Footwear with a board

Abstract

A method of manufacturing a component for a sole structure of footwear articles includes providing a printer having a platform, a first head receiving a first supply, and a second head receiving a second supply. The method further includes printing a base layer on the platform, wherein the base layer comprises a substrate material and defines a longitudinal axis. Additionally, the method includes continuously printing a first fiber layer on the base layer, wherein the first fiber layer defines a first fiber orientation disposed at a first angle relative to the longitudinal axis, and continuously printing a second fiber layer on the first fiber layer, the second fiber layer defining a second fiber orientation disposed at a second angle relative to the longitudinal axis. The first angle differs from the second angle.

Description

[0001] Cross-references to related applications

[0002] This application claims the benefit and priority of U.S. Application No. 17 / 578,752, filed January 19, 2022, which is incorporated herein by reference in its entirety.

[0003] Reference for federally funded research or development

[0004] not applicable

[0005] sequence list

[0006] not applicable Technical Field

[0007] This disclosure generally relates to a footwear article comprising a plate, and more specifically, to a footwear article having a plate formed by an additive manufacturing process to have a customized reinforcement and propulsion pattern. Background Technology

[0008] Many traditional shoes or other footwear items typically consist of an upper and a sole attached to the lower part of the upper. Traditional shoes also include an internal space, that is, a gap or cavity formed by the inner surfaces of the upper and sole, which accommodates the user's foot before the shoe is secured to the foot. The sole is attached to the lower surface or boundary of the upper and is positioned between the upper and the ground. Therefore, when the shoe is worn, the sole typically provides stability and cushioning for the user. In some cases, the sole may include multiple components, such as an outsole, a midsole, and a top section. The outsole can provide adhesion friction to the bottom surface of the sole, and the midsole can be attached to the inner surface of the outsole and can provide cushioning or increased stability to the sole. For example, the sole may include specific foam materials that can increase stability along one or more desired locations on the sole, or foam materials that can reduce stress or impact energy on the foot or leg when the user runs, walks, or performs another activity. The sole may also include additional components embedded in the sole, such as plates, to increase the overall stiffness of the sole and reduce energy loss during use.

[0009] The upper typically extends upwards from the sole and defines the cavity that fully or partially covers the foot. In most cases, the upper extends over the instep and toe areas of the foot, crossing the inner and outer sides of the foot. Many footwear items may also include a tongue that extends across the instep area to bridge the gap between the medial and lateral edges of the upper, defining an opening into the cavity. The tongue may also be positioned below the lacing system and between the medial and lateral sides of the upper to allow adjustment of the shoe's tightness. The tongue can also be manipulated by the user to allow the foot to enter or exit the internal space or cavity. Furthermore, lacing systems allow the user to adjust certain dimensions of the upper or sole, allowing the upper to accommodate a wide variety of foot types with different sizes and shapes.

[0010] The sole can include a variety of materials, which can be selected based on one or more intended uses of the shoe. The sole may also include sections containing different materials specifically designed for certain areas of the upper. For example, increased stability may be needed in the forefoot or heel area of ​​the sole to provide a higher degree of resistance or rigidity. Conversely, other parts of the shoe may be softer to provide areas with flexibility, cushioning, and conformity to the wearer's foot. Furthermore, wearers with flat feet (also known as shin splints) or other special conditions often add inserts to their shoes for more targeted support. This wide range of user preferences leads to a need for a shoe that can be customized to provide cushioning, support, and rigidity along different areas, orientations, and zones of the shoe.

[0011] However, while many currently available shoes possess various features related to the aforementioned characteristics, many lack customized sole constructions because they often incorporate sole structures manufactured in standard sizes and shapes. Furthermore, many athletic shoes, especially running shoes, are produced using methods that generate significant amounts of waste.

[0012] Therefore, footwear items with features that facilitate customization and are manufactured with minimal waste are desired. These and other shortcomings of the prior art are outlined in the following disclosure. Summary of the Invention

[0013] Many advantages of the footwear articles described herein will be apparent to those skilled in the art. The footwear articles described herein can have various constructions. Footwear articles can have an upper and a sole structure attached to the upper.

[0014] In some aspects, a method of manufacturing a component for a sole structure of footwear articles includes providing a printer having a platform, a first head receiving a first supply, and a second head receiving a second supply. The method further includes printing a base layer on the platform, wherein the base layer comprises a substrate material and defines a longitudinal axis. Additionally, the method includes continuously printing a first fiber layer on the base layer, wherein the first fiber layer defines a first fiber orientation disposed at a first angle relative to the longitudinal axis, and continuously printing a second fiber layer on the first fiber layer, the second fiber layer defining a second fiber orientation disposed at a second angle relative to the longitudinal axis. The first angle differs from the second angle. The method also includes processing a printed model in a compression molding process. The printed model includes at least the base layer, the first fiber layer, and the second fiber layer.

[0015] In some embodiments, the first fiber layer comprises at least 60% of the base material. In other embodiments, the second fiber layer comprises at least 50% of the fiber material. Furthermore, the first and second fiber layers define different layer volumes. In some embodiments, the first fiber layer comprises at least one of carbon fiber, aramid fiber, boron fiber, or glass fiber. In some embodiments, the printed pattern comprises at least five fiber layers. The printed pattern includes an arcuate segment extending between a rear section and a front section. Furthermore, a transparent resin is applied to the printed pattern in a compression mold. The printed pattern includes a third fiber layer defining a third fiber orientation, which is disposed at a third angle relative to the longitudinal axis, the third angle being equal to the first angle, and the third fiber layer is separated from the first fiber layer by the second fiber layer.

[0016] In some aspects, a plate for a sole structure of footwear articles is provided, the footwear articles including an upper having an insole. The plate includes a medial side opposite to the outer side, a heel end opposite to the toe end, a base layer including a base material, and a plurality of composite layers connected to the base layer. Each of the plurality of composite layers includes a first volume of base material and a second volume of fibrous material. The first volume of base material and the second volume of fibrous material are different. Each of the plurality of composite layers defines a fiber orientation, and the fiber orientations between adjacent composite layers are different. The plate is printed layer by layer to define a top side and a bottom side, at least a portion of the top side being spaced apart from the insole of the upper.

[0017] In some embodiments, multiple composite layers are stacked between the top and bottom sides of a plate, and the stack has quasi-isotropic properties. Each of the multiple composite layers has anisotropic properties, and the anisotropic properties between adjacent composite layers are different. The anisotropic properties include at least one of bending strength, torsional strength, or tensile stiffness. The base material of the first volume is smaller than the fiber material of the second volume. The fiber material of the second volume includes at least one of carbon fiber, aramid fiber, boron fiber, or glass fiber.

[0018] In another aspect, a method for producing plates for footwear articles using a 3D printer and a compression mold includes supplying a base material to a first head of the printer, supplying a fiber material to a second head of the printer, providing a preform on a platform within the printer, and providing a design model to the printer. The first and second heads are selectively activated and deactivated to print at least two composite layers on the preform. The at least two composite layers are separated from the preform and contained within the compression mold.

[0019] In some embodiments, each of at least two composite layers includes a continuous fiber strand applied by a second head. The plate includes a front section having a first stiffness, an arcuate section having a second stiffness, and a rear section having a third stiffness. The first stiffness is greater than the second stiffness, and the third stiffness is greater than the first stiffness. The first stiffness, the second stiffness, and the third stiffness are equal.

[0020] Other aspects of footwear articles, including their features and advantages, will become apparent to those skilled in the art after studying the accompanying drawings and detailed descriptions herein. Therefore, all these aspects of footwear articles are intended to be included within the detailed descriptions and the content of this invention. Attached Figure Description

[0021] Figure 1 This is a perspective view of the underside and inner side of a footwear article configured as a right shoe according to an embodiment of the present disclosure, the right shoe including an upper and a sole structure;

[0022] Figure 2 yes Figure 1 A top view of footwear items;

[0023] Figure 3 yes Figure 1 A top-down plan view of footwear, in which the upper has been removed and the user's skeletal foot structure is covered over it;

[0024] Figure 4 yes Figure 1 An exploded view of footwear items, showing a plate according to an embodiment of the present disclosure;

[0025] Figure 5A It is along Figure 4 The cross-sectional view of the plate taken from line 5-5 in the diagram;

[0026] Figure 5B It is along Figure 4 A cross-sectional view of footwear taken from line 5-5 in the diagram;

[0027] Figure 6 It is a graph showing the relationship between the elastic modulus and the volume fraction of the fiber;

[0028] Figure 7 This is a schematic representation of a printer for additive manufacturing boards according to embodiments of the present disclosure;

[0029] Figure 8A and Figure 8B This is a flowchart illustrating the process of printing a board according to an embodiment of the present disclosure;

[0030] Figure 9A and Figure 9B It is a schematic representation of a compression-molded component;

[0031] Figure 10-17 This is a schematic top plan view of several layers of a plate for a footwear article through an exemplary manufacturing process;

[0032] Figure 18 This is an exploded view of another embodiment of the sole, which incorporates yet another embodiment of the plate.

[0033] Figure 19 This is a schematic representation of a side elevation view of another embodiment of the plate, which is configured as a shoe outsole with traction elements;

[0034] Figure 20 It is along Figure 19 A schematic representation of the cross-sectional view of the traction element taken from line 20-20; and

[0035] Figure 21 yes Figure 19 A schematic representation of the top view of the holes in the plate. Detailed Implementation

[0036] The following discussion and accompanying figures disclose various embodiments or constructions of shoe and sole structures. While embodiments of shoe or sole structures are disclosed with reference to athletic footwear, such as running shoes, tennis shoes, basketball shoes, etc., the concepts associated with embodiments of shoe or sole structures can be applied to a wide range of footwear and footwear types, including, for example, cross-training shoes, rugby shoes, golf shoes, hiking shoes, hiking boots, ski boots and snowboard boots, soccer shoes and anti-slip shoes, walking shoes and tracked anti-slip shoes. The concepts of shoe or sole structures can also be applied to footwear articles considered non-athletic, including dress shoes, sandals, casual shoes, slippers, and high heels. In addition to footwear, the specific concepts described herein can also be applied to and incorporated into other types of clothing or other sporting equipment, including helmets, padding or protective pads, shin guards, and gloves. Furthermore, the specific concepts described herein can be incorporated into mats, backpack straps, golf clubs, or other consumer or industrial products. Therefore, the concepts described herein can be used in a variety of products.

[0037] As used herein, the term "about" refers to a variation in numerical quantity that can occur, for example, through typical measurement and manufacturing processes used for footwear or other manufactured articles, and may include embodiments of the disclosure herein; unintentional errors in these processes; differences in the manufacture, origin, or purity of the ingredients used to prepare the composition or mixture or to carry out the methods; and so on. Throughout the disclosure, the terms "about" and "approximately" refer to a range of values ​​within ±5% of the preceding numerical value.

[0038] This disclosure relates to footwear articles and / or specific components of footwear articles, such as upper and / or sole structures. Uppers may include knitted components, woven fabrics, and / or non-woven fabrics. Knitted components can be made from knitted yarns, woven fabrics from knitted yarns, and non-woven fabrics from integrally non-woven webs. Knitted fabrics include fabrics formed by warp knitting, weft knitting, plain knitting, circular knitting, and / or other suitable knitting operations. Knitted textiles may have, for example, plain knit structures, mesh knit structures, and / or rib knit structures. Woven fabrics include, but are not limited to, fabrics formed by any of a variety of knitting methods, such as plain weave, twill weave, satin weave, multi-arm jacquard weave, double-sided weave, and / or double-sided fabric weave. Non-woven fabrics include, for example, fabrics made by air-laid and / or spun web methods. Uppers may include various materials, such as first yarns, second yarns, and / or third yarns, which may have different properties or different visual characteristics.

[0039] Figure 1-3 An exemplary embodiment of footwear article 100 is shown, which is configured as a shoe including an upper 102 and a sole structure 104. The upper 102 is attached to the sole structure 104 and together defines an inner cavity 106 into which a foot can be inserted (see...). Figure 2 and Figure 3 For reference, footwear item 100 defines the forefoot area 108, the midfoot area 110, and the heel area 112 (see...). Figure 2 and Figure 3 The forefoot region 108 generally corresponds to the portion of the foot surrounding the footpiece 100, which includes the toes, the ball of the foot, and the joints connecting the metatarsals to the toes or phalanges. The midfoot region 110 is adjacent to and adjacent to the forefoot region 108, and generally corresponds to the portion of the footpiece 100 surrounding the arch and the bridge of the foot. The heel region 112 is adjacent to and adjacent to the midfoot region 110, and generally corresponds to the portion of the footpiece 100 surrounding the rear of the footpiece, including the heel or calcaneus, the ankle, and / or the Achilles tendon. For illustrative purposes, Figure 1The vertical axis V shown is located at the center of the footwear 100 and is generally perpendicular to or orthogonal to the longitudinal axis L. The vertical axis V extends through the midfoot region 110 of the footwear 100 and further defines a vertical plane disposed between the forefoot region 108 and the heel region 112. The longitudinal axis L extends through the sole 104 of the footwear 100 and within the forefoot region 108, the midfoot region 110, and the heel region 112. The longitudinal axis L defines a longitudinal plane that is generally perpendicular to the vertical plane of the vertical axis V, and the longitudinal plane L may be configured to be tangent to or coplanar with a portion of the sole 104.

[0040] Although only a single shoe 100, i.e., a shoe worn on a user's right foot, is depicted, it should be understood that the concepts disclosed herein apply to a pair of shoes (not shown) comprising a left shoe and a right shoe, the size and shape of which can accommodate the user's left and right feet, respectively. However, for ease of disclosure, aspects of this disclosure will be described with reference to a single shoe, but the following disclosure of footwear article 100 applies to both the left and right shoes. However, in some embodiments, differences may exist between the left and right shoes beyond the left / right configuration. Furthermore, in some embodiments, the left shoe may include one or more additional elements not included in the right shoe, and vice versa.

[0041] Many conventional footwear uppers are formed from multiple elements, such as fabrics, polymer foams, polymer sheets, leather, and synthetic leather, which are joined together by bonding or stitching at seams. In some embodiments, the upper 102 of the footwear article 100 is formed from a knitted structure or knitted components. In various embodiments, the knitted components may incorporate various types of yarns that can impart different properties to the upper. For example, one area of ​​the upper 102 may be formed from a first type of yarn that imparts a first set of properties, and another area of ​​the upper 102 may be formed from a second type of yarn that imparts a second set of properties. Using this construction, the properties of the upper 102 can be varied across the entire upper 102 by selecting specific yarns for different areas of the upper 102.

[0042] Regarding the materials including the upper 102, the specific properties that a particular type of yarn will impart to areas of the knitted component can depend at least in part on the materials of the various filaments and fibers forming the yarn. For example, cotton can provide a soft effect, biodegradability, or natural aesthetics to the knitted material. Elastic fibers and stretched polyesters can each provide knitted components with the desired elasticity and resilience. Rayon can provide a high-gloss and moisture-absorbing material, wool can provide a material with increased moisture absorption, nylon can be a durable and abrasion-resistant material, and polyester can provide a hydrophobic and durable material.

[0043] Other aspects of the knitted component can also be varied to influence its properties and provide desired attributes. For example, the yarn forming the knitted component may include monofilament yarn or multifilament yarn, or the yarn may include filaments each formed from two or more different materials. Additionally, the knitted component can be formed using specific knitting processes to impart specific properties to certain areas of the knitted component. Therefore, the material forming the yarn and other aspects of the yarn can be selected to impart various properties to specific areas of the upper 102.

[0044] In some embodiments, the elasticity of the knitted structure can be measured by comparing the width or length of the knitted structure in a first unstretched state with the width or length of the knitted structure in a second stretched state after a force has been applied to the knitted structure in the lateral direction. In other embodiments, the upper 102 may also include additional structural elements. For example, in some embodiments, a heel plate or overlay (not shown) may be provided on the heel area 112 to provide additional support to the user's heel. In some cases, other elements, such as plastic materials, logos, trademarks, etc., may also be applied and fixed to the outer surface using adhesives or thermoforming processes. In some embodiments, properties associated with the upper 102, such as stitch type, yarn type, or properties associated with different stitch types or yarn types, such as elasticity, aesthetic appearance, thickness, breathability, water resistance, or abrasion resistance, may vary. In some embodiments, the upper 102 consists of various layers that are heat-pressed together to bond the various layers of the upper 102. For example, the layers comprising the upper 102 may be heat-pressed together at a single temperature. The materials constituting the upper 102 may include an inner mesh layer, a thermoplastic polyurethane (TPU) film, and an outer mesh layer. In some embodiments, the TPU surface layer may be applied along the outer surface of the upper.

[0045] Refer again Figure 1 The sole structure 104 is attached to or secured to the upper 102 and extends between the user's foot and the ground when the footwear article 100 is worn by the user. The sole structure 104 may include one or more components, including an outsole, a midsole, a heel, an upper, and / or an insole. For example, in some embodiments, the sole structure may include an outsole providing structural integrity and providing traction friction for the user, a midsole providing a cushioning system, and an insole providing arch support for the user. Furthermore, the insole may be a PVC board, forefoot plate, durable plate, or a combination thereof, attached to the upper by PVC stitching, and the insole may be disposed between the upper 102 and the sole structure 104, or the insole may be part of the upper 102.

[0046] Furthermore, the insole may be positioned within the cavity 106 of the upper 102, allowing it to directly contact the user's foot when the footwear 100 is worn. Additionally, the upper 102 may include a lining (not shown) that can increase comfort, for example, by reducing friction between the user's foot and the upper 102, sole 104, insole, etc., and / or by providing moisture-wicking properties. The lining may cover the entire cavity 106 or only a portion thereof. In some embodiments, a joint (not shown) may surround an opening in the cavity 106 to secure the lining to the upper 102 and / or provide an aesthetic element on the footwear 100.

[0047] refer to Figure 2 and Figure 3 The footwear article 100 further defines an outer side 116 and an inner side 118. When a user wears the shoe, the outer side 116 corresponds to the outward-facing portion of the footwear article 100, while the inner side 118 corresponds to the inward-facing portion of the footwear article 100. Thus, the footwear article 100 has opposing outer sides 116 and inner sides 118. The inner side 118 and the outer side 116 are adjacent to each other along the longitudinal center plane or axis 120 of the footwear article 100, which is adjacent to... Figure 1 The longitudinal axis L is coplanar. As will be further discussed herein, the longitudinal central plane or axis 120 may define a central, intermediate axis between the inner side 118 and the outer side 116 of the footwear article 100. In other words, the longitudinal plane or axis 120 may extend between the rear proximal end 122 and the front distal end 124 of the footwear article 100, and may continuously define the middle of the insole 126, the sole structure 104, and / or the upper 102 of the footwear article 100, i.e., the longitudinal plane or axis 120 is a straight axis extending through the rear proximal end 122 of the heel region 112 to the front distal end 124 of the forefoot region 108.

[0048] Unless otherwise stated, see reference. Figure 2 and Figure 3 Footwear article 100 may be defined by a forefoot region 108, a midfoot region 110, and a heel region 112. The forefoot region 108 generally corresponds to a portion of the foot 128 surrounding the footwear article 100, which includes toes or phalanges 130, the ball of the foot 132, and one or more of the metatarsals 136 connecting the foot 128 to the joints 134 of the toes or phalanges 130. The midfoot region 110 is adjacent to and abuts the forefoot region 108. The midfoot region 110 generally corresponds to the arch portion of the footwear article 100 surrounding the foot 128 and the bridge portion of the foot 128. The heel region 112 is adjacent to and abuts the midfoot region 110. The heel region 112 generally corresponds to the rear portion of the footwear article 100 surrounding the foot 128, including the heel or calcaneus 138, the ankle (not shown), and / or the Achilles tendon (not shown).

[0049] Still referencing Figure 2 and Figure 3 The forefoot region 108, midfoot region 110, heel region 112, medial side 118, and lateral side 116 are intended to define the boundaries or areas of the footwear article 100. For this purpose, the forefoot region 108, midfoot region 110, heel region 112, medial side 118, and lateral side 116 generally characterize portions of the footwear article 100. Certain aspects of this disclosure may relate to portions or elements that extend together with one or more of the forefoot region 108, midfoot region 110, heel region 112, medial side 118, and / or lateral side 116. Furthermore, both the upper 102 and the sole structure 104 may be characterized by having portions within and / or along the medial side 118 and / or lateral side 116 of the forefoot region 108, midfoot region 110, heel region 112, and / or the medial side 118 and / or lateral side 116. Therefore, the upper 102 and sole structure 104, and / or individual portions of the upper 102 and sole structure 104 may include portions disposed within the forefoot region 108, midfoot region 110, heel region 112 and / or along the medial side 118 and / or lateral side 116.

[0050] Still referencing Figure 2 and Figure 3 The diagram details the forefoot region 108, midfoot region 110, heel region 112, medial side 118, and lateral side 116. The forefoot region 108 extends from the toe tip 140 to the widest portion 142 of the footwear article 100. The widest portion 142 is defined or measured along a first line 144 perpendicular to the longitudinal axis 120, extending from the distal portion of the toe tip 140 to the distal portion of the heel end 146 opposite to the toe tip 140. The midfoot region 110 extends from the widest portion 142 of the footwear article 100 to the narrowest portion 148. The narrowest portion 148 of the footwear article 100 is defined as the narrowest portion of the footwear article 100 measured across a second line 150 perpendicular to the longitudinal axis 120. The heel region 112 extends from the narrowest portion 148 to the heel end 146 of the footwear article 100.

[0051] It should be understood that, given the foregoing description, many modifications will be apparent to those skilled in the art, and individual components can be incorporated into many footwear articles. Therefore, aspects of footwear article 100 and its components can be described with reference to the general areas or portions of footwear article 100, while understanding that the boundaries of the forefoot region 108, midfoot region 110, heel region 112, medial side 118, and / or lateral side 116 as described herein can vary between footwear articles. However, aspects of footwear article 100 and its individual components can also be described with reference to the exact areas or portions of footwear article 100, and the scope of the appended claims can include limitations associated with these boundaries of the forefoot region 108, midfoot region 110, heel region 112, medial side 118, and / or lateral side 116 discussed herein.

[0052] Still referencing Figure 2 and Figure 3 The inner side 118 begins at the distal end, i.e., the toe end 140, and curves outward along the inner side of the footwear 100 along the forefoot region 108 toward the midfoot region 110. The inner side 118 reaches the first line 144, at which point it curves inward toward the central longitudinal axis 120. From the first line 144, i.e., the widest portion 142, the inner side 118 extends toward the second line 150, i.e., the narrowest portion 148, at which point it enters the midfoot region 110, i.e., upon intersecting with the first line 144. Once reaching the second line 150, the inner side 118 curves outward away from the longitudinal central axis 120, at which point it extends into the heel region 112, i.e., upon intersecting with the second line 150. The inner side 118 then curves outward, then inward toward the heel end 146, and terminates at the point where it intersects with the longitudinal central axis 120.

[0053] The outer side 116 also begins at the distal end, i.e., the toe tip 140, and curves outward along the outer side of the footwear 100 towards the midfoot area 110 along the forefoot region 108. The outer side 116 reaches the first line 144, at which point it curves inward toward the longitudinal central axis 120. From the first line 144, i.e., the widest portion 142, the outer side 116 extends toward the second line 150, i.e., the narrowest portion 148, at which point it enters the midfoot area 110, i.e., upon intersecting with the first line 144. Once reaching the second line 150, the outer side 116 curves outward away from the longitudinal central axis 120, at which point it extends into the heel area 112, i.e., upon intersecting with the second line 150. The outer side 116 then curves outward, then inward toward the heel tip 146, and terminates at the point where it intersects with the longitudinal central axis 120.

[0054] Still referencing Figure 2 and Figure 3The upper 102 extends along the outer side 116 and the inner side 118, and passes through the forefoot region 108, the midfoot region 110, and the heel region 112 to accommodate and surround the user's foot. When fully assembled, the upper 102 also includes an inner surface 162 and an outer surface 164. The inner surface 162 faces inward and generally defines an inner cavity 106, and the outer surface 164 faces outward and generally defines the outer periphery or boundary of the upper 102. The upper 102 also includes an opening 166 at least partially located in the heel region 112 of the footwear article 100, which provides access to the inner cavity 106 and through which the foot can be inserted and removed. In some embodiments, the upper 102 may also include an instep region 168 that extends from the opening 166 in the heel region 112 over a region corresponding to the instep of the foot to a region adjacent to the forefoot region 108. The instep region 168 may include a region similar to the region where the tongue 170 of this embodiment is disposed. In some embodiments, the upper 102 does not include the tongue 170, that is, the upper 102 is tongueless.

[0055] refer to Figure 1 The sole structure 104 includes a sole midsole 172 and an outsole 174. In some cases, the outsole may be defined as a portion of the sole 104 that at least partially contacts an outer surface (e.g., the ground) when the footwear article 100 is worn. The outsole 174 may define the bottom or bottom surface 176 of the sole structure 104, which spans the heel region 112, the midfoot region 110, and the forefoot region 108. Furthermore, the outsole 174 may include a ground-engaging portion or a ground-engaging surface comprising the sole structure 104, and may be opposite its insole. Figure 1 As shown, the bottom surface 176 of the outsole 174 may include a tread pattern 178, which may include various shapes and constructions. The outsole 174 may be formed from one or more materials to impart durability, wear resistance, or adhesive friction to the sole structure 104. In some embodiments, the outsole 174 may be formed from any kind of elastomeric material, such as rubber, including thermosetting elastomers or thermoplastic elastomers, or thermoplastic materials, such as thermoplastic polyurethane (TPU). In some embodiments, the outsole 174 may be defined with a Shore A hardness of up to 95. Furthermore, the outsole 174 may be manufactured by processes including injection molding, vulcanization, layer-by-layer printing, i.e., additive manufacturing systems or methods.

[0056] Still referencing Figure 1The midsole 172 can be defined as at least a portion of the sole 104 extending from the outsole 174 to the upper 102, or at least a portion of the sole extending between and connecting the outsole 174 and the upper 102. The midsole 172 may be constructed solely of a thermoplastic material, such as polyurethane (PU), and / or ethylene-vinyl acetate (EVA), copolymers thereof, or similar materials. In other embodiments, the midsole 172 may be an EVA-solid sponge (“ESS”) material, EVA foam (e.g., ProFoam Lite TM The material can be IGNITE foam, polyurethane, polyether, olefin block copolymer, organic sheet, thermoplastic material (e.g., thermoplastic polyurethane, thermoplastic elastomer, thermoplastic polyolefin, etc.) or supercritical foam. The midsole 172 can be a single polymeric material or a mixture of materials, such as EVA copolymer, thermoplastic polyurethane, polyether block amide (PEBA) copolymer and / or olefin block copolymer. An example of PEBA material is... In some embodiments, the sole interlayer 172 is manufactured by processes involving injection molding, vulcanization, layer-by-layer printing, i.e., additive manufacturing systems or methods.

[0057] In embodiments where the midsole layer 172 is formed using a supercritical foaming process, the supercritical foam may include microporous foam or particulate foam, such as TPU, EVA, etc. Or mixtures thereof, manufactured using a process performed within an autoclave, injection molding apparatus, or any sufficiently heated / pressurized container capable of handling the mixing of supercritical fluids (e.g., CO2, N2, or mixtures thereof) with a material preferably molten (e.g., TPU, EVA, polyolefin elastomers, or mixtures thereof). In an exemplary process, a solution of supercritical fluid and molten material is pumped into a pressurized container, after which the pressure within the container is released, causing the molecules of the supercritical fluid to rapidly convert into gas to form small pockets within the material and cause the material to expand into a foam. In another embodiment, the sole interlayer 172 may be formed using alternative methods known in the art, including the use of an expansion press, injection molding machine, pellet expansion process, cold foaming process, compression molding technique, die cutting, or any combination thereof. For example, the sole interlayer 172 may be formed using a process including an initial foaming step, wherein a supercritical gas is used to foam the material, which is then compression molded or die-cut into a specific shape.

[0058] Return to Figure 2The footwear article 100 also includes a tightening system 180, which includes shoelaces 184 and a plurality of eyelets 188. In this embodiment, the shoelaces 184 extend through the plurality of eyelets 188. In some embodiments, the tightening system 180 may include an elastic band. The tightening system 180 may allow a user to modify the size of the upper 102 according to the wearer's needs, for example, to tighten or loosen the portion of the upper 102 and / or the sole 104 surrounding the foot. The tightening system 180 may also include a strap (not shown) extending along the center of the upper 102 and including one or more loops through which the shoelaces 184 can be guided. In other embodiments, the tightening system 180 may be a hook-and-loop fastening system, such as... For example, in some embodiments, the tightening system 180 may include one or more hook-and-loop fastening straps. In further embodiments, the tightening system 180 may be another strapless fastening system known in the art. In other embodiments, the tightening system 180 may include various manual lacing systems, rotary closure devices, or automatic lacing systems, such as those described in U.S. Patent Application No. 15 / 780,368, filed May 31, 2018, and U.S. Patent Application No. 16 / 392,470, filed April 23, 2019, the entire contents of which are incorporated herein by reference.

[0059] This disclosure provides a board manufactured using an additive manufacturing process (e.g., layer-by-layer printing). The additive manufacturing process combines user metrics collected from various sources (e.g., pressure heatmap information, laser scanners, force plates, user preferences, etc.) with continuous fiber fabrication (CFF) manufacturing techniques to optimize the board to specific user performance preferences for propulsion, stability, and comfort, etc. Compared to conventional subtractive manufacturing processes (e.g., injection molding, grinding, lapping, etc.), additive manufacturing enables the manufacture of boards with minimal waste. Furthermore, additive manufacturing enables the manufacture of boards with fewer steps and iterations, thus avoiding the excessive labor typically required for customized, unique designs optimized for specific user preferences. Moreover, CFF manufacturing technology allows the board to be manufactured efficiently and economically while using expensive high-performance materials such as carbon fiber, glass fiber, and... And so on. Because additive manufacturing involves adding material in a repetitive process to construct a board as designed, waste of materials and time is minimized. This is especially true when considering expensive materials such as carbon fiber and... This is particularly important when considering the associated costs, and when taking into account the availability of supply and / or the need to transport these materials. By reducing waste, users can procure materials in more precise quantities and with greater predictability, while also saving on transportation costs and emissions and / or pollution associated with transporting and delivering expensive materials over long distances (e.g., across the globe).

[0060] Additive manufacturing using CFF is preferably used for manufacturing plates according to this disclosure. The additive manufacturing process can be performed using a 3D printer, such as one manufactured by... A printer is manufactured that can receive a design model and generate printing instructions to 3D print a slab. The design model can be an electronic three-dimensional representation of a slab designed to form a slab for footwear items. In some embodiments, the design model can be a 3D CAD file, or a 3D stereolithography file (.STL file), or any file format compatible with web-based or cloud-based design programs, such as those created by [unclear - likely a 3D model]. Eiger provided TM .

[0061] Alternatively or additionally, the design model can be generated by the controller in response to input data. For example, physical properties collected and input into the software and used to design and generate the design model may include end-user weight, end-user gait, and / or end-user foot pressure maps measured during standing, walking, sharp turns, and / or running. Additionally, various foot measurements can be recorded to determine plate dimensions, and other aspects of the footwear, as well as data associated with foot gait, can be obtained to determine whether foot orientation indicates toe strike or heel strike, and other scenarios. Foot measurements and data can be used to determine the optimal geometry and performance characteristics of the plate, as well as the optimal position of the plate within the shoe. Furthermore, the collected measurements and data can be used to select materials constituting the plate. Moreover, the additive manufacturing process described herein allows for the customization of plate stiffness for a specific wearer based on the measured and collected data. For example, the user's tendon stiffness and calf muscle strength can be measured to determine the appropriate plate stiffness for the wearer's use. Furthermore, the plate stiffness can be adjusted based on the specific user's biomechanics and running mechanics, such as how the wearer's joint angles change during movement, for example, through dorsiflexion and plantarflexion. In some examples, the wearer's force and motion measurements are obtained before a custom plate is manufactured for the user. In other examples, the plate is manufactured with incremental stiffness to provide semi-custom footwear, allowing individual wearers to select the appropriate stiffness.

[0062] Various alternative methods for additive manufacturing methods that can be used to manufacture plates for footwear articles according to this disclosure may include adhesive spraying, direct energy deposition, selective laser melting (SLM), fused deposition modeling (FDM), electron beam melting, laser powder bed melting (LPBF), ultrasonic additive manufacturing, material extrusion, material spraying, Joule printing, electrochemical deposition, cold spray metal printing, DLP metal printing, ultrasonic consolidation or ultrasonic additive manufacturing (UAM), LENS laser-based printing, barrel photopolymerization, sheet lamination or electron beam freeform manufacturing (EBF3).

[0063] As used herein, the term "rigidity" refers to the way a component resists deformation when a load is applied. Specifically, this paper will discuss "rigidity" in relation to elastic deformation, that is, temporary deformation considered non-destructive. Therefore, "rigidity" can be used in conjunction with the terms "resistance" and "strength." Furthermore, "rigidity" in this paper can be described relative to various directions, deformation types, material properties, etc. For example, the "rigidity" of a component can be decomposed into bending rigidity, tensile rigidity, or shear rigidity. In addition, the "rigidity" of a component is related to the elastic modulus (E) of the material used, which can be derived from Young's modulus formula. The term "rigidity" is quantified, where σ is the uniaxial stress, i.e., the force per unit surface area, and ε is the strain, i.e., the deformation ratio. For clarity, "rigidity" in this document may be further defined as referring to a specific type of resistance, such as flexural strength BR and torsional strength TR. In some cases, the "rigidity" of a component can be quantified or calculated relative to its size, mass, or volume. For example, the "rigidity" of a component can be measured in milli-Newtons (N / mm) or gigapascals (GPa), although other units may also be used. Furthermore, "rigidity" can be qualitatively referred to as high or low, and can also be understood as relating to various aspects of the shoe, such as comfort, support, stability, stiffness, and durability.

[0064] Figure 4 An exploded view of a footwear article 100 including a plate 200 according to an embodiment of the present disclosure is depicted. The plate 200 includes a top side 204 opposite to a bottom side 208 and a rear section 212, an arched section 216, and a forefoot section 220. The rear section 212, when incorporated therein, may extend at least through the heel region 112 of the footwear 100 and may correspond to a portion of the plate 200 located near the rear of the foot, as previously discussed herein. The arched section 216 of the plate 200 proximates and abuts the rear section 212 and corresponds to a portion of the plate 200 located near the midfoot region 110 of the footwear 100, which surrounds the arch of the foot and the bridge of the foot. The forefoot section 220 of the plate 200 proximates and abuts the arched section 216 and corresponds to a portion of the plate 200 located near the forefoot region 108 of the footwear 100, which surrounds the toes, the ball of the foot, and the joints connecting the metatarsals to the toes or phalanges. Plate 200 defines a longitudinal reference axis 224 that intersects with plate 200 at the heel end 146 and the toe end 140. Moreover, plate 200 defines a central axis 228 that bisects the heel end 146 and the toe end 140, such that reference axis 224 extends at an angle relative to central axis 228.

[0065] In the illustrated embodiment, the plate 200 is embedded within the sole interlayer 172, as indicated by the dashed exploded line indicating its approximate location within the sole interlayer 172. However, in some embodiments, the plate 200 may be fitted between the sole interlayer 172 and the upper 102, or between the sole interlayer 172 and the outsole 174, or the plate 200 may be configured to be attached to the outsole 174 of the upper 102, or the plate 200 may be included as part of the upper 102.

[0066] For clarity, reference direction coordinates X, Y, and Z are used in this disclosure. Specifically, the X direction corresponds to a transverse-to-central direction orthogonal to the longitudinal direction extending from the longitudinal reference axis 224; the Y direction corresponds to a longitudinal direction parallel to the longitudinal reference axis 224; and the Z direction corresponds to a vertical direction orthogonal to both the X and Y directions. Furthermore, the term "in-plane" will be used herein to refer to a 2D plane extending in the X and Y directions, orthogonal to it in the Z direction. Additionally, it should be understood that the longitudinal reference axis 224 also defines a longitudinal reference plane extending vertically in the Z direction. Figure 1 and Figure 4 It can be understood that the longitudinal plane defined by the longitudinal axis L can be coplanar with or partially coplanar with the in-plane direction of the footwear 100. Furthermore, the vertical plane defined by the vertical axis V can extend in the Z direction and be substantially perpendicular to the in-plane direction and the longitudinal plane.

[0067] Plate 200 defines a periphery 232 that curves outward from the heel end 146 toward the outer side 116 relative to the central axis 228 within the heel region 112 to at least partially define the rear section 212. Periphery 232 further extends along the outer side 116 toward the midfoot region 110 and curves inward relative to the central axis 228 to at least partially define the arched section 216. Additionally, periphery 232 extends within the forefoot region 108 and curves outward before curving inward toward the toe end 140 to at least partially define the forefoot section 220. Similarly, periphery 232 curves outward from the heel end 146 toward the inner side 118 within the heel region 112, thereby at least partially defining the rear section 212. The periphery extends further inward toward the midfoot region and curves inward to at least partially define the arched section 216. Additionally, the periphery 232 extends within the forefoot region 108 and curves outward before curving inward toward the toe tip 140 to at least partially define the forefoot segment 220. Thus, the periphery 232 extends continuously from the rear segment 212 to the front segment 220 across the entire plate 200, and vice versa, from the outer side 116 to the inner side 118, and vice versa. In some embodiments, a plurality of peripheral elements 236 (see...) Figure 5A It can be arranged along a portion or the entire perimeter 232. In other embodiments, the plate 200 does not include any peripheral elements 236 along the perimeter 232.

[0068] However, in certain embodiments, the board 200 may be formed by an additive manufacturing process, wherein the various layers of the board 200 are printed during a printing process, such as any of the additive manufacturing processes mentioned above. Reference Figure 5A The plate 200 includes a plurality of composite layers 240a-g arranged in a vertically stacked order between a top side 204 and a bottom side 208. In this disclosure, the plurality of composite layers 240a-g may be collectively referred to as composite layer 240, and further collectively referred to as reinforcing layer, and may be referred to both commonly and individually. Each composite layer 240 extends continuously from an inner side 118 to an outer side 116, and continuously from a rear section 212 to a front section 220. However, in other embodiments, some composite layers 240 may be discontinuous between the inner side 118 and the outer side 116, discontinuous between the rear section 212 and the front section 220, or some combination thereof.

[0069] exist Figure 5A In this embodiment, plate 200 is described as comprising seven composite layers 240a-g. However, plate 200 may include more or fewer composite layers than shown. In some embodiments, plate 200 comprises only three composite layers, while in other embodiments, plate 200 comprises one hundred or one thousand composite layers or more. Furthermore, in some embodiments, plate 200 comprises thousands of composite layers in certain portions or regions, while fewer composite layers are present in other portions or regions of plate 200. In the illustrated embodiment, a vertical plane V is disposed at the center between the outer side 116 and the inner side 118 of plate 200, while a horizontal plane H is disposed perpendicular to the vertical plane V and tangent to or coplanar with a portion of the bottom side 208 of plate 200. In this particular case, plate 200 has a geometry in which the top side 204 of plate 200 is curved relative to the horizontal plane H between the inner side 118 and the outer side 116, and each of the composite layers 240 has a varying curvature between the inner side 118 and the outer side 116, which may be different from each other and different from the curvature of the top side 204. Furthermore, the bottom side 208 defines a varying curvature relative to the horizontal plane H between the outer side 116 and the inner side 118. Moreover, the periphery 232 of the plate 200 curves along the outer side 116 and the inner side 118.

[0070] Reference Figure 5AThe plate 200 comprises at least a substrate or substrate material 244 and fibers or fiber materials 248. It should be understood that the substrate material 244 may be referred to herein as a filler material, base material, or matrix. Furthermore, it will be understood that the fibers 248 may be referred to herein as fiber strands, filaments, or threads. The plate 200 comprises composite layers 240a-g, which have different properties and / or compositions from each other, or at least differ from adjacent composite layers 240a-g. Therefore, each composite layer 240a-g of the plate 200 has a variety of measurable properties, including layer volume VL, substrate percentage SPL of VL, fiber percentage FPL of VL, fiber orientation or operating direction FOL of the layer, axial effective modulus of elasticity EAL of the layer, transverse effective modulus of elasticity ETL of the layer, and layer thickness TL. Additionally, the plate 200 has various measurable properties, including total volume VT, total substrate percentage SPT, total fiber percentage FPT, total effective fiber orientation or operating direction FOT, total axial effective modulus of elasticity EAT, total transverse effective modulus of elasticity ETT, and total thickness TT.

[0071] In some embodiments, the plate 200 may be formed of a composite material or one or more layers of fibers, such as carbon fiber, aramid fiber (e.g., ...). ), boron fibers, glass fibers, natural fibers, and polymer fibers, or combinations thereof. In these embodiments, the fibers may be fixed or bonded to a substrate of a plastic material, such as nylon, epoxy resin, or ultra-high molecular weight polyethylene (UHMWPE), or a textile material or composite material, and other suitable materials. In some embodiments, during the additive manufacturing process, the fiber material 248 is fused to the substrate material 244 by heat and pressure. In other embodiments, the fiber material 248 is stitched, embroidered, adhered, glued, braided, fastened, or otherwise attached to the substrate material 244 and / or the fiber material 248. In some embodiments, the plate 200 may be formed of a unidirectional tape comprising carbon fibers, such as boron fibers, glass fibers, natural fibers, and polymer fibers, or combinations thereof. Aromatic amide fibers, boron fibers, glass fibers, polymer fibers, or any other material with a high strength-to-weight ratio.

[0072] In the illustrated embodiment, each composite layer 240a-g differs from adjacent composite layers 240a-g in at least one measurable characteristic, as indicated by the different shading used to represent each composite layer 240a-g. In some embodiments, one or more composite layers 240a-g are identical but separated by one or more intermediate composite layers 240a-g with different measurable characteristics. Figure 5AAs shown, the bottom side 208 may be entirely defined by a single composite layer 240g, although in other embodiments, the bottom side 208 may be partially defined by two or more composite layers 240. Similarly, the top side 204 may be entirely defined by a single composite layer 240a, or alternatively, partially defined by two or more composite layers 240. Furthermore, each composite layer 240a-g may be exposed on the outer side 116 and the inner side 118, although in some embodiments, one or more of the composite layers 240a-g may be hidden or recessed relative to the inner side 118 and / or the outer side 116. Additionally, the composite layers 240a-g may be interrupted by voids (not shown) intersecting or separating from one or more composite layers 240a-g. The plate 200 may be manufactured as a tensile arrangement or structure having voids (not shown) and composite layers 240, which allows for tensile behavior, i.e., an increase in lateral dimension when stretched in the longitudinal direction and vice versa. Furthermore, the plate 200 may be formed with channels (not shown) to allow airflow through a portion of the plate 200.

[0073] exist Figure 5B In the illustrated embodiment, the plate 200 is embedded within the sole 104 of the footwear article 100, and more specifically, the plate 200 is embedded within the sole interlayer 172 of the sole 104. Furthermore, the upper 102 includes an insole 126 arranged in a stout configuration such that the insole 126 is spaced apart from and does not directly contact the plate 200. In some embodiments, the plate 200 may be embedded within the sole interlayer 172 in a manner that allows a portion of the plate 200 to contact the insole 126 or the upper 102. Additionally, in some embodiments, a portion of the plate 200 may contact the outsole 174. In other embodiments, the plate 200 may be configured as part of the upper 102. For example, the plate 200 may be included as part of the insole 126, or inserted into the cavity 106 of the footwear 100 similar to a conventional orthotic insert. In some embodiments, the plate 200 may include the entire sole structure 104 of the footwear 100, such that the footwear 100 includes only the upper 102 and the plate 200.

[0074] refer to Figure 5A and Figure 5B The plate 200 is generally curved between the inner side 118 and the outer side 116, and also curved relative to the surrounding components of the footwear 100. For example, the plate 200 curves downward toward the horizontal plane H between the outer side 116 and the vertical plane V, and then curves upward away from the horizontal plane H between the vertical plane V and the inner side 118, such that the plate 200 is convexly curved relative to the horizontal plane H. Because the horizontal plane H and Figure 5BThe outsole 174 is tangent to the insole, so the plate 200 also curves convexly relative to the outsole 174. However, the plate 200 curves concavely relative to the upper 102, such that the plate 200 curves furthest from the upper 102 near the vertical plane V, and closest to the upper 102 at the inner side 118 and the outer side 116. Furthermore, the insole 126 and the plate 200 are described as being in... Figure 5B The footwear 100 has a generally similar curvature, although other configurations are possible. Furthermore, the insole interlayer 172 at least partially surrounds the plate 200 and defines a varying curvature above and below the plate 200, as shown, which differs from the curvature of the plate 200. In the illustrated embodiment, the insole 126, insole interlayer 172, plate 200, and outsole 174 all fit together to conform to each other's curvature, such that no gaps or gaps are formed between them. However, it should be understood that gaps or gaps may be formed between one of the insole 126, insole interlayer 172, plate 200, and outsole 174, such that the curvature of the insole 126 does not match the curvature of the insole interlayer 172, etc.

[0075] Furthermore, considering that the plate 200 can withstand preloading or deformation during assembly into the footwear 100, the curvature of the plate 200 can be altered or reduced during assembly into the sole 104 of the footwear 100 to conform to the curvature of the sole interlayer 172, outsole 174, or insole 126. (Comparison) Figure 5A and Figure 5B For example, due to the relationship with Figure 5BIn the assembly of the sole 104 of footwear 100, the curvature of the underside 208 of the plate 200 is deformed, for example, reversed from concave curvature to convex curvature. As a result, the plate 200 deforms through its interaction with the sole 104 and is subjected to stresses during use that can alter or affect properties such as stiffness and propulsion. This stress caused by the assembly with footwear 100 can provide responsiveness benefits, resulting in enhanced customization of the plate 200 within footwear 100 when combined with adjusted stiffness and geometry. As used herein, the term "responsiveness" can refer to the sensitivity of the plate 200 to applied loads, i.e., external forces applied during use, whether the applied load is due to the user's weight or activities such as running, walking, jumping, changing direction, lifting, etc., and also to the sensitivity of the plate 200 to deformation in one or more directions. In some embodiments, the responsiveness of the plate 200 may vary along the front section 220, the arcuate section 216, and the rear section 212, and the responsiveness may vary between the outer side 116 and the inner side 118. In some cases, the arcuate section 216 of the plate 200 may be preloaded to have increased responsiveness, thereby making the plate 200 more sensitive to walking activities in which it undergoes a smaller amount of deformation, while still providing the user with increased propulsion and support benefits. In some embodiments, the front section 220 may have increased responsiveness to provide maximum propulsion when the user presses down during jumping activities.

[0076] In some embodiments, the plate 200 is disposed at an angle between the upper 102 and the outsole 174, such that the front section 220 is further away from the upper 102 than the rear section 212. Thus, the rear section 212 is positioned higher in the vertical direction relative to the front section 220 and / or the arched section 216, i.e., raised in the Z direction. This allows the plate 200 to be configured to promote propulsion or rebound during use. Furthermore, the plate 200 can be formed in different shapes and have different curvatures along the reference axis 224 and / or between the inner side 118 and the outer side 116 to promote cushioning, propulsion, and support during use.

[0077] In some embodiments, the fiber material 248 of the plate 200 may have a tensile stiffness at least partially defined by a tensile modulus of elasticity, as measured according to a test method defined by test standard ASTM D4018 or an equivalent. For example, in a particular embodiment, the fiber material 248 of the plate 200 may have a tensile modulus of elasticity of at least 70 GPa, or at least about 85 GPa, or at least about 200 GPa, or at least about 300 GPa. In another embodiment, the fiber material 248 has a tensile modulus of elasticity between about 300 GPa and about 400 GPa. Therefore, the fiber material 248 may have a tensile strength between about 500 MPa and about 800 MPa, i.e., a stress defined by the load per unit area, as measured according to a test method defined by test standard ASTM 3039 or an equivalent. Additionally, the fiber material 248 of the board 200 may have a flexural stiffness at least partially defined by its flexural modulus, as measured according to a test method defined by test standard ASTM D790 or C651 or equivalent. For example, the fiber material 248 may have a flexural modulus of at least about 22 GPa, or at least about 50 GPa, or at least about 100 GPa, or at least about 200 GPa. In another embodiment, the fiber material 248 has a flexural modulus between about 50 GPa and about 200 GPa. Therefore, the fiber material 248 may have a flexural strength between about 200 MPa and about 600 MPa, i.e., stress defined by the load per unit area, as measured according to a test method defined by test standard ASTM D790 or equivalent. Furthermore, the density of the fiber material 248 of the board 200 may be about 1.2 g / cm³. 3 Approximately 2.0 g / cm³ 3 between.

[0078] Furthermore, the substrate material 244 of the plate 200 may have a tensile stiffness at least partially defined by the tensile modulus of elasticity, as measured according to a test method defined by test standard ASTM D638 or an equivalent. For example, in a particular embodiment, the substrate material 244 may have a tensile modulus of elasticity of at least about 1 GPa, or at least about 2 GPa, or at least about 4 GPa. Additionally, the substrate material 244 may have a flexural stiffness defined by the flexural modulus of elasticity, as measured according to a test method defined by test standard ASTM D790 or an equivalent. For example, the substrate material 244 may have a flexural modulus of elasticity of at least about 1 GPa, or at least about 2 GPa, or at least about 3 GPa. In another embodiment, the substrate material 244 has a flexural modulus of elasticity between about 1.4 GPa and about 3.7 GPa. Therefore, the substrate material 244 can have a flexural strength between about 50 MPa and about 90 MPa, i.e., stress defined by the load per unit area, as measured according to a test method defined by test standard ASTP D790 or its equivalent. On the other hand, the substrate material 244 of the plate 200 can have a heat deflection temperature, as measured according to a test method defined by test standard ASTM D648 Method B or its equivalent. For example, the substrate material 244 can have a heat deflection temperature between about 41°C and about 150°C. The substrate material 244 used to form the plate 200 can also have a strength of about 1 g / cm³. 3 Up to approximately 1.5 g / cm³ 3 The density between.

[0079] For reference purposes, the tensile modulus of elasticity of steel or steel alloy (e.g., ASTM A36 steel), measured according to a test method defined by test standard ASTM E8 or its equivalent, is approximately 200 GPa, and the density of such steel is approximately 7.85 g / cm³. 3 In some embodiments, the tensile modulus of the plate of this disclosure, as measured according to a test method defined by test standard ASTM E8 or an equivalent, is about 200 GPa. Therefore, the plate 200 is configured to have a tensile modulus similar to that of steel, but with a density less than 25% of the density of steel. Consequently, the plate of this disclosure has a significantly higher strength-to-weight ratio than steel in at least one direction of strength characteristics.

[0080] The composition of board 200 is essentially composed of a base material 244 and a fiber material 248, such that the addition of the base percentage SPT and fiber percentage FPT is approximately 100% of the total volume TV of board 200. Therefore, when the base percentage SPT is approximately 50%, the corresponding fiber percentage FPT is approximately 50%. Furthermore, because the fiber material 248 typically has greater stiffness than the base material 244, including flexural and tensile stiffness, the stiffness of board 200 can be manipulated by controlling or selecting the composition of board 200. For this purpose, manufacturing board 200 using additive manufacturing methods provides precise and efficient selection of material volume and arrangement, allowing the user to select the composition of board 200 according to the desired stiffness. In some embodiments, board 200 may have approximately 75% base percentage SPT, which corresponds to approximately 25% fiber percentage FPT, resulting in board 200 generally having more flexible and resilient properties. This may be desirable when user comfort is a priority. In other embodiments, plate 200 may have a fiber percentage of about 75%, which corresponds to a substrate percentage of about 25%, resulting in plate 200 having generally greater stiffness and strength characteristics. This may be desirable in cases where propulsion and support are prioritized. In some embodiments, the substrate percentage (SPT) of plate 200 may be in the range of about 25% to about 99%, and the fiber percentage (FPT) of plate 200 may be in the range of about 25% to about 99%.

[0081] In some embodiments, the plate 200 and its stiffness may be selected and designed for a particular user. For example, the stiffness of the plate 200 may be selected based on the user's specific muscle strength, tendon flexibility, or joint flexibility. In other embodiments, the stiffness of the plate 200 may vary such that one portion of the plate 200 is stiffer than another portion. In some embodiments, the plate 200 is included within the sole 104 of the footwear article 100. For example, the plate 200 may be embedded within a sole interlayer 172, an outsole 174, or an insole 126. In other embodiments, the plate 200 may be disposed between the insole 126 and the sole interlayer 172, or alternatively, the plate 200 may be disposed between the sole interlayer 172 and the outsole 174.

[0082] Typically, compared to boards made entirely of metal, base materials, or without added fibers, boards made of composite fiber materials, such as... Sheets composed of carbon fiber, glass fiber, etc., have an improved strength-to-weight ratio. However, composite fiber materials exhibit the strongest tensile strength, confined to a specific direction, namely, the axial direction in which the composite fiber material is stretched. Therefore, composite layers with fiber materials arranged in a single uniaxial direction are strongest in that direction but exhibit different properties, such as weaker properties, in other directions. Thus, composite layers are considered to be anisotropic, i.e., exhibiting different sets of strength properties in different directions.

[0083] Composite laminates or structures manufactured using continuous fiber fabrication (CFF) techniques can exhibit quasi-isotropic (QI) properties, such as substantially similar properties in most directions, by comprising multiple layers or sheets having fiber arrays arranged at specific angles relative to a reference plane. In some cases, one or more layers are formed by fiber arrays arranged at 0 degrees relative to the reference plane, some other layers are formed by fiber arrays arranged at + / -45 degrees relative to the reference plane, and still others are formed by fiber arrays arranged at 90 degrees relative to the reference plane. Furthermore, anisotropic biased layers can be formed by fiber arrays arranged at 0 degrees, + / -30 degrees, and 90 degrees. Composite laminates exhibiting QI properties, i.e., QI laminates, can possess in-plane substantially isotropic properties, such as increased tensile strength or stiffness, similar to isotropic materials. Basic QI laminates may comprise randomly oriented or oriented fibers or fiber arrays to provide substantially equal strength in all directions of a single plane. Typically, QI laminates consist of unidirectional layers oriented at 0 degrees, 90 degrees, 45 degrees, and -45 degrees, such as 3D printing layers, with at least 12.5% ​​of these layers disposed in each of these directions. QI properties can also be achieved by layers configured at 0 degrees, 60 degrees, and 120 degrees, as well as other configurations.

[0084] It is understandable that the stiffness of plate 200 and / or its composite layer 240 can be understood using bending strength BR and torsional strength TR. Bending strength BR is a mathematical relationship between lateral force and deflection, and can be referred to here as spring rate or stiffness. Similarly, torsional strength TR is a mathematical relationship between torsional force and deflection, and can be referred to as rotational stiffness. It is well known that bending strength BR and torsional strength TR are proportional to the elastic modulus of the material or material composition. Furthermore, geometry and dimensions are also proportional to bending strength BR and torsional strength TR, depending on the direction and location of the applied load. For example, dimensions defined in a direction parallel to the direction of the applied load have a greater effect on a particular resistance, e.g., when a bending load is applied in the Z direction and the thickness is defined in the Z direction.

[0085] Furthermore, the flexural strength BR and torsional strength TR of each composite layer 240 are related to the effective modulus of elasticity, which depends in part on the direction of the applied load. For axially applied in-plane loads, i.e., in the X and Y directions, the axial effective modulus EAL of the layer is most relevant. For transversely applied loads, i.e., loads applied in the Z direction, which include bending deformation, the transverse effective modulus ETL of the layer is mainly considered. EAL is approximated using the formula EAL = EF × FPL + ES × SPL, where EF is the modulus of elasticity of fiber material 248, FPL is the volume fraction of fiber material 248, EF is the modulus of elasticity of substrate material 244, and SPL is the volume fraction of substrate material 244.

[0086] In addition, ETL uses the formula To approximate the calculation, when the fiber volume fraction FPL is close to 1.0, it means that the fiber material 248 occupies a larger percentage of the volume VL of the composite layer 240, and the ETL is close to the value of the elastic modulus EF of the fiber material 248, such as... Figure 6 The provided graphs illustrate this. Furthermore, for the entire plate 200, the total effective modulus of elasticity (EAT) in the axial direction and the total effective modulus of elasticity (ETT) in the transverse direction can be approximated. For this purpose, the average values ​​of EAT and ETL for each composite layer 240 are calculated, but each value is weighted according to its relationship with the total volume TV of the plate 200 and the offset of the fiber orientation FOL relative to the relevant reference plane. Therefore, composite layers 240 that comprise a larger percentage of the total volume TV of the plate 200 will have a greater influence on the EAT and ETL of the plate 200. Moreover, composite layers 240 that are offset to a greater extent from the reference plane will have a smaller influence on the EAT and ETL. Therefore, EAT and ETL can be used to approximate the flexural strength BR and torsional strength TR of the plate 200.

[0087] Therefore, the arrangement of composite layers 240 with fiber arrays arranged in different directions allows plate 200 to exhibit QI characteristics, such as strength or resistance characteristics that are nearly equal in all directions. For example, when plate 200 is disposed in sole 104 of footwear 100, bending occurs due to the load applied in the Z direction and the user's tendency to arch the heel off the ground to push the forefoot forward. This force is generally orthogonal to the in-plane directions (i.e., the X and Y directions) in which plate 200 and fiber material 248 are arranged, and therefore generally orthogonal to the direction in which composite layer 240 is strongest. However, during this bending process, the top side 204 of plate 200 is in a state of compression, and the bottom side 208 is in a state of tension because the downward force, i.e., the load, causes plate 200 and footwear 100 to deform. Therefore, composite layer 240 disposed near the top side 204 is subjected to compressive force in the longitudinal direction, i.e., the Y direction, while composite layer 240 disposed near the bottom side 208 of plate 200 is subjected to tensile force in the longitudinal direction, i.e., the Y direction. Therefore, in order to increase the bending strength BR, the composite layer 240 near the top side 204 may be provided with fiber material 248 extending in the longitudinal direction, i.e. parallel to the direction of the applied compressive force, and the composite layer 240 near the bottom side 208 may be provided with fiber material 248 extending in the longitudinal direction, i.e. parallel to the direction of the applied tensile force.

[0088] Furthermore, it may be desirable to adjust the flexural strength BR, and consequently, the propulsion force provided by the plate 200. For this purpose, the composite layer 240 can be arranged along different operating directions FOL, i.e., the direction in which the composite layer is strongest due to the axial direction or orientation of the fiber material 248. The flexural strength BR of the composite layer 240 is greatest when the operating direction FOL is parallel to the longitudinal direction, and then gradually decreases as the operating direction FOL shifts from the longitudinal direction to an orthogonal direction, such as through rotation. Therefore, the flexural strength of the composite layer 240 is proportional to the degree to which the operating direction FOL deviates from the bending direction. Furthermore, the combination of composite layers 240 including the plate 200 is strongest when all operating directions FOL are parallel to each other and also parallel to the longitudinal direction orientation. However, by arranging some composite layers 240 in operating directions deviating from the longitudinal direction, the stacking of the composite layers 240 including the plate 200 can be adjusted to achieve a desired amount of flexural strength BR, which allows for greater deflection in response to applied loads and also provides subsequent springback or propulsion.

[0089] It is anticipated that the plate 200 can be manufactured using CFF technology to create local portions or regions with different properties. For example, the rear section 212 of the plate 200 can be manufactured to be more robust than the bow section 216 and the front section 220. To this end, the rear section 212 can be composed of composite layers 240, each defining greater EAL and ETL properties than the composite layers 240 in the bow section 216 or the front section 220. Furthermore, the rear section 212 of the plate 200 can include greater EAT and ETT than those in the bow section 216 and the front section 220. This is possible because the additive manufacturing process using CFF technology offers a wide range of customization and control over variables such as depositing fiber material 248 on different operating directions (FOL), controlling the volume of fiber material 248 within sections and layers, and selecting various materials, etc.

[0090] In some embodiments, EAT and ETT can vary throughout plate 200 and between the rear section 212, the arched section 216, and the front section 220, as well as between the outer side 116 and the inner side 118. For example, plate 200 can be designed to increase propulsion by manufacturing the front section 220 with higher EAT and ETT than the arched section 216, such that the bending strength BR is greater in the front section 220 than in the arched section 216. Plate 200, especially the front section 220, undergoes deformation during wear or use, for example, due to dorsiflexion and plantarflexion movements, particularly within the metatarsophalangeal joint (MTP) of the user's foot. It is known that potential energy PE increases with increasing deformation, i.e., bending, of the structure, and when the structure returns to its undeformed state, the potential energy PE is converted into kinetic energy KE, similar to a spring. When the load decreases or is removed, the front section 220 of plate 200 springs back to its undeformed state, converting the potential energy PE into kinetic energy KE to generate a propulsive force PF between the ground and the user's foot. The rate of rebound of plate 200, especially the front section 220, after deformation can be understood as its flexural strength BR, which is affected by various properties of plate 200, such as specific EAT and ETT values ​​within the front section 220. Therefore, higher EAT and ETT values ​​increase the flexural strength BR and propulsion force PF provided by the front section 220 of plate 200. Without plate 200, the MTP joint of footwear 100 and the user's foot would frequently absorb potential energy PE, and thus, during use, a smaller portion of this potential energy PE would be converted into kinetic energy KE. However, due to the increased stiffness of plate 200, such as flexural strength BR and torsional strength TR, more potential energy PE generated by the user is converted into kinetic energy KE and is therefore returned to the user.

[0091] Reference Figure 7The plate 200 can be manufactured by a printer 300 configured for printing composite structures layer by layer. In the illustrated embodiment, the printer 300 includes a housing 304 containing a print bed or platform 308. The platform 308 is supported by a support 312 and operably engages with a vertical track 316 extending generally in the Z direction within the housing 304. The housing 304 also includes a transverse guide rail 320 extending generally in the X direction and a longitudinal guide rail 324 extending generally in the Y direction. The platform 308 can be vertically translated along the vertical track 316 by operating a drive or motor (not shown) housed within the housing 304. A preform or block 328 is supported by the platform 308 within the housing 304.

[0092] like Figure 7 As shown, printer 300 also includes a first head 332 and a second head 336 within housing 304. In the illustrated embodiment, the first head 332 and the second head 336 are arranged side-by-side, but other configurations are possible. Additionally, scanner 340 is provided adjacent to the first head 332, although scanner 340 may be located elsewhere within housing 304. In some embodiments, scanner 340 is a laser scanner capable of detecting and measuring the size and geometry of objects on platform 308, but other types of scanners, such as 3D cameras, light detection and ranging (LIDAR) devices, etc., may be used. In the illustrated embodiment, first head 332 includes a first nozzle 344 and cooperates with a first supply 348 located within housing 304. Additionally, second head 336 includes a second nozzle 352 and cooperates with a second supply 356 located within housing 304. The first nozzle 344 and the second nozzle 352 may each include a cutter (not shown) capable of cutting or severing the substrate material 244 and / or fiber material 248 during operation. However, in some embodiments, the cutter (not shown) is configured as a separate component from the first nozzle 344 and the second nozzle 352.

[0093] In the illustrated embodiment, the first supply 348 and the second supply 356 are configured as spools or reels, each holding a specific material, and preferably, the first supply 348 and the second supply 356 hold different materials from each other. In the illustrated embodiment, the first supply 348 holds a base material 244, and the second supply 356 holds a fiber material 248, but other configurations are also possible. In other embodiments, the printer 300 may include more than two printheads, or only one printhead. Furthermore, in some embodiments, the printer 300 may also include more than two supplies or only one supply. In some embodiments, more than one supply cooperates with a single head, while in other embodiments, one supply serves more than one head.

[0094] The first head 332 and the second head 336, along with the scanner 340, are operatively coupled to the longitudinal guide rail 324 and the transverse guide rail 320 to form a base 360 ​​that is also capable of vertical translation within the housing 304. The first head 332 and the second head 336 are configured to translate along the longitudinal rail 324 and the transverse rail 320 via a drive motor (not shown), and the base 360 ​​is also capable of vertical translation relative to the platform 308 within the housing 304. Furthermore, the platform 308 is capable of vertical translation relative to the base 360. Therefore, the platform 308 and the base 360, including the first head 332 and the second head 336, are configured to move relative to each other to provide multiple degrees of freedom and range of motion via a dedicated motor (not shown) for precise and convenient movement during the printing process.

[0095] refer to Figure 7 A first head 332 is configured to receive a base material 244 stored on a first supply 348 during a specific step or operation of manufacturing. Therefore, a first nozzle 344 is configured to be compatible with the base material 244, such that the first head 332 is configured to be activated to apply the base material 244 to a component positioned on a platform 308 via the first nozzle 344. Furthermore, a second head 336 is configured to receive a fibrous material 248 stored on a second supply 356 during a specific step or operation of manufacturing. Therefore, a second nozzle 352 is configured to be compatible with the fibrous material 248, such that the second head 336 is configured to be activated to continuously apply the fibrous material 248 to a component located on a platform 308 via the second nozzle 352. In some steps or operations, both the first head 332 and the second head 336 are simultaneously activated to apply the base material 244 and the fibrous material 248 to the component on the platform 308, respectively. In other steps or operations, only one of the first head 332 and the second head 336 is activated, while the other is deactivated, to apply one of the substrate material 244 and the fiber material 248, respectively. The fiber material 248 may be deposited or applied to fuse to the substrate material 244 and / or to another strand or layer of fiber material 248 during the printing process. Furthermore, pressure may be applied, for example, with the second nozzle 352 to continuously compress and guide the fiber material 248 into the desired shape as it is fused.

[0096] Printer 300 includes a controller (not shown) programmed to control the printing process based on a set of instructions (e.g., source code) corresponding to a design model of a 3D part (such as plate 200). Specifically, a design model is generated using software programs, such as browser-based or web-based software programs, where aspects of plate 200 and the printing process are predetermined for use with printer 300. For example, plate 200 can be designed within the software based on specific inputs, such as foot dimensions, dimensions, shape, profile, stiffness, etc., measured or collected using various sources, such as laser scanners, gait analysis, force characteristics, images, medical records, and user preferences. Once the inputs are loaded into the software and utilized—for example, prioritized and considered against each other—the software can be used to optimize the design of plate 200 to suit the user. In some cases, technicians trained to use the software and / or printer 300 can assist the user in optimizing plate 200 for a specific purpose, such as for performance and / or medical applications. The software then generates a design model in a transferable format, such as a file compatible with printer 300. The design model is transmitted to the printer 300 via an Internet connection, Bluetooth connection, RF connection, USB or Ethernet cable, digital storage disk or any other medium suitable for communication between the software and the printer 300.

[0097] Figure 8A A flowchart depicts an exemplary method for designing and 3D printing composite panels. In step S100, measurement results and preferences, such as those mentioned above, are collected from various sources and input as input data into a software program for analysis. In some cases, the software program will be able to automatically perform step S104 by analyzing the input data to automatically generate an optimized design model for the panel. In other cases, a technician or expert will assist in performing step S104 by reviewing and modifying the input data to correct any errors, discrepancies, or unique customization preferences. In step S108, the software program generates a design model based on the provided input data. Thus, the design model is the first representation of the customized panel, presenting it to the user with various properties. An important property is the material and composition selected for the customized panel of the design model. In step S112, the software program may automatically recommend specific materials based on the input data, but the user may also manually select the materials to use. For example, because some types of substrate materials 244 or fiber materials 248 are more expensive than other types of substrate materials or fiber materials, the user may want to reduce the cost associated with the recommended materials.

[0098] In step S116, after the design model has been generated and the material has been selected, the software program is programmed to optimize the design model for 3D printing. Specifically, the software program analyzes various aspects of the design model to identify areas requiring further reinforcement, such as edges that could benefit from applied curvature, like rounded corners, or holes that could benefit from additional fiber material 248 wrapped around them. The software program also generates any warnings or notifications related to areas with thicknesses below a minimum thickness threshold associated with the specific material, geometry, and composite layer 240 specified in the design model. If any warnings and notifications remain unresolved, and depending on their severity, the software program may prevent the user from proceeding beyond step S116.

[0099] In step S120, a simulation of the design model can be performed in the software program; however, this step is optional for the user and does not need to be performed. In some cases, the simulation can be used to troubleshoot any unresolved warnings or notifications before proceeding, or the user can compare simulation data across various material choices or modifications to the input data. In step S124, the user can further refine or modify the input data and material choices to generate a new design model, and, if necessary, a new simulation.

[0100] In step S128, the user now prompts the software program to generate the design model in a transferable file format such as those described above. Furthermore, the software program generates print instructions to communicate with printer 300 or an equivalent. In some embodiments, the print instructions may be generated by the controller (not shown) of printer 300 after receiving the digital model from the software program. The user can transmit or send the file, including the design model and print instructions, to printer 300 using various communication methods such as those mentioned above.

[0101] In step S132, the user activates printer 300 to begin the printing process according to the design model and printing instructions, which includes sub-processes described in more detail below. After printer 300 has completed the printing process, in step S136, the user removes the printed model of plate 200 from printer 300 and, if necessary, separates the printed model from preform mold 328. The term "printed model" as used herein refers to the version of plate 200 immediately after the printing process is completed, and also includes both the original and unprocessed versions of plate 200. In some cases, the user will determine whether any processing is needed or desired, which will also be described in more detail below. If necessary, in step S140, the user will continue processing the printed model of plate 200. Finally, when the printed model of plate 200 is determined to be in a completed state, plate 200 can be installed in the desired position on footwear 100.

[0102] Figure 8BA flowchart depicts an exemplary method for operating printer 300, which involves Figure 8A The subprocess of step S132. In step S200, the printer 300 is powered on and the preheating process is started. The preheating process may take several minutes or longer. Then, in step S204, the user selects and installs a first supply 348 with the desired substrate material 244, and the printer 300 supplies the substrate material 244 to the first head 332. Next, in step S208, the user selects and installs a second supply 356 with the desired fiber material 248, and the printer 300 delivers the fiber material 248 to the second head 336. In step S212, the user selects an appropriate preform die 328 for the specific part to be printed, such as a print model of the board 200. Furthermore, the user positions the preform die 328 on the platform 308 within the printer 300 with an appropriate orientation. Next, in step S216, the user uses a software program to generate a print processing instruction in a transferable file format and sends the file to the printer 300.

[0103] In step S220, the user considers characteristics related to the print processing instruction, such as duration, print cycle, pauses and / or interruptions, material volume, etc., and determines when to start the print process. The software program can provide a recommended optimal start time to avoid downtime. For example, the print process may include 8-hour cycles and 2-hour cycles, so starting the print process at the end of the workday may be optimal, for example, around 5:00 PM, so the 8-hour cycle can be completed overnight, while the shorter 2-hour cycle can be completed the next day. In this way, the user can make printer 300 available for shorter cycles during workdays, such as normal business hours, and also keep printer 300 in production during non-working hours, such as overnight. After considering the characteristics of the print process and the recommendations provided by the software program, the user determines when to activate printer 300 to start the print process.

[0104] Next, in step S224, the user activates the printing process and monitors the printer 300 as needed. For example, the printing process may require the user to replenish the first supply 348 of the substrate material 244 or to replace it with a substrate material 244 of a different type. Then, in step S228, after the printer 300 has completed the printing process, the user can remove the printed model from the printer 300 and separate the pre-formed model from the printed model of the board 200. Various hand tools, such as screwdrivers, chisels, hammers, etc., can be used for this. As shown in step S232, the user performs a quality check on the printed model of the board 200 to identify any defects or risks. In one instance, the quality check may include a visual inspection of the printed model of the board 200 to identify any visible defects, such as cracks, inappropriate holes or shapes, loose wire ends or loops, etc. In another instance, the user may perform non-destructive testing on the printed model of the board 200 to verify that the strength in each direction is satisfactory compared to the design data. Furthermore, the user may measure the weight and / or volume of the printed model to verify the composition by comparing it with the design data. Other tests can be performed to identify any defects and / or deviations from the design data associated with the printed model.

[0105] In step S236, the user determines whether any defects identified from the quality check in step S232 pose a significant risk to the performance and / or quality of the printed model. If the user determines that a defect poses a significant risk, the user can determine whether those defects can be repaired through another process. Furthermore, in step S240, the user can also determine the costs associated with repair, such as whether time and materials are economical, before deciding whether to perform repairs. If the defect is determined to be repairable and economical, the user submits the printed model for such repair, as in step S244, which may involve additional printing or processing procedures. In step S248, if the defect is irreparable or uneconomical, the printed model can be discarded according to any applicable local regulations. If no defects are found, the user can proceed to step S252.

[0106] In step S252, the user determines whether the printed model should undergo any processing. Such processing may include applying a coating, compression to alter the characteristics of the printed model, sanding and / or polishing, attaching pins or rods to the printed model to aid in installation in the footwear 100, and other finishing techniques. In step S256, the user performs or schedules any appropriate processing that has been performed, through which the printed model becomes the finished plate 200. In step S260, after the processing is complete, the user performs another quality check to identify any defects or risks. If a defect is identified, the user again determines in step S268 whether repair should be performed. In step S272, if the repair is worthwhile and economical, it is performed. After the repair is completed, the quality check of step S264 is performed again for a final inspection. If no defects are identified in the quality check of step S264, regardless of whether repair has been performed, the user proceeds to step S276, in which the plate 200 is installed or assembled in the footwear 100 in its finished state.

[0107] As part of steps S204 and S208, the user identifies specific materials specified by the design model, namely the substrate material 244 and the fiber material 248. In doing so, the user can consider the costs associated with variations in the substrate material 244 and the fiber material 248. Typically, the fiber material 248 is more expensive and costly than the substrate material 244, and in some cases, it may be scarcer or harder to procure in sufficient quantities. Therefore, boards using large amounts of fiber material 248 are generally more expensive and, in some cases, more sensitive to supply chain disruptions and resource fluctuations. Furthermore, conventional manufacturing methods involve the removal of material and therefore require a larger volume of excess material to accommodate this removal, e.g., cutting blanks from larger material sheets. In contrast, additive manufacturing eliminates the need for such excess material. Due to the optimized use of fiber material 248 in the additive manufacturing methods of this disclosure, such as utilizing CFF technology, users are offered the ability to achieve improved board performance, such as increased and customized stiffness, while minimizing costs. Therefore, the additive manufacturing process of this disclosure can be optimized for various factors, including cost, availability, and performance.

[0108] Next, the user loads the first supply 348 and the second supply 356 containing the specified materials into the printer 300, and in particular, the user supplies a portion of the base material 244 from the first supply 348 to the first head 332, and also supplies a portion of the fiber material 248 from the second supply 356 to the second head 336.

[0109] After activating printer 300 in step S224 to begin the printing process, printer 300 operates according to instructions associated with the design model to selectively activate first head 332 and second head 336 to print plate 200 layer by layer. In some cases, printer 300 prints plate 200 from bottom to top, such that bottom side 208 is printed before top side 204. In other cases, the geometry and / or aspects of plate 200 are printed layer by layer with an inverted orientation, such that top side 204 is printed before bottom side 208. Thus, printer 300 guides first head 332 and second head 336 to print composite layers 240 of plate 200 in an optimized orientation and manner as informed by the design model. Upon completion of the printing process, plate 200 is provided in an unfinished state as a printed model composed of composite layers 240, the range of which can be from two layers to thousands of layers.

[0110] As noted in step S256, and now referring to Figure 9A and Figure 9B The printed model can be processed in a compression mold 370, such as a merging mold. Specifically, the printed model can be received within the negative shape 374 of a first block 378 corresponding to a specific shape and geometry, while a second block 382 is arranged to operate together with the first block 378 during the compression molding process. In some aspects, the second block 382 is provided with a positive shape 386 extending from the second block 382 and configured to protrude into the negative shape 374 of the first block 378 during the compression molding process. In other aspects, the second block 382 is provided with a flat surface that surrounds the printed model within the negative shape 374 of the first block 378.

[0111] During the compression molding process, the first block 378 and the second block 382 are pressed against each other, with the printing model positioned between them. The amount of compression, measured in Newtons (N) or pounds per square inch (PSI), can vary over time throughout the compression molding process, or it can remain constant throughout the process. Additionally, heat can be applied to the printing model via the first block 378 and / or the second block 382, ​​or heat can be applied directly to the printing model. Heat can be applied for varying durations at different temperatures through various media (e.g., steam, glycol, hot water, hot air) or through a heat exchanger. Furthermore, cooling can be applied to the printing model via the first block 378 and / or the second block 382, ​​or cooling can be applied directly to the printing model. Cooling can be applied for varying durations at different temperatures through various media (e.g., glycol, cold water, cold air) or through a heat exchanger.

[0112] Furthermore, the compression molding process may include injecting a volume of resin, such as thermoplastic polyurethane (TPU), acrylonitrile butadiene styrene (ABS), epoxy resin, vinyl resin, nylon, polyetherimide (PEI), polyetheretherketone (PEEK), polylactic acid (PLA), or liquid crystal polymers, which serves as a coating for the printed model. That is, the printed model can be coated with resin during the compression molding process. Various aspects of the compression molding process can be adjusted or modified to achieve specific coating characteristics or to suit specific resin materials. For example, a thicker coating may require a longer compression time, a higher heating temperature, and a larger volume of resin applied to the printed model. In some embodiments, the resin material is transparent or translucent, making the composite layer 240 visible through the coating. In other embodiments, the resin is opaque, thus the composite layer 240 is hidden beneath the coating.

[0113] During the compression molding process, the composite layer 240 of the printed pattern can react to compression, heat, and / or coating to alter its properties and aspects. For example, the substrate material 244 can have a lower melting point or heat distortion temperature than the fiber material 248. Therefore, the substrate material 244 of the printed pattern can be melted to form according to the negative shape 374 of the first piece 378, thereby forming or shaping the plate 200 during the compression molding process. In one example, the compression molding process can compress the printed pattern and reduce the total thickness TT, thereby reducing the thickness TL of one or more composite layers 240. It is also considered that the substrate material 244 can be thermally melted by the compression molding process, such that the composite layers 240 are thermally melted to each other during the compression molding process. Therefore, the compression molding process can transform the composite layers 240 of the plate 200 from discrete layers bonded to each other into a monolithic matrix 244 of substrate material in which strands of multiple continuous fiber materials 248 are impregnated. Due to the heat fusion during the compression molding process, the plate 200 can become more rigid, and therefore, stiffness, such as bending strength BR and torsional strength TR, can be increased.

[0114] Furthermore, the fiber material 248 can be entangled or rearranged due to the compression molding process, thereby altering the rigidity, flexibility, and orientation strength properties of the printed model. It is conceivable that the compression molding process can cause the fiber material 248 to melt or deform due to exposure to heat and pressure. It is also considered that the fiber material 248 can be thermally fused to the substrate material 244 and / or to the surrounding portions of the fiber material 248 through the compression molding process. Therefore, the compression molding process can transform the composite layer 240 of continuous strands of fiber material 248 from discrete layers separated or spaced apart from each other into a monolithic fiber web of fiber material 248 impregnated within the matrix of the substrate material 244. Due to the thermal fusion during the compression molding process, the plate 200 can become more rigid; therefore, stiffness, such as flexural strength BR and torsional strength TR, can be increased. Furthermore, if a coating is applied to the printed model during the compression molding process, the coating can impart certain properties to the printed model, such as surface roughness, moisture resistance, or vibration damping characteristics.

[0115] Therefore, plate 200 can be formed in various shapes and sizes and can be provided as part of footwear 100, such as in sole 104 or upper 102. In some embodiments, plate 200 is provided as part of upper 102, for example, as part of insole 126. Plate 200 can be configured to be at least partially customized to influence or enhance requirements such as gait, standing, posture, propulsion, and agility. For example, plate 200 can be constructed to alleviate pain and / or improve the performance of users with medical problems or deformities. Fiber reinforcement can increase stiffness in local areas of plate 200, such as in the rear section 212, the fore section 220, or the arched section 216, or some combination thereof. Furthermore, stiffness can be increased by the array and orientation of fibers made of generally rigid materials, or by depositing, for example, printing, a more compact and dense array of fiber material, or by adding additional composite layers in specific areas, or by depositing fibers around perimeter 232. In this way, flexural strength BR and torsional strength TR, taking into account and relating to moment of inertia MOI and modulus of elasticity values, can be increased and customized for specific applications. Fiber reinforcement can also provide directional stiffness and quasi-isotropic QI properties in localized areas of the plate 200 by using additive manufacturing methods implemented through CFF technology.

[0116] Example 1

[0117] refer to Figure 10-17 The document describes an embodiment of a board 400 in several unfinished states, wherein the various composite layers 404 are visible from a top plan view. Specifically, the board 400 is depicted as being in a successive stage of an exemplary experiment in additive manufacturing (i.e., printing) as performed using example CFF technology in a layer-by-layer configuration, a sample of which includes a first composite layer 404a (see...). Figure 10 ), second composite layer 404b (see Figure 11), third composite layer 404c (see Figure 12 ), fourth composite layer 404d (see Figure 13 ), fifth composite layer 404e (see Figure 14 ), sixth composite layer 404f (see Figure 15 ), seventh composite layer 404g (see Figure 16 ) and the eighth composite layer 404h (see Figure 17 ).from Figure 10-17 As can be understood, plate 400 defines a central axis 228 that bisectes the toe tip 140 and the heel tip 146. The central axis 228 is set at a centerline angle 408 relative to the reference axis 224. In the illustrated embodiment, the centerline angle 408 is approximately -4 degrees, but other configurations are possible. Furthermore, several aspects were measured during the exemplary test printing process and recorded in Table 1 below. Therefore, layer 1 corresponds to... Figure 10 The first composite layer is 404a, etc.

[0118] Table 1

[0119]

[0120] It should be understood that the plate 400 may include multiple composite layers in addition to the eight composite layers 404a-h, and the plate 400 may be subjected to a compression molding process in which coatings are applied. It should be understood that the term "array" as used herein may include various types of patterns and arrangements, such as boustrophedon arrays, checkerboard arrays of various polygons, concentric double-twisted line patterns, concentric circular or elliptical patterns, curvilinear geometric shapes, or any other 2D or 3D pattern formed by continuous strands.

[0121] refer to Figure 10 The first composite layer 404a is a base layer composed of strands of substrate material 244 printed in a substrate array 412a oriented at a base angle 416a relative to the reference axis 224. The base angle 416a can be approximately 45 degrees, but other configurations are also possible. In the illustrated embodiment, the base layer 404a consists entirely of substrate material 244, which can be a top layer or a protective layer used to surround the fibrous material 248 deposited in subsequent layers (see...). Figure 11-17 However, in some embodiments, the base layer 404a may be removed before being installed or assembled into the footwear 100.

[0122] Reference Figure 11The board 400 includes a second composite layer 404b comprising continuous strands of fibrous material 248 printed in a first fiber array 412b oriented parallel to a reference axis 224. Thus, the first fiber array 412b is oriented at a first fiber angle 416b (not shown) different from the base angle 416a. Furthermore, the first fiber array 412b of the second composite layer 404b includes U-shaped hairpin bends 420 arranged along a portion of the periphery 232 of the board 400. Additionally, the second composite layer 404b includes peripheral elements 236 that engage with one or more turns 420 along various portions of the first fiber array near the periphery 232. The peripheral elements 236 are formed of the fibrous material 248 and provide additional reinforcement; however, the peripheral elements 236 may be formed of other materials and / or may be located in more or fewer locations. In other embodiments, the peripheral elements 236 may be located further inward from the periphery 232, or alternatively, no peripheral elements 236 may be provided. Referring to Table 1, the second composite layer 404b includes a layer thickness TL of 0.1 mm and a thickness of 1.57 cm. 3 The layer volume VL is 248, of which fiber material accounts for 96.8%.

[0123] Reference Figure 12 The board 400 includes a third composite layer 404c comprising continuous strands of fibrous material 248 printed in a second fiber array 412c oriented relative to a reference axis 224 at a second fiber angle 416c. In the illustrated embodiment, the second fiber angle 416c is approximately -45 degrees. Therefore, the second fiber angle 416c differs from the first fiber angle 416b (not shown). Furthermore, the second fiber array 412c of the third composite layer 404c includes wire turns 420 arranged along a portion of the periphery 232 of the board 400. Additionally, the third composite layer 404c includes peripheral elements 236 that are engaged with one or more wire turns 420 along various portions of the second fiber array 412c near the periphery 232. Referring to Table 1, the third composite layer 404c comprises a layer thickness TL of 0.1 mm and a thickness of 1.56 cm. 3 The layer volume VL is 248, of which fiber material accounts for 96.8%.

[0124] refer to Figure 13The board 400 includes a fourth composite layer 404d, which comprises continuous strands of fiber material 248 printed in a third fiber array 412d oriented relative to a reference axis 224 at a third fiber angle 416d. In the illustrated embodiment, the third fiber angle 416d is approximately 90 degrees. Therefore, the third fiber angle 416d differs from the second fiber angle 416c. Furthermore, the third fiber array 412d of the fourth composite layer 404d includes wire turns 420 arranged along a portion of the periphery 232 of the board 400. Additionally, the fourth composite layer 404d includes peripheral elements 236 that engage with one or more wire turns 420 along various portions of the third fiber array 412d near the periphery 232. Referring to Table 1, the fourth composite layer 404d comprises a layer thickness TL of 0.1 mm and 1.53 cm. 3 The layer volume VL, of which fiber material 248 accounts for 98.0%.

[0125] Reference Figure 14 The board 400 includes a fifth composite layer 404e, which comprises continuous strands of fiber material 248 printed in a fourth fiber array 412e oriented at a fourth fiber angle 416e relative to a reference axis 224. In the illustrated embodiment, the fourth fiber angle 416e is approximately 45 degrees. Therefore, the fourth fiber angle 416e differs from the third fiber angle 416d. Furthermore, the fourth fiber array 412e of the fifth composite layer 404e includes wire turns 420 arranged along a portion of the periphery 232 of the board 400. Additionally, the fifth composite layer 404e includes peripheral elements 236 that engage with one or more wire turns 420 along various portions of the fourth fiber array 412e near the periphery 232. Referring to Table 1, the fifth composite layer 404e comprises a layer thickness TL of 0.1 mm and 1.56 cm. 3 The layer volume VL is composed of 96.8% fiber material.

[0126] Reference Figure 15 The board 400 includes a sixth composite layer 404f, which comprises continuous strands of fiber material 248 printed in a fifth fiber array 412f oriented with a fifth fiber angle 416f relative to a reference axis 224. In the illustrated embodiment, the fifth fiber angle 416f is approximately -45 degrees. Therefore, the fifth fiber angle 416f differs from the fourth fiber angle 416e. Furthermore, the fifth fiber array 412f of the sixth composite layer 404f includes wire turns 420 arranged along a portion of the periphery 232 of the board 400. Additionally, the sixth composite layer 404f includes peripheral elements 236 that engage with one or more wire turns 420 along various portions of the fifth fiber array 412f near the periphery 232. Referring to Table 1, measurements of the sixth composite layer 404f are provided, including a layer thickness TL of 0.1 mm and 1.54 cm. 3 The layer volume VL is 248, of which fiber material accounts for 96.8%.

[0127] Reference Figure 16 The board 400 includes a seventh composite layer 404g, which comprises continuous strands of fiber material 248 printed in a sixth fiber array 412g oriented relative to a reference axis 224 at a sixth fiber angle 416g. In the illustrated embodiment, the sixth fiber angle 416g is approximately 90 degrees. Therefore, the sixth fiber angle 416g differs from the fifth fiber angle 416f. Furthermore, the sixth fiber array 412g of the seventh composite layer 404g includes wire turns 420 arranged along a portion of the periphery 232 of the board 400. Additionally, the seventh composite layer 404g includes peripheral elements 236 that engage with one or more wire turns 420 along various portions of the sixth fiber array 412g near the periphery 232. Referring to Table 1, the seventh composite layer 404g comprises a layer thickness TL of 0.1 mm and 1.54 cm. 3 The layer volume VL, of which fiber material 248 accounts for 98.0%.

[0128] Reference Figure 17 The board 400 includes an eighth composite layer 404h, which comprises continuous strands of fiber material 248 printed in a seventh fiber array 412h oriented relative to a reference axis 224 at a seventh fiber angle 416h. In the illustrated embodiment, the seventh fiber angle 416h is approximately 90 degrees. Therefore, the seventh fiber angle 416h differs from the sixth fiber angle 416g. Furthermore, the seventh fiber array 412h of the eighth composite layer 404h includes wire turns 420 arranged along a portion of the periphery 232 of the board 400. Additionally, the eighth composite layer 404h includes peripheral elements 236 that engage with one or more wire turns 420 along various portions of the seventh fiber array 412h near the periphery 232. Referring to Table 1, the eighth composite layer 404h comprises a layer thickness TL of 0.1 mm and 1.56 cm. 3 The layer volume VL is composed of 248 fiber materials, which account for 96.8%.

[0129] Therefore, one example of CFF technology includes the deposition of multiple layers of continuous strands of fiber material 248, these layers being vertically stacked or arranged in a continuous composite layer 404, arranged in different arrays 412, and arranged at varying angles 416 relative to a reference axis 224. Furthermore, each fiber array 412 includes continuous strands of fiber material 248 extending continuously in-plane between the toe end 140 and the heel end 146 of the plate 400. That is, the CFF technology for manufacturing the plate 400 includes several composite layers 404 in which fiber material 248 is deposited in fiber arrays 412 that are uniform and continuous throughout the rear section 212, the arched section 216, and the front section 220, and that the fiber arrays 412 are also uniform between the inner side 118 and the outer side 116 of the plate 400. Furthermore, each fiber array 412 is composed of continuous strands of fiber material 248 that are different from and separate from the fiber arrays 412 of adjacent composite layers 404. For this purpose, the cutter (not shown) of the printer 300 is used to define the continuous strands of each fiber array 412.

[0130] Additionally, the fiber angle 416 differs from the fiber angle 416 of the adjacent composite layer 404. Furthermore, the fiber array 412 of each composite layer 404 defines the fiber surface area (FSAL) of the composite layer 404, such that the fiber array 412 can be quantified as a percentage of the total surface area (SAL) defined by the composite layer 404. In one case, the fiber array 412 comprises at least about 90% of the layer surface area (SAL). Because the composite layer 404 extends across the entire plate 400 and partially defines the plate 400 and its perimeter 232, the layer surface area (SAL) is generally equal to the in-plane surface area (SAP) of the plate 400. Therefore, the fiber surface area (FSAL) of the fiber array 412 corresponds to the in-plane surface area (SAP) of the plate 400. For this purpose, the fiber array 412 is printed substantially continuously over the entire in-plane surface area (SAP) of the plate 400, meaning that the fiber array 412 comprises at least about 90% of the in-plane surface area (SAP) of the plate 400. It should be understood that the fiber percentage (FPL) of the layer volume VL corresponds proportionally to the fiber surface area (FSAL) covered by the fiber array 412. However, in some embodiments, due to the introduction of a third element and / or material, or due to the concentration of fiber material 248 in specific regions or segments of the composite layer 404 and / or plate 400, the fiber percentage (FPL) may not correspond to the fiber surface area (FSAL). In some embodiments, the fiber surface area (FSAL) of each fiber array 412 differs from the fiber surface area (FSAL) of the fiber array 412 of the adjacent composite layer 404.

[0131] refer to Figure 18 Another embodiment of the plate 500 is provided, which is used within the sole structure 504 of the footwear article 100. Figure 18Plate 500 and sole structure 504 are similar to plates 200, 400 and sole structure 104; therefore, the same reference numerals are used to denote the same elements. Figure 18 In the illustrated embodiment, the plate 500 includes an inner fork 508 and an outer fork 512 separated by a gap 516 within the front section 220. The plate 500 narrows relative to a reference plane 224 that moves longitudinally toward the heel end 146, i.e., measured in the X direction. That is, the plate 500 narrows from the front section 220 to the arched section 216, and also from the arched section 216 to the rear section 212. In the illustrated embodiment, the sole 504 also includes an outsole 520 and a sole interlayer 528 to which the plate 500 is attached.

[0132] Plate 500 is manufactured using additive manufacturing, similar to plates 200 and 400, such that plate 500 comprises multiple composite layers (not shown) including fiber material 248 and base material 244 in various orientations. As a result, the dimensions and shape of plate 500 are designed to have customized flexural strength BR and torsional strength TR. For example, due to the location of the gap 516 between the inner fork 508 and the outer fork 512, the front section 220 of plate 500 has smaller material volumes VL and VT than those of plates 200 and 400. Therefore, the flexural strength BR and torsional strength TR are reduced compared to those of plates 200 and 400. Additionally, the rear section 212 also defines smaller VL and VT than plates 200 and 400. However, the arcuate section 216 of plate 500 defines VT and VL equal to or greater than those of plates 200 and 400. In this way, by changing the shape and size of plate 500, plate 500 is adjusted to provide specific bending strength BR and torsional strength TR compared to plates 200 and 400.

[0133] Furthermore, the inner fork 508 and outer fork 512 of the plate 500 can be configured to have different properties from each other. For example, the inner fork 508 can have greater rigidity than the outer fork 512, such as a flexural strength BR, to provide increased propulsion for the user in the inner or medial portion near the ball of the foot, i.e., near the big toe. In contrast, the outer fork 512 can have greater flexibility than the inner fork 508, such as a lower flexural strength BR, to provide greater comfort for the user in the outer or lateral portion near the ball of the foot, such as near the distal toe.

[0134] In addition, refer to Figure 1-3In embodiment 18, plate 500 is configured as part of sole structure 504, which is assembled with upper 102. Specifically, plate 500 is configured to be positioned between outsole 520 and upper 102 such that plate 500 contacts both outsole 520 and upper 102. For this purpose, plate 500 extends through sole interlayer 528, and specifically, the rear segment 212 of plate 500 extends through a slot 532 formed through sole interlayer 528. In the illustrated embodiment, plate 500 gradually curves along front segment 220 and arched segment 216 relative to horizontal plane H, and plate 500 has an increased curvature relative to horizontal plane H along arched segment 216 and rear segment 212 compared to the curvature in front segment 220.

[0135] During assembly, the rear section 212 of the plate 500 rests on the platform 536 flush with the bottom surface 540 of the midsole 528. When the upper 102 is attached to the midsole 528, the insole 126 of the upper 102 is positioned along the bottom surface 540 and the rear section 212 of the plate 500. Thus, when the sole 504 is assembled, the plate 500 is positioned at a downward angle relative to a horizontal plane H extending in the X and Y directions, and this horizontal plane is coplanar with at least a portion of the bottom surface 540 of the midsole 528 and / or the insole 126 of the upper 102. The downward angle is at least about 5 degrees, but can be 10 degrees or greater. At this downward angle, and in combination with a specific curvature, the plate 500 is configured to deflect under applied loads during use, causing the plate 500 to spring back and thus provide propulsion to the user's gait under light loads, such as simply walking and striding. As described above, in combination with the specific shape and size of the plate 500, the plate 500 is arranged within the sole 504 to increase responsiveness, thereby making propulsion easier to achieve, i.e., under a lighter load, compared to a plate laid flat along the sole interlayer 528.

[0136] Therefore, plates 200, 400, and 500 can be formed in various shapes and sizes and can be incorporated into footwear 100, for example, in the sole 104 or upper 102. In some embodiments, plate 400 is incorporated into the upper 102, for example, into the insole 126. Plates 200, 400, and 500 can be configured to be at least partially customized to influence or enhance requirements such as gait, stance, posture, propulsion, and agility. For example, plates 200, 400, and 500 can be configured to alleviate pain and / or improve the performance of users with medical problems or deformities. Fiber reinforcement can increase rigidity in localized areas of plates 200 and 400, such as in the rear section 212, the fore section 220, or the arch section 216, or certain combinations thereof. Furthermore, rigidity can be increased by the array and orientation of fibers made of generally rigid materials, or by depositing, for example, printing, a more compact and dense array of fiber material, or by adding additional composite layers in specific areas, or by depositing fibers around the perimeter 232. In this way, the flexural strength (BR) and torsional strength (TR), taking into account the moment of inertia (MOI) and modulus of elasticity, can be increased and customized for specific applications. Fiber reinforcement can also provide directional stiffness and quasi-isotropic QI properties in localized areas of the 200, 400, and 500 mm plates by using additive manufacturing methods implemented through CFF technology.

[0137] Figure 19 Another embodiment of the plate 600 manufactured by the above-described additive manufacturing process is depicted. The plate 600 is constructed as an integral sole structure 104, such that the plate 600 includes an upper 102 (see...). Figure 1-3 The entire sole structure 104 is attached to the plate 600. Specifically, the plate 600 includes a plurality of traction elements 604 integrally provided as part of the plate 600. Therefore, the same additive manufacturing process and, in some cases, the same materials can be used to manufacture the plate 600 and the traction elements 604. Thus, the traction element 604 is a composite element comprising a base material 244 and a fiber material 248, as combined above. Figure 1-18 As stated above. (Reference) Figure 20 , Figure 20 yes Figure 19 A cross-sectional view of one of the traction elements 604 shows that the fiber material 248 is wound in a concentric circular path within the traction element 604. Furthermore, the traction element 604 defines an outer diameter D, which narrows as the traction element 604 extends away from the plate 600. Therefore, the concentric circular path of the fiber material 248 tightens or expands proportionally to the diameter D within the traction element 604. In this way, the traction element 604 is strengthened to have strength-weight characteristics similar to those of the aforementioned plates 200, 400, and 500.

[0138] Reference Figure 21The illustration provides a schematic representation of an example of a hole 620 that can be disposed within a plate 600. In the illustrated embodiment, fibrous material 248 extends in a concentric circular path around the hole 620 and is proportional to the diameter D1 defined by the hole 620. Thus, the fibrous material 248 serves to reinforce the hole 620 of the plate 600. Such a hole 620 can be formed within the plate 600 as a through-hole or as a void or cavity that is not exposed to the outside of the plate 600.

[0139] It is conceivable that any panel described in this disclosure may include embedded functions in addition to the structural rigidity characteristics described above. For example, it is conceivable that the fiber material 248 may have or be modified to have conductive, thermally conductive, electrically insulating, thermally insulating, light-transmitting, or fluid-transmitting properties. Alternatively or additionally, a device (not shown) may be embedded within any of the panels of this disclosure. In one case, the device (not shown) may be a sensor, such as a transducer, accelerometer, geolocation sensor, temperature sensor, moisture sensor, or humidity sensor. Furthermore, the device (not shown) may be capable of providing tactile feedback to a user, allowing the user to be notified to avoid prolonged standing, sitting, or immobility. Moreover, the device (not shown) may be an object or structural element, such as an inflatable or liquid-filled sac or pod. Further contemplated, the device (not shown) may be capable of collecting and storing energy caused by deformation of the panel and / or footwear during use, such as a piezoelectric transducer.

[0140] In other embodiments, other configurations are possible. For example, certain features and combinations of features presented with respect to specific embodiments in the above discussion may be suitably used in other embodiments and in other combinations. Furthermore, any embodiment described herein may be modified to include any structures or methods disclosed in conjunction with other embodiments. Additionally, this disclosure is not limited to footwear articles of the specific types shown. Moreover, aspects of footwear articles of any embodiment disclosed herein may be modified to work with any type of footwear, apparel, or other athletic equipment.

[0141] As for the foregoing, those skilled in the art will understand that although the invention has been described above in conjunction with specific embodiments and examples, the invention is not to be so limited, and many other embodiments, examples, uses, modifications, and deviations from the embodiments, examples, and uses are intended to be covered by the appended claims. The full disclosure of each patent and publication cited herein is incorporated by reference, just as each such patent or publication is individually incorporated by reference. Various features and advantages of the invention are set forth in the following claims.

[0142] Industrial applicability

[0143] In view of the foregoing description, many modifications to the present invention will be apparent to those skilled in the art. Therefore, this specification should be construed as illustrative only and is presented for the purpose of enabling those skilled in the art to make and use the invention. Exclusive rights are reserved to all modifications falling within the scope of the appended claims.

Claims

1. A method for manufacturing a component for a sole structure of footwear articles, the method comprising: A 3D printer is provided, the 3D printer having a platform, a first head for receiving a first supply, and a second head for receiving a second supply; A substrate is printed on the platform, the substrate comprising a base material and defining a longitudinal axis. A first fiber layer is continuously printed on the substrate, the first fiber layer defining a first fiber orientation disposed at a first angle relative to the longitudinal axis; A second fiber layer is continuously printed on the first fiber layer, the second fiber layer defining a second fiber orientation disposed at a second angle relative to the longitudinal axis, wherein the first angle is different from the second angle; as well as A printing model is processed in a compression molding process, wherein the printing model includes at least the base layer, the first fiber layer, and the second fiber layer.

2. The method according to claim 1, wherein, The first fiber layer comprises at least 60% of the base material.

3. The method according to claim 1, wherein, The second fiber layer comprises at least 50% fiber material.

4. The method according to claim 1, wherein, The first fiber layer and the second fiber layer define different layer volumes.

5. The method according to claim 4, wherein, The first fiber layer includes at least one of carbon fiber, aramid fiber, boron fiber or glass fiber.

6. The method according to claim 1, wherein, The printed model includes at least five fiber layers.

7. The method according to claim 1, wherein, The printed model includes an arc-shaped segment extending between the rear and front sections.

8. The method according to claim 1, wherein, Transparent resin is applied to the printed model inside the compression mold.

9. The method according to claim 1, wherein, The printed model includes a third fiber layer defining a third fiber orientation, the third fiber orientation being set at a third angle relative to the longitudinal axis, the third angle being equal to the first angle, and the third fiber layer being separated from the first fiber layer by a second fiber layer.

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