwear article according to any one of Clauses 1-6, wherein the sole structure has a plurality of grooves extending partially through the sole structure at the outer surface of the sole structure, and the grooves are adapted to open when the tensioning member is tensioned.

[0108] Clause 8: Footwear articles according to Clause 7, wherein the sole structure includes a plurality of grooves extending partially through the sole structure at the inner surface of the sole structure, the grooves at the inner surface of the sole structure being offset from and alternating with the grooves at the outer surface of the sole structure, and the grooves at the inner surface of the sole structure being adapted to at least partially close when the tensioning member is tensioned.

[0109] Clause 9: A footwear article according to any one of Clauses 1-5, wherein the guide is a first guide, the channel is a first channel, and the tensioning member is a first tensioning member having a fixed end fixed to the inner surface of the sole structure, the first tensioning member extending from the fixed end along the first guide in the first channel and extending out of the channel at the inner side of the upper; and the footwear article further comprises: a second guide fixed to the inner surface of the sole structure, the upper and the second guide forming a second channel; and a second tensioning member having a fixed end fixed to the inner surface of the sole structure, the second tensioning member extending from the fixed end along the second guide in the second channel and extending out of the channel at the outer side of the upper.

[0110] Clause 10: Footwear articles according to Clause 9, wherein: the fixed end of the first tensioning member is fixed to the sole structure closer to the outer edge of the sole structure than to the inner edge of the sole structure; and the fixed end of the second tensioning member is fixed to the sole structure closer to the inner edge than to the outer edge.

[0111] Clause 11: Footwear articles according to Clause 9 or Clause 10, wherein the first guide and the second guide are spaced apart from each other in the longitudinal direction of the sole structure on the inner surface of the sole structure.

[0112] Clause 12: Footwear articles according to Clause 11, wherein: the first guide is one of a plurality of medial guides, each medial guide being fixed to the inner surface of the sole structure, and each medial guide forming a channel together with the upper; the second guide is one of a plurality of lateral guides, each lateral guide being fixed to the inner surface of the sole structure, and each lateral guide forming a channel together with the upper; the medial guides and the lateral guides are arranged in an alternating sequence; the first tensioning member is one of a plurality of medial tensioning members, each medial tensioning member having a fixed position closer to the outer edge of the sole structure than the medial edge of the sole structure. The sole structure has a fixed end, and each inner tensioning member extends from the fixed end along one of the inner guides in one of the channels and extends out of the channel at the inner side of the upper; and the second tensioning member is one of a plurality of outer tensioning members, each outer tensioning member having a fixed end to the sole structure closer to the inner edge of the sole structure than the outer edge of the sole structure, and each outer tensioning member extends from the fixed end along one of the outer guides in one of the channels and extends out of the channel at the outer side of the upper.

[0113] Clause 13: Footwear articles according to Clause 12, wherein: the inner guide extends on the inner side of the upper to the inner side support and is integrally formed as a one-piece component with the inner side support; and the outer guide extends on the outer side of the upper to the outer side support and is integrally formed as a one-piece component with the outer side support.

[0114] Clause 14: A method of manufacturing a footwear article, the method comprising: placing an upper on a shoe last; applying an adhesive to an inner surface of a sole structure; placing a guide on the adhesive on the inner surface of the sole structure; placing a tensioning member on the guide; and placing the inner surface of the sole structure against an outer surface of the upper to secure the sole structure to the upper using the adhesive, a channel formed by the upper and the guide, and the tensioning member in the channel.

[0115] Clause 15: The method according to Clause 14, wherein when the adhesive is placed on the inner surface of the sole structure, the inner surface of the sole structure is substantially planar, and the adhesive is placed on the inner surface of the sole structure by rolling the adhesive on the inner surface of the sole structure.

[0116] Clause 16: The method according to Clause 15 further comprises: heating the sole structure before placing the inner surface of the sole structure against the outer surface of the upper; and forming the sole structure onto the outer surface of the upper, wherein the sole structure partially wraps around and conforms to the upper at the inner and outer sides of the upper, such that the inner surface of the sole structure is non-planar.

[0117] Clause 17: The method according to Clause 16 further comprises: cutting a groove in the outer surface of the sole structure before the sole structure is formed onto the outer surface of the upper; wherein the groove is adapted to open when the sole structure is formed onto the upper, and the groove is adapted to further open in response to an increase in tension in the tensioning member when the upper is removed from the last.

[0118] Clause 18: The method according to Clause 17 further comprises: cutting a groove in the inner surface of the sole structure before forming the sole structure onto the outer surface of the upper; wherein the groove in the inner surface of the sole structure is adapted to partially close when the sole structure is formed onto the upper, and the groove in the inner surface of the sole structure is adapted to further close in response to an increase in tension in the tensioning member when the upper is removed from the last.

[0119] Clause 19: The method according to Clause 14, wherein placing the guide on an adhesive on the inner surface of the sole structure includes aligning the guide with a positioning feature on the inner surface of the sole structure.

[0120] Clause 20: The method according to Clause 14, wherein the tensioning member is a first tensioning member, and the method further comprises: placing a second tensioning member on the guide, the second tensioning member passing over the first tensioning member, before placing the inner surface of the sole structure against the outer surface of the upper.

[0121] Clause 21: The method according to Clause 14, wherein placing the tensioning member on the guide comprises positioning the tensioning member such that an end of the tensioning member extends out of the guide and into the inner surface of the sole structure, the end being secured to the sole structure by the adhesive, and the tensioning member extending from the end along the guide and extending the channel at the inner or outer side of the upper.

[0122] Clause 22: The method according to Clause 21, wherein the guide is a first guide, the channel is a first channel, the tensioning member is a first tensioning member extending out of the first channel at the inner side of the upper, and the method further comprises: placing a second guide on the adhesive on the inner surface of the sole structure before placing the inner surface of the sole structure against the outer surface of the upper; and placing a second tensioning member on the second guide, the upper and the second guide forming a second channel, and the second tensioning member extending from the second guide to an end on the inner surface of the sole structure, the end of the second tensioning member being secured to the sole structure by the adhesive, the second tensioning member extending from the end of the second tensioning member along the second guide and extending out of the second channel at the outer side of the upper.

[0123] Clause 23: The method according to Clause 22, wherein the first guide is one of a plurality of medial guides, each medial guide being fixed to the inner surface of the sole structure and each medial guide extending along the inner surface and forming a channel together with the upper; wherein the second guide is one of a plurality of lateral guides, each lateral guide being fixed to the inner surface of the sole structure and each lateral guide extending along the inner surface of the sole structure and forming a channel together with the upper; and the method further comprises: placing the medial guide and the lateral guide on the inner surface of the sole structure such that the medial guide and the lateral guide are arranged in an alternating sequence.

[0124] To aid in and clarify the description of the various embodiments, various terms are defined herein. Unless otherwise indicated, the following definitions apply throughout this specification (including the claims). Furthermore, all references mentioned are incorporated herein in their entirety.

[0125] "Footwear articles," "footwear products," and "footwear" can be considered as both machines and manufactured goods. Assembled footwear articles ready for wear (e.g., shoes, sandals, boots, etc.) and separate components of footwear articles (e.g., insoles, outsoles, upper components, etc.) are considered and may be referred to herein, either in the singular or plural, as "footwear articles" before being finally assembled into footwear articles ready for wear.

[0126] The terms “a,” “an,” “the,” “at least one,” and “one or more” are used interchangeably to indicate at least one of the items present. Multiple such items may exist unless the context clearly indicates otherwise. Unless the context explicitly or clearly indicates otherwise, all numerical values ​​of parameters (e.g., quantities or conditions) in this specification (including the appended claims) should be understood to be modified in all cases by the term “about,” regardless of whether “about” actually precedes the numerical value. “About” indicates that the stated numerical value allows for some slight imprecision (somewhat close to the accuracy of the value; about or moderately close to the value; almost). If the imprecision provided by “about” is not otherwise understood in this ordinary sense in the art, then “about” as used herein at least indicates variations that may arise from common methods of measuring and using these parameters. Furthermore, the disclosure of a range should be understood to specifically disclose all values ​​within that range and further subdivisions of the range.

[0127] The terms “comprising,” “including,” and “having” are inclusive and therefore specify the presence of the stated features, steps, operations, elements, or components, but do not exclude the presence or addition of one or more other features, steps, operations, elements, or components. The order of steps, processes, and operations may be changed where possible, and alternative or optional steps may be used. As used in this specification, the term “or” includes any and all combinations of the associated listed items. The term “any” is understood to include any possible combination of the referenced items, including “any one” of the referenced items. The term “any” is understood to include any possible combination of the referenced claims in the appended claims, including “any one” of the referenced claims.

[0128] For consistency and convenience, directional adjectives may be used throughout this detailed description corresponding to the illustrated embodiments. Those skilled in the art will recognize that terms such as “above,” “below,” “upward,” “downward,” “top,” “bottom,” etc., may be used descriptively with respect to the drawings and are not intended to limit the scope of the invention as defined by the claims.

[0129] The term "longitudinal" refers to the direction extending along the length of a component. For example, the longitudinal direction of a shoe extends between the forefoot and heel areas. The terms "forward" or "anterior" are used to refer to the general direction from the heel area toward the forefoot area, and the terms "rearward" or "posterior" are used to refer to the opposite direction, i.e., from the forefoot area toward the heel area. In some cases, a component can be identified by a longitudinal axis and the forward and rearward longitudinal directions along that axis. The longitudinal direction or longitudinal axis can also be referred to as the front-rear direction or front-rear axis.

[0130] The term "transverse" refers to the direction that extends along the width of a component. For example, the transverse direction of a shoe extends between the outer and inner sides of the shoe. The transverse direction or transverse axis can also be referred to as the lateral direction or lateral axis, or the mid-lateral direction or mid-lateral axis.

[0131] The term "vertical" refers to a direction that is generally perpendicular to both the lateral and longitudinal directions. For example, when a shoe sole is laid flat on a ground surface, the vertical direction can extend upwards from the ground surface. It should be understood that each of these directional adjectives can be applied to various parts of the sole. The term "upward" or "upwards" refers to a vertical direction pointing towards the top of a part, which may include the instep, fastening area, and / or throat of the upper. The term "downward" or "downwards" refers to a vertical direction opposite to the upward direction, pointing towards the bottom of the part, and may generally point towards the bottom of the sole structure of the footwear.

[0132] The “interior” of footwear (such as a shoe) refers to the portion of the space occupied by the wearer’s foot when the shoe is worn. The “inner side” or “inner surface” of a component refers to the side or surface of the component oriented toward (or to be oriented toward) the interior of the component or footwear in an assembled footwear article. The “outer side,” “outer surface,” or “exterior” of a component refers to the side or surface of the component oriented away from (or to be away from) the interior of the shoe in an assembled shoe. In some cases, other components may be located between the inner side of a component and the interior of the assembled footwear. Similarly, other components may be located between the outer side of a component and the space outside the assembled footwear. Furthermore, the terms “inward” and “inner” refer to a direction toward the interior of a component or footwear (e.g., a shoe), and the terms “outward” and “outer” refer to a direction toward the exterior of a component or footwear (e.g., a shoe). Furthermore, the term "proximal" refers to the direction closer to the center of the footwear component or closer to the foot when the foot is inserted into the footwear. Similarly, the term "distal" refers to the relative position further away from the center of the footwear component or further away from the foot when the foot is inserted into the footwear. Therefore, the terms proximal and distal can be understood as providing largely opposite terms to describe relative spatial positions.

[0133] While several embodiments have been described, this description is intended to be exemplary and not restrictive, and it will be apparent to those skilled in the art that further embodiments and implementations are possible within the scope of these embodiments. Any feature of any embodiment may be used in combination with or in lieu of any other feature or element in any other embodiment, unless specifically limited thereto. Therefore, the embodiments are not limited except as provided in the appended claims and their equivalents. Moreover, various modifications and variations may be made within the scope of the appended claims.

[0134] While several modes of implementing many aspects of this teaching have been described in detail, those skilled in the art to which this teaching relates will recognize a variety of alternative aspects of implementing this teaching within the scope of the appended claims. It is intended that all content contained in the foregoing description or shown in the accompanying drawings be construed as an illustration and example of the overall scope of alternative embodiments that will be recognized by those of ordinary skill, such alternative implementations being implied by, structurally and / or functionally equivalent to, or otherwise apparent based on the contained content, and not limited to those embodiments explicitly depicted and / or described.

Claims

1. A type of footwear, comprising: An upper, the upper being adapted to accommodate the wearer's foot, the upper having an inner side and an opposing outer side; A sole structure is connected to the upper, the sole structure having an outer surface that contacts the ground and an inner surface opposite to the outer surface that contacts the ground, the sole structure further including an inner sidewall portion on the inner side of the upper and an opposite outer sidewall portion on the outer side of the upper; An adhesive layer that extends across the inner surface of the sole structure to connect the sole structure to the upper; A guide member, the guide member being fixed to a portion of the inner surface of the sole structure via the adhesive layer, the guide member extending to at least one of the inner sidewall portion or the outer sidewall portion of the sole structure; The upper is adhered to the inner surface of the sole member via the adhesive layer around the guide, and the guide extends between the adhesive layer and the upper to prevent a portion of the adhesive layer from contacting the upper. A tensioning member is fixed to the sole structure and extends along the guide in a channel defined between the guide and the upper. The tensioning member also extends the channel at at least one of the inner or outer sidewall portions of the sole member. The tensioning member is capable of moving in the channel relative to the upper and the guide in response to an increase in tension in the tensioning member.

2. The footwear article according to claim 1, wherein: The outer surface of the guide is adhered to a first portion of the inner surface of the sole structure; The outer surface of the upper adheres to a second portion of the inner surface of the sole structure; and The outer surface of the shoe upper does not adhere to the inner surface of the guide at the channel.

3. The footwear article according to any one of claims 1-2, wherein the upper is configured as a non-Stronbel insole or insole lining.

4. The footwear article according to any one of claims 1-3, wherein the adhesive layer extends uniformly across the entire inner surface of the sole structure; and wherein the adhesive layer is applied by spraying or roller coating.

5. The footwear article according to any one of claims 1-4, wherein the guide defines an X-shape, two intersecting channels are formed between the guide and the upper, the tensioning member is a first tensioning member disposed in one of the two intersecting channels, and the footwear article further comprises: A second tensioning member extends along the guide and over the first tensioning member in the other of the two intersecting channels.

6. The footwear article according to any one of claims 1-5, wherein the sole structure has a plurality of grooves extending partially through the outer surface of the sole structure that contacts the ground, and the grooves are adapted to open when the tensioning member is tensioned.

7. The footwear article of claim 6, wherein the sole structure includes a plurality of grooves extending partially through the sole structure at the inner surface of the sole structure, the grooves at the inner surface of the sole structure being offset from and alternating with the grooves at the outer surface of the sole structure in contact with the ground, and the grooves at the inner surface of the sole structure being adapted to at least partially close when the tensioning member is tensioned.

8. The footwear article according to any one of claims 1-4, wherein the guide is a first guide, the channel is a first channel, and the tensioning member is a first tensioning member having a fixed end fixed to the inner surface of the sole structure, the first tensioning member extending from the fixed end along the first guide in the first channel and extending out of the first channel at the inner side of the upper; The footwear items also include: A second guide member is fixed to the inner surface of the sole structure, and the upper and the second guide member form a second channel; as well as A second tensioning member having a fixed end fixed to the inner surface of the sole structure, the second tensioning member extending along the second guide in the second channel from the fixed end and extending out of the second channel at the outer side of the upper.

9. The footwear article according to claim 8, wherein: The fixed end of the first tensioning member is fixed to the sole structure closer to the outer edge of the sole structure than to the inner edge of the sole structure; and The fixed end of the second tensioning member is fixed to the sole structure closer to the inner edge than the outer edge.

10. The footwear article according to claim 8 or claim 9, wherein the first guide and the second guide are spaced apart from each other in the longitudinal direction of the sole structure on the inner surface of the sole structure.

11. The footwear article according to claim 10, wherein: The first guide is one of a plurality of inner guides, each inner guide being fixed to the inner surface of the sole structure, and each inner guide forming a first channel together with the upper; The second guide is one of a plurality of outer guides, each outer guide being fixed to the inner surface of the sole structure, and each outer guide forming a second channel together with the upper; The inner guide and the outer guide are arranged in an alternating sequence; The first tensioning member is one of a plurality of inner tensioning members, each inner tensioning member having a fixed end fixed to the sole structure closer to the outer edge of the sole structure than the inner edge of the sole structure, and each inner tensioning member extending from the fixed end of the inner tensioning member along one of the inner guides in a first channel of the first channel and extending from the first channel at the inner side of the upper; and The second tensioning member is one of a plurality of outer tensioning members, each outer tensioning member having a fixed end fixed to the sole structure closer to the inner edge of the sole structure than the outer edge of the sole structure, and each outer tensioning member extending from the fixed end of the outer tensioning member along one of the outer guides in a second channel of the second channel and extending from the second second channel at the outer side of the upper.

12. The footwear article according to claim 11, wherein: The inner guide extends onto the inner side of the upper to the inner side support, and together with the inner side support, forms an integral, one-piece component; and The outer guide extends to the outer side support on the outer surface of the shoe upper and together with the outer side support forms an integral one-piece component.

Images