Post-production laser modification of an article of footwear

Abstract

A sole assembly for an article of footwear includes a midsole formed from at least a bladder and a foam midsole component. The midsole has a ground-facing surface and a sidewall, and the bladder interfaces with the foam midsole at a component boundary on the sidewall. An etch extends into both the foam midsole and the bladder. An etch channel has a depth between about 2 mm and about 1000 μm in the sidewall and extends continuously across the component boundary.

Description

[0001] Cross-references to related applications

[0002] This application claims the benefit of priority to U.S. Provisional Patent Application No. 63 / 032,688, filed May 31, 2020, which is incorporated herein by reference in its entirety. Technical Field

[0003] This teaching generally deals with methods for decorative modification of footwear using laser etching equipment.

[0004] background

[0005] Footwear typically includes a sole that is constructed to sit beneath the wearer's foot to separate the foot from the ground or floor surface. The sole can be designed to provide a desired level of cushioning. The sole can be a component that includes a midsole and an outsole. In athletic footwear, in particular, polyurethane or ethylene-vinyl acetate foam or other resilient materials are sometimes used in the sole to provide cushioning. In some configurations, the sole may also include one or more fluid-filled chambers to modify cushioning properties.

[0006] Overview

[0007] In one configuration, the sole assembly for footwear articles includes a sole interlayer formed by at least a bladder and a foam sole interlayer component. The sole interlayer has a ground-facing surface and sidewalls, and the bladder is in contact with the foam sole interlayer at the component boundary on the sidewall. An etching extends into both the foam sole interlayer and the bladder. The etched channels have a depth between about 2 μm and about 1000 μm in the sidewalls and extend continuously across the component boundary.

[0008] Furthermore, in some embodiments, the footwear article includes an upper and a sole structure attached to the upper, the upper defining a cavity operable to receive a wearer's foot. The sole structure includes a surface in contact with the ground opposite the upper, a sole interlayer formed of thermoplastic polymer foam, and a fluid-filled bladder. The sole interlayer has foam sidewalls defining a first portion of the outer perimeter of the sole structure. The foam sidewalls extend upward at an angle relative to the surface in contact with the ground, and the fluid-filled bladder has bladder sidewalls defining a second portion of the outer perimeter of the sole structure. The bladder sidewalls directly abut the foam sidewalls at component boundaries. Finally, etched portions extend continuously from the foam sidewalls across the component boundaries to the bladder sidewalls.

[0009] In another aspect of this disclosure, the etched portion can form a graphic design or logo and can be created from a visual image received via a network computing system. In some embodiments, the etched portion can at least partially expose or further make the inner material layer visible, and the inner material layer can be colored differently from the outermost material layer. The etched portion can include a texture that may be useful for individuals with visual impairments in distinguishing the left and right shoes within a coordinated pair of shoes. Furthermore, the etched portion can provide a unique identifier from which the authenticity of the footwear article can be determined. Other aspects and advantages of this design are provided below, including related methods for generating the etched portion. Brief description of the attached diagram

[0011] Figure 1 It is a side perspective view of footwear articles based on the principles of this disclosure;

[0012] Figure 2 yes Figure 1 An exploded view of footwear articles showing footwear articles with upper and sole structures arranged in a layered configuration;

[0013] Figure 3 This is a schematic diagram of a laser etching system;

[0014] Figure 4 This is a schematic diagram of a design applied to the sidewalls of footwear.

[0015] Figure 5 This is a schematic flowchart illustrating the method of laser etching for footwear.

[0016] Detailed description

[0017] This disclosure generally relates to a method for altering the visual and / or tactile properties of a footwear article after it has been fully assembled. In doing so, graphics or tactile textures can extend continuously across multiple adjacent parts, which could otherwise be difficult to perform correctly if the graphics or textures were applied prior to assembly.

[0018] Example configurations will now be described more fully with reference to the accompanying drawings. These configurations are provided so that this disclosure will be thorough and will fully communicate the scope of this disclosure to those skilled in the art. Specific details, such as examples of specific components, apparatus, and methods, are set forth to provide a thorough understanding of the configurations of this disclosure. It will be apparent to those skilled in the art that the specific details are not required, that the example configurations may be implemented in many different forms, and that the specific details and example configurations should not be construed as limiting the scope of this disclosure.

[0019] The terminology used herein is for the purpose of describing particular exemplary configurations only and is not intended to be restrictive. As used herein, the singular articles “a,” “an,” and “the” may also be intended to include plural forms unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having” are inclusive and therefore specify the presence of features, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof. Unless specifically identified as the order of execution, the method steps, processes, and operations described herein should not be construed as requiring them to be performed in the particular order discussed or shown. Alternative or alternative steps may be employed.

[0020] When an element or layer is referred to as “on another element or layer,” “joined to,” “connected to,” “attached to,” or “linked to” another element or layer, it may be directly on, joined to, connected to, attached to, or linked to another element or layer, or there may be an intermediate element or layer. Conversely, when an element is referred to as “directly on another element or layer,” “directly joined to,” “directly connected to,” “directly attached to,” or “directly linked to” another element or layer, there may not be an intermediate element or layer. Other terms used to describe relationships between elements should be interpreted in a similar manner (e.g., “between” vs. “directly between,” “adjacent” vs. “directly adjacent,” etc.). As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0021] The terms first, second, third, etc., may be used herein to describe various elements, components, regions, layers, and / or segments. These elements, components, regions, layers, and / or segments should not be limited by these terms. These terms may be used only to distinguish one element, component, region, layer, or segment from another. Terms such as “first,” “second,” and other numerical terms do not imply sequence or order unless the context clearly indicates otherwise. Therefore, the first element, first component, first region, first layer, or first segment discussed below may be referred to as the second element, second component, second region, second layer, or second segment without departing from the teachings of the example configuration.

[0022] refer to Figures 1-2Footwear article 10 includes an upper 100 and a sole structure 200. Footwear article 10 may be divided into one or more regions. These regions may include a forefoot region 12, a midfoot region 14, and a heel region 16. The midfoot region 14 may correspond to the arch region of the foot, and the heel region 16 may correspond to the posterior part of the foot (including the calcaneus). Footwear 10 may also include a front end 18 associated with the foremost point of the forefoot region 12, and a rear end 20 corresponding to the rearmost point of the heel region 16. The longitudinal axis of footwear 10 extends generally along the length of footwear 10 from the front end 18 to the rear end 20, and generally divides footwear 10 into a lateral and medial side. Thus, the lateral and medial sides correspond to opposite sides of footwear 10, respectively, and extend through regions 12, 14, and 16.

[0023] The upper 100 includes an inner surface defining an internal cavity 102 configured to receive and secure the foot for support on the sole structure 200. The upper 100 may be formed of one or more materials stitched or adhesively bonded together to form the internal cavity 102. Suitable materials for the upper may include, but are not limited to, mesh, textiles, foam, leather, and synthetic leather. These materials can be selected and positioned to impart properties of durability, breathability, abrasion resistance, flexibility, and comfort.

[0024] refer to Figure 2 In some examples, the upper 100 includes a strobel (midsole fabric) 104 having a bottom surface opposite the sole structure 200 and a top surface opposite the footbed defining the internal cavity 102. The strobel can be attached to the upper 100 by stitching or adhesive. The footbed can be profiled to conform to the profile of the bottom surface of the foot (e.g., the plantar). Alternatively, the upper 100 may also include an additional layer (such as an insole or insole) that can be placed on the strobel 104 and within the internal cavity 102 of the upper 100 to receive the plantar surface of the foot, thereby improving the comfort of the footwear article 10. Ankle opening 114 in the heel area 16 provides access to the internal cavity 102. For example, the ankle opening 114 can receive the foot to secure the foot within the cavity 102 and facilitate the foot's entry into and exit from the internal cavity 102.

[0025] In some examples, one or more fasteners 110 extend along the upper 100 to adjust the fit of the upper 100 around the foot and to accommodate foot entry into and exit from the upper 100. The upper 100 may include holes 112 (such as eyelets) and / or other engagement features (such as fabric or mesh loops) that receive the fasteners 110. The fasteners 110 may include laces, straps, cords, hooks and loops, or any other suitable type of fastener. The upper 100 may include a tongue portion 116 extending between the internal cavity 102 and the fasteners.

[0026] Continue to refer to Figures 1-2 The sole structure 200 includes a cushioning member 208 that defines a portion of the outer periphery of the sole structure 200 within the heel region 16. The cushioning member 208 may include a fluid-filled bladder 210 and an outsole portion 220. In some configurations, the outsole portion 220 may be integrally connected to the fluid-filled bladder 210, such as via an overmolding process, or by integrally molding the outsole portion 220 while forming the walls of the bladder 210. The outsole portion 220 extends along the ground-facing side of the fluid-filled bladder 210 and may define a first portion of the ground-contacting surface 202 of the sole structure 200.

[0027] The sole structure 200 also includes a forefoot midsole component 230 in the forefoot region 12 and the midfoot region 14. The forefoot midsole component 230 may be formed of an energy-absorbing material, such as, for example, polymer foam. Forming the forefoot midsole component 230 with an energy-absorbing material, such as polymer foam, allows the forefoot midsole component 230 to reduce ground reaction forces caused by the movement of the footwear 10 on the ground during use.

[0028] Reference Figure 2The fluid filling bladder 210 may be formed of a plurality of polymer sheets (e.g., a first polymer sheet 212a and a second polymer sheet 212b) fused together at a peripheral flange or seam 214 to define an internal volume between the respective sheets 212a, 212b. This internal volume is adapted to receive pressurized fluid (e.g., air) that can provide cushioning mass for the sole structure. In some embodiments, the seam 214 may extend around some or all of the periphery of the fluid filling bladder 210, however, it may preferably be concealed by the outsole portion 220. Although the seam 214 is shown as forming a relatively prominent flange projecting outward from the fluid filling bladder 210, in some embodiments, the seam 214 may be a flat seam such that the upper polymer sheet 212a and the lower polymer sheet 212b are substantially continuous with each other. In some embodiments, an additional polymer sheet may be provided between the first polymer sheet 212a and the second polymer sheet 212b to define one or more additional volumes within the fluid filling bladder 210.

[0029] The first polymer sheet 212a and the second polymer sheet 212b may each be formed from one or more layers of a substantially transparent thermoplastic material, such as thermoplastic polyurethane (TPU). Examples of other suitable polymeric materials that can be used to form the fluid-filled capsule 210 include thermoplastic polyurethane, polyester, polyester polyurethane, and polyether polyurethane. Furthermore, each of the polymer sheets 212a and 212b forming the fluid-filled capsule 210 may include layers of different materials. In one embodiment, the polymer sheets 212a and 212b may be formed from a plurality of alternating films comprising one or more thermoplastic polyurethane (TPU) layers and one or more barrier layers comprising a copolymer of ethylene and vinyl alcohol (EVOH). In use, the EVOH layers may be configured such that they are impermeable to pressurized fluid contained therein. Such a construction is further disclosed in U.S. Patent No. 6,082,025 to Bonk et al., which is incorporated herein by reference in its entirety.

[0030] In some embodiments, polymer sheets 212a, 212b may also be formed of a material comprising alternating layers of thermoplastic polyurethane and ethylene-vinyl alcohol copolymer, as disclosed in U.S. Patents 5,713,141 and 5,952,065 to Mitchell et al., which are incorporated herein by reference in their entirety. Alternatively, these layers may comprise ethylene-vinyl alcohol copolymer, thermoplastic polyurethane, and a re-polished material of ethylene-vinyl alcohol copolymer and thermoplastic polyurethane. The polymer sheets 212a, 212b of the fluid-filled capsule 210 may also be flexible microlayer films comprising alternating layers of gas-barrier material and elastomeric material, as disclosed in U.S. Patents 6,082,025 and 6,127,026 to Bonk et al., which are incorporated herein by reference in their entirety. Further suitable materials for the fluid-filled capsule 210 are disclosed in U.S. Patents 4,183,156 and 4,219,945 to Rudy, which are incorporated herein by reference in their entirety. Other suitable materials for the fluid-filled capsule 210 include thermoplastic films containing crystalline materials (as disclosed in Rudy’s U.S. Patent Nos. 4,936,029 and 5,042,176), and polyurethanes comprising polyester polyols (as disclosed in Bonk et al.'s U.S. Patent Nos. 6,013,340, 6,203,868, and 6,321,465), which are incorporated herein by reference in their entirety.

[0031] When selecting the material for the fluid-filled bladder 210, engineering properties such as tensile strength, tensile properties, fatigue characteristics, dynamic modulus, and loss tangent can be considered. The thickness of the polymer sheets 212a, 212b used to form the fluid-filled bladder 210 can be selected to provide these properties. The fluid-filled bladder 210 is resilient and provides cushioning and flexibility that can be adjusted, for example, by selecting the pressurization level. Optionally, tension members and / or reinforcing structures can be integrated with the fluid-filled bladder 210 to provide desired responsiveness, such as that disclosed in U.S. Patent No. 4,906,502 to Rudy et al. and U.S. Patent No. 8,061,060 to Swigart et al., which are incorporated herein by reference in their entirety.

[0032] In some embodiments, the outsole portion 220 extends over a portion of the pouch 210 to provide increased durability and resilience to the pouch 210. Therefore, the outsole portion 220 may be formed of a different material than the pouch 210 and may include at least one of a different thickness, different hardness, and different abrasion resistance than the second / lower polymer sheet 212b. In some examples, the outsole portion 220 may be integrally formed with the second polymer sheet 212b of the pouch 210 using an overmolding process. In other examples, the outsole portion 220 may be formed separately from the second polymer sheet 212b and may be adhesively bonded to the second barrier layer 212b by a subsequent process.

[0033] Continue to refer to Figures 1-2 The fluid-filled bladder can be continuously exposed along the outer periphery of the heel region 16 from the distal end 219 on the outer surface to a similar distal end on the inner surface. For example, the first barrier layer 212a can be continuously exposed along the outer periphery of the sole structure 200 between the upper 100 and the outsole portion 220, such that a transparent first polymer sheet 212a is exposed around the periphery of the heel region 16.

[0034] The sole structure 200 may also include a heel counter 270, which may be formed of the same transparent TPU material as the first polymer sheet 212a and may further extend onto a portion of the forefoot sole interlayer component 230. As shown, the heel counter 270 extends from a first distal end 219 of the pouch 210 around the rear end 20 and extends to the distal end of the pouch 210 located on the opposite side of the sole structure 200.

[0035] Generally, the fluid filling bladder 210 and the forefoot midsole component 230 can cooperate to define at least a portion of the entire sole midsole of the footwear article. The sole midsole typically has outward-facing sole midsole sidewalls formed at least partially by the sidewalls of the fluid filling bladder and the forefoot midsole component. The sole midsole sidewalls can extend generally upward toward the upper from the surface 202 of the contact surface and can form at least a portion of the overall side profile of the footwear article 10.

[0036] In one embodiment, the visual and / or tactile appearance of the footwear article 10, and particularly the sole structure 200 of the footwear article, can be customized using an etching process. Specifically, such as Figure 3The laser etching system 300 shown can be used to line one or more designs into the sidewalls of the midsole, wherein the designs may extend across one or both of the fluid-filled bladder sidewall and the forefoot midsole component sidewall. System 300 typically includes a laser head 302, a workpiece holder 304 configured to hold and / or move a workpiece 306, a movement system 308 configured to provide movement between the laser head 302 and the workpiece, and a computer digital controller 310 configured to control the movement between the laser head 302 and the workpiece. The laser head 302 can emit a strong beam of light at a specific wavelength and can be driven by a laser oscillator 312, which in turn is powered by a transformer 314.

[0037] The laser etching system 300 may include any suitable type of laser cutting machine for cutting shoe sole materials. For example, the laser etching system 300 may include a pulsed fiber laser, a continuous-wave carbon dioxide laser, an ultraviolet solid-state laser, a yttrium lithium fluoride laser, or an excimer (recombined excited-state) laser cutting machine, such as the ML1515VZ20 5-axis computer numerical control laser cutting machine manufactured by Mitsubishi Corporation. In another example, Sumitomo Heavy Industries, Ltd. manufactures laser cutting machines such as the INDEX-848K KrF excimer laser with a wavelength of 248 nm.

[0038] The wavelength of the laser can be varied depending on the properties of the material to be cut and the desired effect. In some embodiments, the wavelength can be in the ultraviolet portion of the spectrum, i.e., from about 10 nm to about 400 nm. In other embodiments, a specific portion of the ultraviolet spectrum can be selected, such as from about 200 nm to about 300 nm. For example, 248 nm light may be effective for cutting / etching many polymers. In other embodiments, other portions of the electromagnetic spectrum can be selected for the laser. Infrared light can also be selected; for example, a carbon dioxide laser in the 940 nm–1064 nm wavelength range may be desirable for certain materials / effects. In other embodiments, lasers operating at 355 nm, 532 nm, and 1064 nm may be desirable. When used with thermoplastic materials, IR (e.g., >700 nm) lasers may tend to thermally convert / melt the polymer (i.e., “hot” processes), while UV lasers (e.g., <400 nm) may break molecular bonds at the surface in “cold” photoablation processes (which can produce smoother edge features). Similar to the choice of wavelength, the power of the laser and / or any laser pulse or the duration of exposure to the laser beam can be selected based on factors such as wavelength, power source, type of material to be cut / etched, and type of cutting / etching effect desired.

[0039] Laser head 302 can be connected to laser oscillator 312 and can be configured to focus the laser generated by laser oscillator 312. Laser head 302 may include laser nozzle 316 disposed on the bottom of laser head 302. Laser nozzle 316 can be configured to further focus the laser and emit a laser beam, and can be adjusted to increase and / or decrease the focus of the laser beam. In some embodiments, laser nozzle 316 can be adjusted by local processing device 318. Local processing device 318 is discussed in more detail below. The type of laser head 302 and / or laser nozzle 316 can be selected based on a variety of factors. For example, the type of laser head and laser nozzle can be selected based on the type of laser cutting machine used and / or the desired depth and shape of the etched pattern.

[0040] The workpiece retainer 304 may include any suitable type of retainer operable to hold footwear items. For example, such as Figure 3 As shown, the workpiece holder 304 may include a workpiece stage 320. In other embodiments, the workpiece holder 304 may include a shoe last on which footwear articles are mounted.

[0041] Figure 3 The laser etching system 300 may include a movement system 308 that provides motion between the laser head 302 and the workpiece, such as the ML1515VZ20 from Mitsubishi Corporation as described above. In one configuration, the laser etching system 300 may include a 5-axis cutter configured to move the laser head 302 in three directions and the workpiece in two directions. In some embodiments, the laser etching system 300 may include a 5-axis cutter configured to move the laser head 302 in two directions and the workpiece in three directions. Alternatively, the laser etching system 300 may include a 6-axis cutter configured to move the laser head 302 in three directions and the workpiece in three directions. Providing multiple directions of movement between the laser head 302 and the workpiece holder 304 can provide a variety of etching pattern possibilities.

[0042] When used to etch visual patterns in the sole structure 200, the laser beam emitted from the laser head 302 can be adjusted to maintain a smooth surface of the sole structure 200 after cutting, although this can alter the visual appearance of the polymer. In some embodiments, the laser beam emitted from the laser head 302 can be adjusted to leave a mark in the laser beam wake. The marks produced by laser cutting can be so fine and uniform that the resulting surface roughness of the sole structure 200 can be very low or unchanged relative to the pre-etched state. In some embodiments, Figure 3 The laser etching system 300 can be used to cut fine lines and / or other repeating patterns, which can add texture to the surface of the sole structure 200.

[0043] As described above, the laser etching system 300 may include a computer digital controller 310 configured to control movement between the laser head 302 and the workpiece. For example, as described above, Mitsubishi manufactures 5-axis computer digital control laser cutting machines, such as the ML1515VZ20. In some embodiments, the computer digital controller 310 may be configured to control the focusing of the laser beam emitted from the laser head 302. The computer digital controller 310 may include any suitable type of computer digital controller. The type of computer digital controller can be selected based on various factors. For example, the type of computer digital controller can be selected based on the type of laser head and / or the type of workpiece stage used.

[0044] Figure 3 The laser etching system 300 may include a local processing device 318 operable to control the laser head 302 and / or the computer digital controller 310. In some embodiments, the local processing device includes a local user interface operable to configure the system 300. The local processing device 318 may include one or more dedicated processors, or one or more computing devices that communicate locally with the computer digital controller 310. For example, in some embodiments, the local processing device 318 may include a desktop or laptop computer, tablet computer, or suitable portable computing device that communicates wirelessly with the computer digital controller 310, either via wired or direct wireless communication.

[0045] In some embodiments, the local processing device 318 may communicate with one or more networked user interfaces 322 via a digital computer network, a local area network, a wide area network, or via point-to-point RF communication such as using Bluetooth. The networked user interface 322 may be displayed or provided on any suitable portable computing device (such as a smartphone, tablet, laptop, or similar device) and may enable the user to provide one or more designs 324 desired to be etched into the sole structure 200. In some embodiments, the networked user interface 322 may include a dedicated application operating on the user's device, or may include an internet-based web application viewable through a suitable internet browser.

[0046] like Figure 3As shown, a user can access the networked user interface 322 via a display screen or other human-machine interface device in response to a set of user prompts. For example, the display screen may be a touchscreen, and the user prompt may be one or more icons and / or text-based prompts requesting input of desired surface features or designs (such as custom depths, patterns, or effects that can be etched into the sole structure 200). Alternatively, the user prompt may request input of desired markings on the outer surface of the sole structure 200, wherein the term "mark" as used herein refers to any image, letter, character, or similar object that would effectively form a custom watermark or etched image.

[0047] As described above, in one embodiment, the footwear article 10, and particularly the sole structure 200 of the footwear article, can have a visual appearance customized by the laser etching system 300. In particular, the laser etching system 300 can be configured to controllably apply laser energy to the outer surface of the footwear article 10 for the purpose of altering the visual properties of the material used to form the article and / or altering the physical properties of the article itself.

[0048] Figure 4 An embodiment of footwear article 10 is schematically shown, having an etched pattern 350 embossed in an outer surface 352. As generally shown, the etched pattern 350 can extend continuously across multiple parts without interruption. In one particular embodiment, this continuous aspect of the etched pattern 350 can be formed by controlling a movement system 308, a computer digital controller 310, and / or a workpiece holder 304 such that a laser beam emitted from a laser head 302 is approximately orthogonal to the outer surface 352 at the point where the laser beam strikes the outer surface.

[0049] Figure 5 An embodiment of a method 400 for laser etching footwear articles is schematically illustrated. As shown, method 400 may include providing (or receiving) footwear article 10 on a workpiece holder 304 (at 402) and identifying the outline or outer surface profile of the footwear article (at 404), followed by identifying etchable working spaces on the outer surface of the article (at 406). The identification of the outline profile may occur manually (e.g., by receiving an indication of the model and size of the footwear article from a user interface) or automatically (e.g., by scanning the outer surface of the article with a laser). In one embodiment, the identified etchable working spaces extend continuously over a plurality of components, such as a polymer foam sole interlayer (e.g., Figures 1-2 The forefoot sole interlayer component 230 shown), and the polymer fluid filling chamber (e.g., Figures 1-2 The fluid-filled chamber 210 shown), and / or the heel stabilizer (e.g., Figures 1-2 The heel stabilizer 270 shown.

[0050] Method 400 also includes receiving a design from a user (at 408) via a local processing device 318 and / or a networked user interface 322. In one configuration, the design may include a repeating pattern of discrete graphic primitives, such as a repeating grid pattern or a repeating herringbone design. In another configuration, the design may include more complex graphics, such as a logo, image, or other creative work.

[0051] After receiving the design at 408, the local processing device 318 can apply / project the design onto the etchable workspace (at 410) and then construct a series of digital codes (at 412) that can be used to instruct the motion system 308 and / or the computer digital controller 310 to move the laser head 302 such that the laser beam tracks the design onto the article (at 414). In one embodiment, the local processing device 318 can utilize the dimensional geometry of the outer surface of the article to construct the digital codes, which keep the laser beam in an orientation approximately orthogonal to the surface it illuminates. After creating the digital codes, the local processing device can instruct the motion system 308 and / or the computer digital controller 310 to move the laser head 302 while modulating the laser oscillator 312 and / or the laser power to etch the prescribed design into the article.

[0052] Applying this design in this manner can result in a complete article having at least one etched line formed by a laser, which extends continuously across the boundary between two components. In one embodiment, the laser can cut or partially melt the outer surface of one or more components to create a channel having a depth between about 2 μm and about 1000 μm, or between about 2 μm and about 500 μm, or between about 2 μm and about 125 μm, or even between about 2 μm and about 25 μm, as measured from one or more directly adjacent step regions.

[0053] In one embodiment, the sole interlayer (e.g., in...) Figures 1-2 The forefoot sole interlayer component 230 shown in the figure), and the polymer fluid filling chamber (e.g., in...) Figures 1-2 The fluid-filled chamber 210 shown in the figure) and / or the heel stabilizer (e.g., in the...) Figures 1-2At least one of the heel stabilizers 270 shown may have an outer skin or outer material structure comprising multiple layers. One or more layers may have a substantially constant thickness, and at least two layers may be formed of materials with different pigmentation. In such embodiments, the depth of laser etching may be greater than 75% of the thickness of the outermost layer, such that the second layer (i.e., the layer immediately below the outermost layer) is at least partially visible through the etched channels and / or the remaining material of the outer layer. In one embodiment, the depth of laser etching may be greater than or equal to the thickness of the outermost layer, such that the second layer is at least partially exposed within the channels formed by the etching. In some configurations, the second layer may be a different color from the outermost layer and may also be visible only through the etched channels.

[0054] In another embodiment, the etching process can alter one or more pigments on the outer surface of the sole structure 200, or it can alter the light transmittance of the polymer, such as in the barrier layer 212a of the fluid-filled chamber 210. Changes in the pigment deposition and / or transmittance of the polymer can occur, for example, by altering the polymer chain structure or by initiating hyperlocalized chemical reactions that result in visible changes.

[0055] Etchable workspaces can include various parts of footwear items, including toe bumpers, sidewalls of sole structures, ground-facing surfaces, heel stabilizers, fluid-filled chambers, and / or uppers.

[0056] In some configurations, the methods and systems described herein can be used to apply textures to the outer surface of footwear articles and across multiple discrete parts. This texture can achieve non-visual differentiation between right and left shoes, which may be beneficial for individuals with visual impairments. For example, in one configuration, the texture may be applied to only one shoe in a corresponding pair. In another configuration, a similar texture may be applied to each shoe; however, the texture may be applied to only one of the outer or inner sides of each article (however consistent between the two—i.e., both outer or both inner sides). In yet another configuration, a first texture may be applied to a first article in a corresponding pair of shoes, while a second texture, distinguishable from the first texture, may be applied to a second article in the pair. In these embodiments, the applied texture may typically include recessed or etched surface profiles with sufficient roughness or surface geometry to be perceptible and identifiable by human touch.

[0057] In another configuration, the applied pattern or mark can contain sufficiently unique content to authenticate footwear articles as genuine rather than counterfeit. In particular, the ability to produce convincing counterfeits can be further complicated by etching across multiple parts of the sole and / or upper. In one configuration, the authentication or identification mark can be digitally encoded within a broader texture or visual design, as described in U.S. Patent Application No. 17 / 116,527, the entire contents of which are incorporated herein by reference.

[0058] While the best mode for carrying out the invention has been described in detail, those skilled in the art will recognize various alternative designs and embodiments for practicing the invention within the scope of the appended claims. It is intended that everything contained in the foregoing description and shown in the accompanying drawings should be considered illustrative rather than restrictive.

Claims

1. A sole structure for footwear, comprising: A midsole includes a bladder and a foam midsole component, wherein the bladder defines a fluid-filled chamber, the foam midsole component has a ground-facing surface and sidewalls, and wherein the bladder forms a visible portion of the sidewalls, and wherein the bladder is in contact with the foam midsole component to define a component boundary on the sidewalls; Etched channels extending into both the foam sole interlayer and the bladder, the etched channels having approximately 2 [units / areas] in the sidewall. m and approximately 1000 The depth is between m, and the etched channel extends continuously across the component boundary. The etched channels are formed by laser after the footwear has been fully assembled.

2. The sole structure according to claim 1, wherein the etched channels form a design or mark.

3. The sole structure according to claim 1, wherein at least one of the bladder or the foam sole interlayer comprises a plurality of material layers, wherein the outermost layer forms the outer surface of the sole interlayer; and The depth therein is greater than 75% of the thickness of the outermost layer.

4. The sole structure of claim 3, wherein the plurality of material layers includes a second layer directly adjacent to the outermost layer; and The second layer is at least partially visible through the etched channel.

5. The sole structure of claim 4, wherein the second layer is a different color from the outermost layer, and wherein the second layer is visible only through the etched channels.

6. The sole structure of claim 1, wherein the bladder has a convex surface profile relative to the sole structure, and wherein the etched channel is at least partially formed in the convex surface profile.

7. A footwear article having a forefoot portion, a midfoot portion, and a heel portion, said footwear article comprising: An upper that defines an inner cavity operable to receive the wearer's foot; A sole structure, the sole structure being connected to the upper, the sole structure comprising: The surface that contacts the ground, and the surface that contacts the ground is opposite to the shoe upper; The sole interlayer is formed of thermoplastic polymer foam; Fluid-filled capsules; and The sole interlayer has foam sidewalls that define a first portion of the outer periphery of the sole structure and extend upward at an angle relative to the surface in contact with the ground. The fluid-filled bladder has a bladder sidewall defining a second portion of the outer periphery of the sole structure, the bladder sidewall being directly adjacent to the foam sidewall at the component boundary; and An etched portion extends continuously from the foam sidewall across the component boundary to the bladder sidewall. The etched portion is formed by laser after the footwear has been fully assembled.

8. The footwear article of claim 7, wherein the etched portion includes a channel having a radius of approximately 2 mm relative to an adjacent outer perimeter. m and approximately 1000 Channel depth between m.

9. The footwear article of claim 7, wherein the fluid filling bladder is disposed in the heel portion of the footwear article.

10. The footwear article of claim 9, wherein the pouch sidewall is convex in a plane orthogonal to the surface in contact with the ground.

11. The footwear article of claim 7, wherein the etched portion forms a design or logo.

12. The footwear article of claim 7, wherein at least one of the fluid filling bladder or the sole interlayer comprises a plurality of material layers, wherein the outermost layer forms the outer surface of the sole structure; and The etched portion has a depth greater than 75% of the thickness of the outermost layer.

13. The footwear article of claim 12, wherein the plurality of material layers includes a second layer directly adjacent to the outermost layer; and The second layer is at least partially visible through the etching.

14. The footwear article of claim 13, wherein the second layer is a different color from the outermost layer, and wherein the second layer is visible only through the etched portion.

15. A footwear article having a forefoot portion, a midfoot portion, and a heel portion, said footwear article comprising: An upper that defines an inner cavity operable to receive the wearer's foot; A sole structure, the sole structure being connected to the upper, the sole structure comprising: The surface that contacts the ground, and the surface that contacts the ground is opposite to the shoe upper; A midsole layer formed of thermoplastic polymer foam, the midsole layer having foam sidewalls defining at least a portion of the outer perimeter of the midsole structure, the foam sidewalls extending upward at an angle relative to the surface in contact with the ground; A heel stabilizer having a heel stabilizer sidewall defining a portion of the outer perimeter of the footwear article, the heel stabilizer sidewall being directly adjacent to the foam sidewall; and An etched portion, the etched portion extending continuously from the foam sidewall to the heel stabilizer sidewall, The etched portion is formed by laser after the footwear has been fully assembled.

16. The footwear article of claim 15, wherein the etched portion includes a channel having a distance of approximately 2 mm relative to an adjacent outer perimeter. m and approximately 1000 Channel depth between m.

17. The footwear article of claim 15, wherein the sole structure further comprises: A fluid-filled bladder having a bladder sidewall defining a portion of the outer periphery of the sole structure, the bladder sidewall being directly adjacent to the foam sidewall; and The etched portion extends continuously from the foam sidewall to the bladder sidewall and from the heel stabilizer to the bladder element.

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