Footwear with traction elements

Abstract

The invention relates to an article of footwear with traction elements, and systems and methods for making the article of footwear. An example footwear includes an upper and a sole plate including a lower surface adapted for ground contact, the lower surface having: a first sole portion including a first traction element having a distal end and a sidewall with an extension portion extending from a central core; and a second sole portion including a second traction element having at least one geometric feature different in one or more aspects from the corresponding geometric feature of the first traction element.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to and the benefit of co-pending U.S. application serial number 14 / 741,094, filed on June 16, 2015, which is a continuation-in-part of U.S. application serial number 14 / 134,948, filed on December 19, 2013, which claims priority to and the benefit of U.S. provisional patent application serial number 61 / 739,346, filed on December 19, 2012, the entire disclosures of which are incorporated herein by reference. Technical Field

[0003] The present invention relates generally to the field of footwear and, more particularly, to an article of footwear having a sole plate with traction elements thereon.

[0004] Background of the Invention

[0005] Many aspects of the performance and comfort of footwear depend on various performance and physical characteristics of the footwear wearer. For example, step length, stride frequency, foot strike position, pronation / supination, running style, and running speed can be affected by the elements of the footwear worn. In addition, the athlete's physical characteristics, such as height, weight, shoe size, foot shape, leg shape and size, etc., can affect the athlete's performance and the footwear worn.

[0006] While each athlete has a unique set of performance and physical characteristics, as well as a unique set of aesthetic and performance requirements, athletes have generally been limited in selecting footwear to basic choices such as brand, style, size, width, and (for running and cleated footwear) spike size and shape, with fully customized footwear that meets an individual's specific performance and aesthetic requirements not being available under traditional manufacturing techniques and product distribution channels. Summary of the invention

[0007] The present invention relates to customized footwear, apparel and athletic equipment and components thereof, and related systems and methods for designing and manufacturing customized footwear, apparel and athletic equipment and components thereof.

[0008] One aspect of the present invention includes a sole plate for an article of footwear. The sole plate includes a lower surface adapted for ground contact, wherein the lower surface includes a first sole portion having a plurality of first traction elements and a second sole portion having a plurality of second traction elements, the first traction elements having a distal end and a sidewall, the sidewall including a plurality of extensions extending from a central core, and the second traction elements having at least one geometric feature that is different from a corresponding geometric feature of the first traction elements in at least one aspect. In one embodiment, the sidewall of the first traction element includes or is primarily comprised of three tapered extensions extending from the central core. The orientation of at least one first traction element in a first area of ​​the first sole portion may be different from the orientation of at least one first traction element in a second area of ​​the first sole portion. In one embodiment, the second traction element has a distal end and a sidewall, the sidewall including or primarily comprised of a generally hexagonal cross-section. Alternatively, the second traction element may have a distal end and a sidewall having at least one of a generally circular cross-section, a generally oval cross-section, and a generally polygonal cross-section including at least one of a triangular, square, rectangular, pentagonal, or hexagonal polygon.

[0009] In one embodiment, the second sole portion includes three second traction elements arranged in a generally triangular pattern proximate a first metatarsal region of a foot of a wearer of the footwear article. The three second traction elements arranged in a generally triangular pattern may have generally the same height, or may have different heights. The second sole portion may also include a fourth second traction element positioned in a medial forefoot region of a foot of the wearer of the footwear article.

[0010] The second sole portion can extend from the medial side edge of the sole plate to the central region of the sole plate, and the first sole portion can extend from the lateral side edge of the sole plate to the central region of the sole plate proximate at least one of the midfoot region of the sole plate, the forefoot region of the sole plate, and the metatarsal region of the foot of the wearer of the article of footwear. In one embodiment, the second sole portion extends from the medial side edge to the central region over a maximum of between about 50% and about 80% of the width of the sole plate. In one embodiment, the second sole portion includes: a first edge proximate the edge of the sole plate, a second edge extending from the edge of the sole plate to the central region of the sole plate, and a third edge extending from the edge of the sole plate to the central region of the sole plate, wherein the second edge and the third edge converge and meet in the central region of the sole plate.

[0011] In one embodiment, the first sole portion and the second sole portion are separated by one or more flexion grooves. In one embodiment, the first sole portion includes a first material, or is mainly composed of a first material, and the second sole portion includes a second material different from the first material, or is mainly composed of a second material different from the first material. The first material and / or the second material may include nylon and / or thermoplastic polyurethane (TPU), or are mainly composed of nylon and / or thermoplastic polyurethane (TPU). The first sole portion can be bonded to the second sole portion, co-molded with the second sole portion, mechanically attached to the second sole portion, or otherwise removably or permanently attached to the second sole portion. In one embodiment, one, some, or all of the first and / or second traction elements can include a metal portion and, for example, a metal distal end portion. The metal can include any suitable metal, such as, but not limited to, aluminum or steel. In one embodiment, at least one or more of the first and second traction elements have a metal distal end portion, and at least one or more of the first and second traction elements have a TPU distal end portion. In one embodiment, each of the first and second traction elements has a TPU distal end portion.

[0012] In one embodiment, at least one of the first sole portion and the second sole portion further comprises at least one of a tread pattern and a plurality of third traction elements. The third traction element may, for example, comprise raised extensions connected by a plurality of interconnected elongated elements. In one embodiment, at least one of the first sole portion and the second sole portion further comprises a structural support element, wherein the structural support element comprises, for example, a plurality of interconnected elongated elements.

[0013] Another aspect of the present invention includes an article of footwear including an upper and a sole, the sole including a sole plate including a lower surface adapted for ground contact. The lower surface of the sole plate can include a first sole portion having a plurality of first traction elements and a second sole portion having a plurality of second traction elements, the first traction elements having a distal end and a sidewall including a plurality of extensions extending from a central core, the second traction elements having at least one geometric feature that differs in at least one aspect from a corresponding geometric feature of the first traction elements.

[0014] In one embodiment, the upper includes a first upper portion having a first surface texture and a second upper portion having a second surface texture. The first surface texture may, for example, include a plurality of generally evenly distributed indentations (e.g., oval, circular, or polygonal indentations), while the second surface texture may include, for example, a plurality of generally parallel ridges. The ridges may, in one embodiment, be oriented at an angle of between about 30° and about 60° to the longitudinal axis of the article of footwear, and, for example, be oriented at an angle of about 45° to the longitudinal axis of the article of footwear. The second surface texture can extend over any suitable area of ​​the shoe upper, and, for example, can extend over the medial forefoot portion of the upper.

[0015] At least one of the first upper portion and the second upper portion can include a multilayer material, or be primarily composed of a multilayer material. The multilayer material can, for example, include a first material layer near the inside of the article of footwear, a second material layer near the outside of the article of footwear, and a third material layer positioned between the first material layer and the second material layer, the third material layer including a foam material, or being primarily composed of a foam material. The third material layer can include a material layer having a plurality of substantially evenly distributed holes extending through it, the holes having at least one of an oval, circular, or polygonal cross section. In one embodiment, at least a portion of the upper near the midfoot region of the article of footwear also includes at least one support structure on its outer surface, the support structure being composed of a fourth layer of material. In one embodiment, the multilayer material extends over at least a portion of the medial midfoot region, the forefoot region, and the lateral midfoot region of the article of footwear.

[0016] Another aspect of the present invention includes an article of footwear including an upper and a sole including a sole plate having a lower surface adapted for ground contact, the lower surface including a first sole portion having a plurality of first traction elements, the first traction elements having a distal end and a sidewall having a plurality of extensions extending from a central core. The lower surface also includes a second sole portion having a plurality of second traction elements having a distal end and a sidewall having a generally circular or hexagonal cross-section, wherein (i) the second sole portion extends over a medial portion of the lower surface of the sole plate proximate at least one of a midfoot region and a forefoot region of the sole plate, (ii) the second sole portion includes three second traction elements arranged in a generally triangular pattern proximate a first metatarsal region of a wearer's foot, and a fourth second traction element positioned in the medial forefoot region of the wearer's foot, and (iii) the first sole portion includes, or is primarily composed of, a first material, and the second sole portion includes, or is primarily composed of a second material different from the first material.

[0017] Yet another aspect of the present invention includes an article of footwear comprising an upper and a sole, the sole comprising a sole plate having a lower surface adapted for ground contact. The lower surface comprises a first sole portion having a plurality of first traction elements, the first traction elements having a distal end and a sidewall having a plurality of extensions extending from a central core. The lower surface also comprises a second sole portion having a plurality of second traction elements, the second traction elements having a distal end and a sidewall having a plurality of extensions extending from the central core, wherein (i) the second sole portion extends over a medial portion of the lower surface of the sole plate proximate at least one of a midfoot region and a forefoot region of the sole plate, (ii) the first sole portion comprises, or consists essentially of, a first material and the second sole portion comprises, or consists essentially of, a second material different from the first material, (iii) the orientation of at least one first traction element in a first region of the first sole portion is different from the orientation of at least one first traction element in a second region of the first sole portion, and (iv) the second sole portion further comprises a plurality of third traction elements.

[0018] These and other objects, together with advantages and features of the invention disclosed herein, will become more apparent by reference to the following description, drawings and claims. In addition, it should be understood that the features of the various embodiments described herein are not mutually exclusive and can exist in various combinations and arrangements. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In the drawings, similar reference numerals generally refer to the same parts throughout the different views. Likewise, the drawings are not necessarily drawn to scale, but rather emphasis is generally placed on illustrating the principles of the invention. In the following description, various embodiments of the invention are described with reference to the following drawings, in which:

[0020] Figure 1 is a flow chart of a method for designing at least a portion of a sole of a user-customized article of footwear according to one embodiment of the present invention;

[0021] Figure 2 is a schematic diagram of a system for acquiring experimental data representing performance characteristics of an athlete according to one embodiment of the present invention;

[0022] Figure 3 is a schematic perspective view of an article of footwear according to one embodiment of the present invention;

[0023] Figure 4A is a side view of a coordination system for an article of footwear according to one embodiment of the present invention;

[0024] Figure 4Bis a side view of another coordination system for an article of footwear according to one embodiment of the present invention;

[0025] Figure 5A is a plan view of a pressure sensing insole for an article of footwear according to one embodiment of the present invention;

[0026] Figure 5B is a plan view of another pressure sensing insole for an article of footwear according to one embodiment of the present invention;

[0027] Fig. 6A is a schematic diagram of pressure distribution for a foot of an athlete experiencing initial heel-strike ground contact during a running motion according to one embodiment of the present invention;

[0028] Figure 6B It is for the toe-off phase of running. Fig. 6A Schematic diagram of pressure distribution of an athlete's foot;

[0029] Figure 6C It is for those who are running during the toe-off phase of the running motion when running around the corner of the track. Fig. 6A Schematic diagram of pressure distribution of the left and right feet of an athlete;

[0030] Fig. 7A is a schematic diagram of pressure distribution for a foot of an athlete experiencing ground contact at an initial mid-foot strike during a running motion according to one embodiment of the present invention;

[0031] Figure 7B is a schematic diagram of pressure distribution for the athlete's foot of FIG. 7 undergoing the toe-off phase of the running motion;

[0032] Figure 7C It is for those who are running during the toe-off phase of the running motion when running around the corner of the track. Fig. 7A Schematic diagram of pressure distribution of the left and right feet of an athlete;

[0033] Fig. 8A is a schematic diagram of pressure distribution for a foot of another athlete experiencing ground contact at an initial midfoot strike during a running motion according to one embodiment of the present invention;

[0034] Figure 8B It is for the toe-off phase of running. Fig. 8A Schematic diagram of pressure distribution of an athlete's foot;

[0035] Figure 8C It is for those who are running during the toe-off phase of the running motion when running around the corner of the track. Fig. 8ASchematic diagram of pressure distribution of the left and right feet of an athlete;

[0036] Fig. 9A is a schematic diagram of pressure distribution for a foot of another athlete undergoing initial forefoot strike ground contact during a running motion according to one embodiment of the present invention;

[0037] Fig. 9B It is for the toe-off phase of running. Fig. 9A Schematic diagram of pressure distribution of an athlete's foot;

[0038] Fig. 9C It is for running around the corner of the track during the toe-off phase of the running movement. Fig. 9A Schematic diagram of pressure distribution of the left and right feet of an athlete;

[0039] Fig. 10A is a schematic diagram of pressure data measurement and pressure center calculation for an athlete who is experiencing a heel-strike ground contact phase of a running motion according to one embodiment of the present invention;

[0040] Fig. 10B is a schematic diagram of pressure data measurement values ​​and center of pressure data for an athlete who is experiencing a ground contact phase of a mid-foot landing in a running motion according to an embodiment of the present invention;

[0041] Fig. 10C is a schematic diagram of pressure data measurements and center of pressure data for another athlete who is experiencing a ground contact phase of a mid-foot strike in a running motion according to an embodiment of the present invention;

[0042] Fig. 10D is a schematic diagram of pressure data measurements and center of pressure data for another athlete who is experiencing a forefoot landing ground contact phase of a running motion according to one embodiment of the present invention;

[0043] Fig.11A is a graph of force measurements between an article of footwear and the ground during a ground contact phase of a running motion for a heel-strike running style according to one embodiment of the present invention;

[0044] Fig. 11B is a graph of force measurements between an article of footwear and the ground during a ground contact phase of a running motion for a midfoot strike running style according to one embodiment of the present invention;

[0045] Fig. 12Ais a schematic representation of pressure measurements on a plurality of pressure sensors in an insole of an article of footwear during an initial heel strike ground contact phase of a running motion in accordance with one embodiment of the present invention;

[0046] Fig. 12B During the mid-ground contact phase of running Fig. 12A Schematic representation of pressure measurements in the inner bottom of;

[0047] Fig. 12C During the toe-off phase of running Fig. 12A Schematic representation of pressure measurements in the inner bottom of;

[0048] Fig.13A is a schematic diagram of both force and local pressure data during the initial heel strike ground contact phase of a running motion according to one embodiment of the present invention;

[0049] Fig. 13B During the ground contact phase of running Fig.13A Schematic diagram of both force and local pressure data of a shoe;

[0050] Fig. 13C During the toe-off phase of running Fig.13A Schematic diagram of both force and local pressure data of a shoe;

[0051] Fig.14A is a schematic diagram of pressure and distribution performance metric data during the initial heel strike ground contact phase of a running motion according to one embodiment of the present invention;

[0052] Fig. 14B During the ground contact phase of running Fig.14A Schematic diagram of both pressure and distributed performance metric data of a shoe;

[0053] Fig. 14C During toe-off during running Fig.14A Schematic diagram of both pressure and distributed performance metric data of a shoe;

[0054] Fig.15A yes Fig.14A Schematic diagram of distributed performance measurement data;

[0055] Fig. 15B yes Fig. 14B Schematic diagram of distributed performance measurement data;

[0056] Fig. 15C yes Fig. 14C Schematic diagram of distributed performance measurement data;

[0057] Fig.16A According to an embodiment of the present invention FIG. 14A to FIG. 14C A schematic diagram of the combined distributed performance measurement data;

[0058] Fig. 16B Is based on Fig.16A A schematic plan view of a structural characteristic of an outsole for an article of footwear and performance metric data;

[0059] Fig. 16C Is based on Fig.16A a schematic plan view of another outsole for an article of footwear that provides structural characteristics of performance metric data;

[0060] FIG. 17A to FIG. 17B are plan and side views of a traction element for an outsole element of an article of footwear according to one embodiment of the present invention;

[0061] FIG. 17C to FIG. 17D are plan and side views of another traction element for an outsole element of an article of footwear according to one embodiment of the present invention;

[0062] FIG. 17E to FIG. 17F are plan and side views of another traction element for an outsole element of an article of footwear according to one embodiment of the present invention;

[0063] FIG. 17G to FIG. 17H are plan and side views of another traction element for an outsole element of an article of footwear according to one embodiment of the present invention;

[0064] FIG. 17I to FIG. 17J are plan and side views of another traction element for an outsole element of an article of footwear according to one embodiment of the present invention;

[0065] Figures 17K to 17L are plan and side views of another traction element for an outsole element of an article of footwear according to one embodiment of the present invention;

[0066] FIG. 17M to FIG. 17N are plan and side views of another traction element for an outsole element of an article of footwear according to one embodiment of the present invention;

[0067] Figures 17O to 17P are plan and side views of another traction element for an outsole element of an article of footwear according to one embodiment of the present invention;

[0068] Fig.18 is a perspective view of an outsole element for an article of footwear having a plurality of traction elements thereon according to one embodiment of the present invention;

[0069] Fig.19Ais a schematic representation of the center of a pressure vector for a foot of an athlete experiencing a heel strike ground contact phase of a running motion in accordance with one embodiment of the present invention;

[0070] Fig.19B is a graph with example data representing pressure at multiple locations along the center of the pressure vector Fig.19A A schematic plan view of the center of the pressure vector;

[0071] Fig. 20A is a schematic representation of the center of a pressure vector for a foot of an athlete experiencing a mid-foot strike ground contact phase of a running motion according to one embodiment of the present invention;

[0072] Fig. 20B is a graph with example data representing pressure at multiple locations along the center of the pressure vector Fig. 20A A schematic plan view of the center of the pressure vector;

[0073] Fig.21A is a schematic representation of the center of a pressure vector for a foot of an athlete experiencing a forefoot strike ground contact phase of a running motion in accordance with one embodiment of the present invention;

[0074] Fig. 21B is a graph with example data representing pressure at multiple locations along the center of the pressure vector Fig.21A A schematic plan view of the center of the pressure vector;

[0075] Fig.22A According to an embodiment of the present invention, Fig.17A A schematic plan view of the distribution of the mesh parts of the foot;

[0076] Fig. 22B According to an embodiment of the present invention, Fig.17A A schematic plan view of another distribution of the mesh portion of the foot;

[0077] Fig.23A is a schematic representation of a method for developing structural characteristics of an article of footwear based on performance metric information using a circle filling analysis technique in accordance with one embodiment of the present invention;

[0078] Fig. 23B is a schematic representation of a method for developing structural characteristics of an article of footwear based on performance metric information using a Delaunay triangulation analysis technique in accordance with one embodiment of the present invention;

[0079] Fig.23Cis a schematic representation of a method for developing structural characteristics of an article of footwear based on performance metric information using Voronoi diagrams analysis techniques according to one embodiment of the present invention;

[0080] FIG. 24A to FIG. 24C is a plan view of an outsole plate of an article of footwear based on measured performance data of a single athlete but under different sets of selection criteria according to one embodiment of the present invention;

[0081] FIG. 25A to FIG. 25E is a plan view of another outsole plate for an article of footwear based on measured performance data of a single athlete but under a different set of selection criteria according to an embodiment of the present invention;

[0082] FIG. 26A to FIG. 26B is a plan view of an outsole plate of an article of footwear based on first and second athlete measured performance data analyzed using the same selection criteria according to one embodiment of the present invention;

[0083] Fig. 27 is a side view of an outsole plate for a shoe for an athlete including a base element for insertable spikes according to one embodiment of the present invention;

[0084] Fig.28A and Fig.28B is a plan view of an outsole plate for a left shoe and a right shoe of an athlete based on performance data measured while running around a corner portion of a track according to one embodiment of the present invention;

[0085] Figure 29A and Fig.29B is a plan view of an outsole plate for a left shoe and a right shoe of another athlete based on performance data measured while running around a corner portion of a track according to one embodiment of the present invention;

[0086] Fig. 30A and Fig. 30B 29A and 29B are based on performance data measured while running along a straight portion of a running track according to one embodiment of the present invention. Fig.29B A plan view of the outer sole plate of the left shoe and the right shoe of the athlete;

[0087] Fig.31A and Fig.31B yes Fig. 30A and Fig. 30B A perspective view of an outer bottom plate;

[0088] Fig.32A is a side view of a midsole for an article of footwear according to one embodiment of the present invention;

[0089] Fig.32B yes Fig.32A A plan view of the midsole;

[0090] Fig.32C yes Fig.32A A perspective view of the midsole;

[0091] Fig.32D Is used for design Fig.32A A perspective view of the mathematical grid of the midsole;

[0092] Fig.33 is a schematic perspective view of a scalar hexahedral pressure map distribution for calculating a mid-bottom mesh according to one embodiment of the present invention;

[0093] Fig.34A is a lateral side view of another midsole for an article of footwear according to one embodiment of the present invention;

[0094] Fig.34B yes Fig.34A A medial side view of the midsole;

[0095] Fig.34C yes Fig.34A A top view of the midsole;

[0096] Fig.34D yes Fig.34A A bottom view of the midsole;

[0097] Fig.34E yes Fig.34A A perspective view of the midsole;

[0098] Fig.34F yes Fig.34A Another perspective view of the midsole;

[0099] Fig.35 is a perspective bottom view of another midsole for an article of footwear according to one embodiment of the present invention;

[0100] Fig.36A is a lateral side view of an article of footwear according to one embodiment of the present invention;

[0101] Fig.36B yes Fig.36A a medial side view of the article of footwear;

[0102] Fig.36C yes Fig.36A a top view of an article of footwear;

[0103] Fig.36D yes Fig.36A a bottom view of the article of footwear;

[0104] Fig.36E yes Fig.36A a perspective view of an article of footwear;

[0105] Fig.37A is a bottom view of a midsole for an article of footwear having hexagonal cells according to one embodiment of the present invention;

[0106] Fig.37B yes Fig.37A A side view of the midsole;

[0107] Fig.37C yes Fig.37A A perspective view of the midsole;

[0108] Fig.37D Has an indentation on the bottom surface Fig.37A A perspective view of the midsole;

[0109] Fig.38A is a bottom view of another midsole for an article of footwear according to one embodiment of the present invention;

[0110] Fig.38B yes Fig.38A A perspective view of the midsole;

[0111] Fig.39A is a bottom view of another midsole for an article of footwear according to one embodiment of the present invention;

[0112] Fig.39B yes Fig.39A A side view of the midsole;

[0113] Fig.40A is a bottom view of a midsole for an article of footwear having circular units according to one embodiment of the present invention;

[0114] Fig.40B yes Fig.40A A side view of the midsole;

[0115] Fig.41A is a bottom view of another midsole for an article of footwear having circular units according to one embodiment of the present invention;

[0116] Fig.41B yes Fig.41A A side view of the midsole;

[0117] Fig.42 is a perspective view of a midsole for an article of footwear having circular units and a top plate according to one embodiment of the present invention;

[0118] Fig.43A is a bottom view of another midsole for an article of footwear according to one embodiment of the present invention;

[0119] Fig.43B yes Fig.43A A side view of the midsole;

[0120] Fig.44 is a perspective view of another midsole for an article of footwear according to one embodiment of the present invention;

[0121] Fig.45 is a top view of a midsole for an article of footwear that conforms to the shape of a foot according to one embodiment of the present invention;

[0122] Fig.46 is a perspective view of a midsole for an article of footwear having triangular cells according to one embodiment of the present invention;

[0123] Fig.47A is a perspective view of another midsole for an article of footwear having triangular cells according to one embodiment of the present invention;

[0124] Fig.47B yes Fig.47A A bottom view of the midsole;

[0125] Fig.48 is a perspective view of another midsole for an article of footwear having triangular cells according to one embodiment of the present invention;

[0126] Fig.49 is a perspective view of another midsole for an article of footwear having triangular cells according to one embodiment of the present invention;

[0127] Fig.50 is a perspective view of another midsole for an article of footwear having triangular cells according to one embodiment of the present invention;

[0128] Fig.51A is a bottom view of a midsole for an article of footwear having spherical-based cells according to one embodiment of the present invention;

[0129] Fig.51B yes Fig.51A A side view of the midsole;

[0130] Fig.51C yes Fig.51A A perspective view of the midsole;

[0131] Fig.51D yes Fig.51A A top view of the midsole;

[0132] Fig.52 is a perspective view of another midsole for an article of footwear having sphere-based cells according to one embodiment of the present invention;

[0133] Fig.53 is a perspective view of a warped array structure according to one embodiment of the present invention;

[0134] Fig.54A is a side view of a foot shape formed using foot scan data according to one embodiment of the present invention;

[0135] Fig.54B yes Fig.54A perspective view of the foot shape;

[0136] Fig.55A is a side view of another foot shape formed using foot scan data according to one embodiment of the present invention;

[0137] Fig.55B yes Fig.55A perspective view of the foot shape;

[0138] Fig.56A is a top view of another foot shape formed using foot scan data according to one embodiment of the present invention;

[0139] Fig.56B yes Fig.56A Side view of the foot shape;

[0140] Fig.57 is a perspective view of a coupling system for a midsole of an article of footwear according to one embodiment of the present invention;

[0141] Fig.58A According to one embodiment of the present invention, Fig.57 A perspective view of a midsole for an article of footwear using a connection system;

[0142] Fig.58B yes Fig.58A A bottom view of the midsole;

[0143] Fig.58C A slightly extended connection Fig.58A Another bottom view of the midsole;

[0144] Fig.58D yes Fig.58C A side view of the midsole;

[0145] Fig.58E The angles of some joints have been modified. Fig.58C A side view of the midsole;

[0146] FIG. 59A to FIG. 59D is a perspective view of various outsole plates having traction elements with cleats according to one embodiment of the present invention;

[0147] Fig.59E is a bottom view of another outsole plate having traction elements with cleats according to one embodiment of the present invention;

[0148] Fig.60Ais a bottom view of an outsole plate having traction elements with cleats and flex grooves according to one embodiment of the present invention;

[0149] FIG. 60B to FIG. 60E is a perspective view of various outsole plates having traction elements with cleats and flex grooves according to one embodiment of the present invention;

[0150] Fig.61A is a schematic plan view of an outsole plate having a mapping structure superimposed thereon according to one embodiment of the present invention;

[0151] Fig.61B is with Fig.61A an outer sole plate with cleats having cleats in positions corresponding to the mapping structure;

[0152] FIG. 62A to FIG. 62D is a schematic plan view of an outsole plate having cleated traction elements positioned and oriented based on various processing algorithms for processing athlete data in accordance with one embodiment of the present invention;

[0153] Figures 63A to 63G Several steps are shown for processing athlete data to produce a customized outsole plate having cleated traction elements in accordance with one embodiment of the present invention;

[0154] Fig.64A is a top view of a studded sole plate having hollow studded traction elements according to one embodiment of the present invention;

[0155] Fig.64B yes Fig.64A A bottom view of a sole plate with cleats;

[0156] Fig.65 is a perspective view of an article of footwear including an upper having ground-contacting elements positioned within and extending through the upper according to one embodiment of the present invention.

[0157] 66A is a top view of an article of footwear having a sole plate with cleats according to one embodiment of the present invention;

[0158] Fig.66B is a lateral side view of the article of footwear of FIG66A ;

[0159] Fig.66C is a bottom view of the sole plate of the article of footwear of FIG. 66A ;

[0160] Fig.66D is a lateral side view of a sole plate of the article of footwear of FIG. 66A ;

[0161] Fig.67Ais a top view of an article of footwear having a sole plate with cleats according to one embodiment of the present invention;

[0162] Fig.67B yes Fig.67A a lateral side view of the article of footwear;

[0163] Fig.67C yes Fig.67A a bottom view of a sole plate of the article of footwear;

[0164] Fig.67D yes Fig.67A a lateral side view of a sole plate of the article of footwear; and

[0165] Fig.67E yes Fig.67A A medial side view of a sole plate of an article of footwear. DETAILED DESCRIPTION

[0166] The invention described herein generally relates to methods and systems for designing and manufacturing articles of footwear, clothing and / or athletic equipment (and, for example, customized articles of footwear) or one or more elements thereof, and customized or non-customized footwear, clothing and / or athletic equipment manufactured using such methods and systems. More specifically, in one embodiment, the present invention relates to footwear or footwear elements that are specifically customized to meet one or more needs of an athlete, thereby improving the athlete's performance during a sporting activity, and / or improving the comfort of the article of footwear when worn.

[0167] Customization of footwear may benefit a variety of populations, such as, but not limited to, athletes (who desire improved performance through their footwear), persons with medical conditions (who seek footwear that provides better support and / or treatment for their particular condition), or recreational runners or walkers who seek footwear that has both improved and customized performance benefits and / or a customized aesthetic appearance (including, for example, decorative elements, trademarks, names, etc.). While the description herein generally relates to customizing footwear to provide improved performance characteristics for athletes, it should be noted that the methods, algorithms, processes, and structures described herein are equally applicable to customizing elements for any purpose and for any user.

[0168] Customization of footwear or elements thereof may include various factors such as, but not limited to, customized size and shape to better fit the wearer, customized cushioning to meet one or more specific characteristics of the athlete's movement, customized traction elements on the outsole of the footwear (or ground-contacting midsole) to provide improved grip during one or more specific athletic activities, customized materials (e.g., specific materials used, material weight, material properties, etc.). Customization may also specifically include forming footwear and footwear elements to meet the aesthetic and / or performance needs of an athlete's personal preferences.

[0169] The invention described herein allows for customization of entire articles of footwear (e.g., shoes, flip-flops, sandals, socks, athletic supports (such as compression support elements)) and / or customization of elements of articles of footwear for incorporation into finished products. Example footwear elements include, but are not limited to, customized elements for the outsole, midsole, and / or insole of a shoe, and / or placed within the outsole, midsole, and / or insole, such as elements inserted into or attached (e.g., by mechanical attachment, bonding, or other suitable attachment means) to the sole of a shoe at specific areas of the shoe (e.g., in the heel, midfoot, and / or forefoot areas).

[0170] The customization of footwear or footwear elements can be based on a variety of physical, performance (e.g., kinematic performance), and / or user preference characteristics associated with an individual or a group of individuals. For example, in addition to standard parameters such as shoe size, physical characteristics such as the shape of an individual's foot, including, for example, bone structure, callus distribution on the foot, injuries (both historical injuries and / or possible future injuries), ankle shape, range of motion, strength, toe shape, and preference for hosiery (e.g., socks, tights, or tights) or no hosiery, and / or straps worn with the footwear (e.g., ankle and / or foot support straps or straps) can all be taken into account when designing and manufacturing shoes that are specifically customized for a given wearer or a subgroup of wearers. Other parameters can include, or can be primarily composed of, breathability characteristics, perspiration characteristics, circulation considerations, and / or diabetic factors (such as, but not limited to, minimizing friction within the shoe).

[0171] Additional characteristics of an individual that are not directly associated with the foot can also have an impact on the individual's athletic performance, using customized footwear to potentially address limitations or disadvantages in the individual's mechanics and / or support forces in the individual's mechanics. Such characteristics that can affect the customization of footwear or clothing include, but are not limited to, the individual's height, weight, age, gender, bone structure, leg bone length (e.g., calf length and / or thigh length), overall level of physical fitness, medical history and / or medical requirements. Medical requirements that can be addressed by using customized footwear components can include elements such as structural supports for situations such as, but not limited to, problems related to the muscles, tendons, bones and / or skin of the foot, such as flat feet, fallen arches, hammer toes, gout, edema (swelling), long and short feet, amputations, big toe deformities or other foot deformities, Morton's neuroma, problems related to leg or knee alignment, and / or planar fasciitis, or cushioned and substantially frictionless supports for diabetes.

[0172] Footwear may be customized to address performance aspects of a specific athlete or subgroup of athletes, such as, but not limited to, foot strike position (e.g., heel strike, midfoot strike, or forefoot strike during initial ground contact of the foot during the gait cycle or other athletic movement), step length, step frequency (i.e., cadence), pronation or supination of the foot at foot strike, pivoting of the foot during ground strike and toe-off, running style, running speed, circulation, breathability, and / or flexibility of one or more joints, where specific performance characteristics are supported or compensated for, if necessary, to improve the athlete's performance during athletic activity and / or improve the comfort of the footwear worn during athletic activity.

[0173] In addition, when customizing footwear for a specific athlete or athlete's subgroup, the performance requirements of specific sports activities can be taken into consideration. For example, depending on whether the runner is a sprinter or a long-distance runner, and / or whether the runner requires the traction element on the sole of the footwear to support running around a corner (for example, on a standard indoor or outdoor sports track) or whether it is mainly in a straight line (for example, during a road race or a jog), the traction requirement for the runner (such as, track runner, road runner or cross-country runner) can be different. The customization of footwear can also depend on weather and conditions under the feet when the athlete performs, for example, wet / dry conditions and / or soft / hard conditions under the feet require different traction requirements. In addition, different sports may require traction elements (for example, spikes, cleats or anti-skid columns, gripping elements and / or sole pattern patterns) of different shapes, sizes and / or configurations, for example, the cleats for soccer, American football, hockey, baseball, etc. all require different cleat types and configurations, and different positions in each of these sports may require different performance characteristics of traction elements.

[0174] Other athletic activities for which footwear can be customized include activities with a large number of cut-in type movements (e.g., basketball, baseball, softball, soccer, football, hockey, ice hockey, skating, speed skating, rugby, tennis, squash, racquetball, skateboarding, cycling, etc.), where individual skills and physical characteristics can vary greatly from person to person, and where specifically customized traction elements, support elements, and / or structural support areas can greatly improve individual performance in the sport. Other activities, such as jumping, crouching, kicking, throwing, turning, pivoting, etc., can also be considered in creating a unique combination of traction elements that enhance or support the performance characteristics of an activity and / or a specific athlete.

[0175] According to various embodiments of the present invention, customization of footwear for an athlete can be performed by utilizing an analytical tool to process input parameters specific to an athlete (or group of athletes) to generate a design including body elements specifically positioned and configured to meet the athlete's specific performance and physical characteristics. The design can then be manufactured to produce an article of footwear and / or footwear element specific to the athlete.

[0176] exist Figure 1 An example method for designing at least a portion of a sole of an article of footwear customized for an athlete is shown in . The method includes the steps of obtaining / determining 105 one or more input parameters related to the athlete, and analyzing 110 the input parameters to determine at least one performance metric of the user's foot. The at least one performance metric is then used to determine 115 one or more structural characteristics of at least a portion of a sole of the article of footwear for the athlete based on the performance metric, after which the customized sole portion can be manufactured 120, for example, by using additive / rapid manufacturing techniques, such as, but not limited to, rapid manufacturing methods (e.g., selective laser sintering).

[0177] In various embodiments, the input parameter(s) can include experimental performance data, measured biometric information, and / or selected user preferences and / or performance information. The input parameter(s) may be directly related to one or more characteristics of at least a portion of the user's foot, and / or include characteristics associated with the athlete's legs and / or upper body (such as height, weight, leg length, athletic ability, injuries, etc.), and / or related to the performance requirements of the sporting activity for which the customized shoe is intended.

[0178] In one embodiment of the invention, the input parameters used to design a custom shoe component include experimental data representing performance characteristics of the foot during at least a portion of a gait cycle or ground contact phase of other athletic activities. Figure 2An example system for acquiring experimental data is shown in . In this embodiment, an athlete 125 performs a sporting activity (e.g., track running) for which the shoe to be customized is intended, in an environment that includes a data collection device designed to capture and record data representing various performance characteristics of the athlete's 125 foot during the sporting activity. Figure 2 In the example of , the data acquisition device includes: a force plate 130, which is used to capture the force between the foot 135 of the athlete 125 and the ground 145; and an array of pressure sensors 140, which are located between the foot 135 and the ground 145. The pressure sensors 140 can be located in the insole placed within the shoe 150 of the athlete 125. In alternative embodiments, the pressure sensors 140 can be embedded in the midsole 155 of the shoe 150, or, located in or attached to the ground-contacting outsole 157 of the shoe 150. Alternatively or in addition, the pressure sensors or any other sensors utilized in the methods described herein can be located at any appropriate location on the athlete's foot, leg, and / or upper body. Figure 3 1 shows an example shoe 150 for athlete 125, where an example coordinate system 160 provides an orientation axis for the data capture system. The shoe includes an upper 158 and a sole (including an insole and outsole 157 and a midsole 155), where a foot receiving cavity 159 is defined by the upper 158 and the sole 152. The shoe 150 can be a slip-on type shoe or have a tightening / fastening mechanism such as, but not limited to, laces, hook and loop fasteners, zippers, cords, elastic elements, buttons, and / or buckles.

[0179] In one embodiment, the pressure sensor 140 forms part of a portable data capture system worn by the athlete 125 during the athletic activity, wherein the pressure sensor 140 is located within the shoe 150 and is coupled to a data capture system that can power the sensor, record data acquired from the sensor, and / or wirelessly transmit the data to a data processing system for analysis. In an alternative embodiment, the pressure data capture system may only record the pressure data during the athletic activity, and then transmit the data to the data processing system at a later time via a wireless or wired connection. In another alternative embodiment, the data processing system may be located within the portable data capture system.

[0180] In one embodiment, pressure sensor 140 includes a distribution of individual sensor elements 180 arranged in an array for placement between the sole of foot 135 and ground surface 140 (e.g., within insole 187 placed within shoe 150 of athlete 125). Figure 5A and Figure 5B An example sensor array can be seen in Figure 5AAn array having two hundred and nineteen sensor elements 180 arranged in a regular distribution is shown, and Figure 5B An array is shown having fifty-nine sensor elements 180 arranged in a regular distribution. In alternative embodiments, any size sensor array may be utilized (e.g., 10, 20, 50, 99, 100, 200, 500, etc. sensor elements 180), with the sensor elements 180 arranged regularly or in an irregular pattern (e.g., very important / high impact areas contain more sensor elements 180). As discussed above, each sensor element 180 may form part of a portable data capture that includes components for powering the system, recording data from each pressure element 180, and / or transmitting the data for analysis.

[0181] In one embodiment, force plate 130 is embedded in, fixed to, or placed on ground surface 140, and the athlete runs on force plate 140 during data capture. In alternative embodiments, force sensors may be located on or in the sole of shoe 150 and may form part of a portable data capture system.

[0182] In one embodiment, data may be captured and processed using a single coordinate system associated with the outsole 155 of the shoe 150, the ground surface 145, the sole of the foot itself, or any other suitable element of the foot. Figure 4A An example embodiment with a single coordinate system 160 is shown in FIG. In alternative embodiments, multiple coordinate systems associated with various elements of the foot 135 and shoe 150 may be utilized. For example, Figure 4B A system is shown having a first coordinate system 160 associated with a forefoot 165 of a shoe 150 and a second coordinate system 170 associated with a heel portion 175 of the shoe 150. Utilizing multiple coordinate systems enables the collected data to be processed and oriented at several locations along the foot 135 relative to the sole of the foot 135 or any other suitable element of the foot, regardless of how the foot flexes during the ground contact phase of the gait cycle. In certain embodiments, this can allow for more accurate data processing and analysis relative to the performance metrics desired for a particular custom goal, however in certain embodiments such as Figure 4A The single axis system shown may be sufficient to provide accurate analysis results.

[0183] Figure 2The system allows for simultaneous measurement of both the pressure distribution on the sole of the foot 135 throughout the ground contact phase of the gait cycle and the force interaction between at least a portion of the sole of the foot and the ground surface during at least a portion of the ground contact phase of the gait cycle. In one embodiment, the pressure sensor 140 measures only the normal pressure between the ground 145 and the foot 135, while the force plate 130 measures the force between the foot 135 and the ground 140 in all three directions of the coordinate system 160, thereby allowing for the calculation of the magnitude and both vertical and horizontal directions of the force between the foot 135 and the ground 140 throughout the ground contact phase. Measuring both the normal pressure distribution and the force vector data on the sole of the foot 135 allows for the calculation of performance metrics to identify the magnitude of the force applied between the foot 135 and the ground 140 throughout the ground contact phase and the direction of this interaction at multiple locations on the foot 135.

[0184] In an alternative embodiment, pressure sensor 140 may measure pressure in all three directions (i.e., normal, rearward, and lateral) of a coordinate system associated with foot 135, thereby allowing directional data to be acquired without the need for separate three-dimensional force measurements. In another alternative embodiment, normal pressure distribution data on the sole of foot 135 may be combined with respect to time to produce directional vector data that represents the direction of the force between foot 135 and ground surface 140 throughout the ground contact phase, thereby again allowing directional data to be acquired without the need for a separate force plate.

[0185] exist 6A to 9C Example stress data for four different athletes can be seen in . More specifically, Fig. 6A , Fig. 7A , Fig. 8A and Fig. 9A shows pressure distribution data for four athletes near the point of initial contact with the ground during foot strike, Fig. 6A shows the pressure distribution in the area of ​​the heel (heel strike) of a first athlete for initial contact with the ground during straight running, Fig. 7A and Fig. 8A shows the pressure distribution in the area of ​​the mid-foot (mid-foot strike) of the second and third athletes for initial ground contact during straight-line running, and Fig. 9A 1 shows the pressure distribution for initial contact with the ground in the area of ​​the fourth athlete's front foot (front foot strike) during straight running. Similarly, Figure 6B , Figure 7B , Figure 8B and Fig. 9B The pressure distribution on the soles of four athletes' feet at the end of the foot strike event just before the foot leaves the ground (ie, before toe-off) during straight-line running is shown. Figure 6C , Figure 7C , Figure 8C and Fig. 9C Shown is the pressure distribution on both the left and right feet of four athletes prior to toe-off as they run around a corner on a standard 400 meter sports track. 6A to 9C The pressure distribution graph shows a contour plot of pressure (in kilopascals (kPa)) based on experimental pressure data obtained from an array of ninety-nine sensors embedded in the insole 190 of each athlete's shoe, with the (multiple) centers 195 of each shaded contour plot representing the location of the highest pressure perpendicular to the surface of the insole 190, and the unshaded portions 197 representing areas where no significant normal pressure was measured (e.g., because that portion of the foot was not in contact with the ground at that time).

[0186] As can be seen, the pressure distribution during the initial foot strike phase of ground contact differs significantly for different athletes, with the center of pressure being located in the heel region 200 for heel strikers, the center of pressure being distributed throughout the midfoot region 205 for midfoot strikers, and the center of pressure being located in the forefoot region 210 for forefoot strikers. Additionally, the maximum pressure readings at the center of pressure for athletes striking at the midfoot have a significantly lower maximum value than the maximum pressure readings measured for heel strikers and forefoot strikers, because the load at initial ground contact is distributed over a larger area for midfoot strikers than for heel and toe strikers.

[0187] While the pressure distribution during the toe-off phase is more similar, differences in pressure distribution between athletes can again be observed, with the center of pressure and pressure distribution being significantly different for different athletes. Figure 7B The athlete of shows the pressure peak value near the 4th toe area 215, other athletes do not observe this situation, and each athlete shows different pressure distributions around its metatarsal head area 220 (that is, the head of the metatarsal adjoining the phalanges). The result change at the metatarsal area is due to the shape and configuration difference of the metatarsal head of each athlete, such as the change of running style. As a result, it can be clearly seen that for different athletes, the interaction between foot and ground can be significantly different, and this depends on the physical characteristics of each athlete's running technique and the foot of each athlete, for example. This identification of the unique characteristics of the ground interaction for a given athlete can be measured and analyzed by appropriate algorithms to ensure that the wearer's shoes are optimized to enhance the performance of each athlete based on the input parameters of the athlete's own individuality.

[0188] exist Figure 6C , Figure 7C , Figure 8C and Fig. 9CIn the figure, other variation between pressure distribution can be seen, these figures show pressure distribution on the left foot and right foot of four athletes before toe-off when the athlete runs around a corner on a standard 400-meter sports track (in the counterclockwise direction of standard).As can be seen, the pressure distribution on the left foot and right foot of each athlete is not completely symmetrical, and the different ground interactions between the shoes on the ground and each foot are subject to the influence of the athlete's turning action.In addition, when the pressure distribution is not completely symmetrical, the force measurement value for each foot is significantly different, and the force is directed toward the outer edge of the bend (that is, on the inner foot, the force is directed toward the instep of the foot, and on the outer foot, the force is directed toward the outside of the foot).Allowing to customize between the left foot and the right foot to make up for this pressure difference and force distribution difference can be of benefit to the athlete in the situation of turning at high speed. In various embodiments, the methods and systems described herein can be used to provide customized footwear for any type of running track, such as, but not limited to, a standard 200 meter track or a 400 meter track and / or a track with any bank angle at turns and / or along straights.

[0189] exist FIG. 10A to FIG. 10D Example raw pressure measurement data can be seen in FIG, which shows pressure data (in kPa) for ninety-nine pressure sensor element insoles for four different athletes at the initial ground contact point. Fig. 10A Data for an athlete who lands on his heels is shown. Fig. 10B and Fig. 10C shows a dataset of two athletes landing mid-foot, and Fig. 10D Data for athletes who forefoot strike is shown. Also shown in each data set is the center of each athlete's pressure vector 189 during the entire process of the foot strike event.

[0190] exist Fig.11A and Fig. 11B Example force data obtained from the force plate 130 during the entire length of the foot strike event can be seen in FIG. Fig.11A shows force data for an athlete who is heel-strike, and Fig. 11BForce data for an athlete landing mid-foot is shown, in which the vertical axis represents the force measured on a given axis in Newtons (N) and the horizontal axis represents time (the time is normalized so that '0.0' represents initial ground contact and '100.0' represents toe-off). For each figure, the top graph with the vertical axis labeled "Force (N)" represents the vertical component of the force applied to the foot 135 by the ground 145 that is perpendicular to the ground (i.e., along the 'Z' axis in coordinate system 160), the middle graph with the vertical axis labeled "Force (N-Backward)" represents the horizontal component of the force applied to the foot 135 by the ground 145 that is parallel to the direction of travel (i.e., along the 'X' axis in coordinate system 160), and the lower graph with the vertical axis labeled "Force (N-Lateral)" represents the horizontal component of the force applied to the foot 135 by the ground 145 that is perpendicular to the direction of travel (i.e., the 'Y' axis in coordinate system 160). As can be seen, for each athlete, the forces between foot 135 and ground surface 145 vary significantly during the length of the foot strike event and are significantly different for heel-strike and mid-foot-strike running motions.

[0191] In one embodiment, rather than being embedded in or attached to a portion of the foot, a plurality of pressure sensors may be positioned on the ground, the sensors measuring the pressure exerted by the foot when it contacts an array of sensors located on the ground.

[0192] In various embodiments, the experimental data may include, in addition to Figure 2 The pressure and / or force data captured by the system is either in addition to or in lieu of Figure 2 The system can include sensors for measuring the following elements: such as, but not limited to, position, velocity, acceleration, rotation rate, rotational acceleration, shape change of at least a portion of the foot, friction, mass distribution, energy distribution, stress, strain, temperature, deformation, moisture content, and / or the time after the event occurs. In addition to measuring the force / pressure vector associated with the interaction between the foot 135 and the ground 140 or replacing the force / pressure vector associated with the interaction between the foot 135 and the ground 140, such sensors can be used to measure the following events: such as, ground contact time, initial foot landing position, toe-off position, pronation / supination characteristics, and / or shape and / or position changes of at least a portion of the user's foot during at least a portion of the ground contact phase of the gait cycle or other sports. An example portable system suitable for identifying parameters associated with the performance of athletes during sports activities (such as, but not limited to, foot landing position) is described in U.S. Patent Publication No. 2013-0041617A1, and its entire disclosure is incorporated herein by reference.

[0193] The various sensors used with the methods and systems described herein may include or consist essentially of an accelerometer, a pressure sensor, a force sensor, an optical stress / strain sensor, a temperature sensor, a chemical sensor, a global positioning system, a piezoelectric sensor, a rotational position sensor, a magnetometer, a gyroscopic sensor, a heart rate sensor, and / or a goniometer. In various embodiments of the present invention, other sensors may also be utilized, such as, but not limited to, an electrocardiogram sensor, a skin resistance graph sensor, an electroencephalograph sensor, an electromyograph sensor, a feedback thermometer sensor, a photoplethysmograph sensor, and / or a spirograph sensor. For example, any suitable sensor suitable for measuring skin conductance factors (e.g., a galvanic skin response (GSR), a galvanic skin response (EDR), a psychogalvanic skin reflex (PGR), a skin conductance response (SCR), or a skin conductance level (SCL) sensor) may be used to measure parameters related to moisture in the human body.

[0194] For example, one embodiment of the present invention may include one or more shear stress sensors on the sole of a shoe, with the distributed shear stress measurements providing directional data indicative of the direction of the interaction between the foot 135 and the ground 140. Stress and / or strain measurements on the sole of the shoe may also be used to determine the flexion of the shoe and foot during a foot strike event. This data may be used in addition to or in lieu of pressure and / or force data to determine the magnitude and direction of the interaction between the foot 135 and the ground 140 during a foot strike event.

[0195] The above list of measurement options is not limiting, and in various embodiments of the present invention, any appropriate sensor or combination of sensors may be utilized to capture data representing the performance of the athlete 125 while performing a sporting activity, which data is used as an input parameter for analyzing the athlete's specific performance characteristics to allow for the design of customized footwear elements. More specifically, each of the performance characteristics and data sets identified by the above measurement options may vary significantly depending on the athlete's specific athletic skills and physical characteristics, and therefore, measurement of any of these elements may be extremely helpful in identifying performance metrics that may be used to customize shoes for a particular athlete.

[0196] The data collected for any experimental measurement described herein can be sampled according to any appropriate rate, but generally speaking, according to the rate that is enough to fully capture a series of measured values ​​in the ground contact portion of the whole gait cycle, to allow customization for the accuracy required by the athlete. In each example, the sampling rate of about 10Hz, 20Hz, 50Hz, 100Hz or 200Hz can be utilized, yet, if appropriate, different rates and larger or smaller rates can also be used. In one embodiment, the mean value of the collected data can be asked to any appropriate number of foot landing events, so that the average representation of the performance characteristics of the athlete can be provided. In one embodiment, any appropriate filtering technique (for example, high-pass, low-pass and / or Butterworth (Butterworth) filtering) can be used to filter the raw data, to filter out unnecessary information and to ensure that only suitable data are analyzed in the custom algorithm. For example, in one embodiment, high-pass filtering can be applied to the result, to filter out the data below the size set, and only allow the data of higher size to be processed in the custom design algorithm. Additionally, various forms of data smoothing may be applied to the data to provide further filtering of the results (eg, where the arrangement of traction elements needs to be configured to control for differences in size, shape, orientation, etc. between adjacent traction elements).

[0197] In one embodiment, in addition to or in lieu of the experimental data described herein, input parameters for the custom design process may include one or more physical characteristics of the athlete's 125 foot 135. These physical characteristics may include, but are not limited to, physiological structural characteristics of the foot and / or body, such as, at least one of shape, size, wear pattern, injury profile, bone structure, ligament structure, sweat gland distribution, moisture content, circulation arrangement or measurement, muscle activity, friction measurement, blood pressure, heart rate, volume change, hydration level, perspiration level, ligament structure, toe shape and / or distribution (e.g., length and relative position of toes, relative position of metatarsal heads, etc.), arch shape, and / or heel shape (e.g., calcaneal shape). For example, these physical characteristics may be manually measured, scanned, and recorded by an automated 2D or 3D scanning device, or determined by 3D processing of a photographic image of the foot 135.

[0198] exist FIG. 12A to FIG. 16AAn example method for analyzing input parameters, and more specifically, input parameters such as normal pressure distribution data and three component data, to produce performance metrics to be used in the customization of footwear can be seen in . In this embodiment, the pressure data and force data can be processed and multiplied to form a vector (having both magnitude and direction) representing the interaction between the ground 145 and the foot 135 over the entire plantar area of ​​the foot, and the resulting vector is used to identify the location and distribution of structural characteristics of the footwear that best meets the requirements of the individual athlete.

[0199] Figures 12A to 12C Shows the use of Figure 5B A schematic representation of the pressure data measured by the pressure sensor element 180 of the inner sole 187, Fig. 12A shows pressure measurements at or near initial ground contact for a heel-strike athlete, Fig. 12B shows pressure measurements for the athlete near the midpoint of the ground contact phase, and Fig. 12C 1 shows the pressure measurements for the athlete just before toe-off. The magnitude of the pressure perpendicular to the surface of the insole 187 is represented by the size of the shaded circles 225 placed on each sensor element 180, with larger circles representing greater pressure and smaller circles representing less pressure. As can be seen, the measurements show that during the entire ground contact event, the pressure moves from the heel 190 near the insole (at initial heel strike), through the midfoot area 205, and forward to the forefoot area 207 (at toe-off). As discussed above, the specific changes in pressure magnitude and distribution may vary greatly for different athletes. Although in FIG. 12A to FIG. 12C Only three time steps within a foot strike event are shown in FIG, but any suitable number of time steps may be used in the overall analysis of the input parameters depending on the acquisition rate of the measurement device utilized and the requirements of the processing algorithm utilized.

[0200] FIG. 13A to FIG. 13C Shown with FIG. 12A to FIG. 12C 145 with the addition of a horizontal component 230 of the force applied by the foot 135 on the ground surface 145 as measured by the force plate 140 at that time (the horizontal component of the force is represented by the vector 230 showing the direction of the horizontal component of the force, with the relative magnitude of the force represented by the length of the vector). As can be seen, for the heel-strike ground contact represented, the foot 135 applies a relatively large force generally in the direction of travel of the foot at initial foot strike, a relatively small horizontal force during the middle of the foot strike event, and a relatively large force generally rearwardly in a direction opposite to the direction of travel at toe-off.

[0201] The pressure and force data can then be processed to determine the appropriate performance metric to be used for customization. In this embodiment, the pressure data at each point is multiplied by the force vector at that time to produce a vector representing the foot / ground interaction at each point on the sole of the foot at each time step within the foot strike event to obtain a performance metric vector (PMV) according to the following formula:

[0202] PMV 在各个时间步骤处 ={C1×pressure×force} 在各个时间步骤处 Function

[0203] where C1 is the appropriate multiplication / adjustment factor.

[0204] FIG. 14A to FIG. 14C Shows the use of FIG. 13A to FIG. 13C The performance metric vector 235 is calculated based on the data, the pressure data at each point is represented by a circle 225, and the length of the vector 235 represents the magnitude of the vector. FIG. 15A to FIG. 15C The performance metric vector 235 is shown at three illustrated time steps, with all other information removed. Once the performance metric vector 235 has been calculated for each time step, in one embodiment, the final performance metric at each location on the sole of the foot can be determined by summing the individual performance metric vectors at each location for each time step according to the following function:

[0205] PMV 总计 =[C2×PMV{t 1,t2 ,t3,...t N}] and

[0206] where C2 is the appropriate multiplication / adjustment factor.

[0207] exist Fig.16A The resulting distribution of performance metric vectors (PMVs) can be seen in , with each vector 240 representing the sum of the performance metric vectors at each time step at that location on the sole of the foot. These vectors 240 provide an indication of the magnitude and direction of the horizontal component of the interaction between the ground 145 and the foot 135 during the course of the ground contact event.

[0208] In various embodiments, correction factors C1 and C2 may be used to weight and / or adjust the results to ensure that the resulting performance metric vectors represent the performance characteristics that are important in the analysis. For example, correction factors may be used to ensure that the results at various locations focus on the magnitude and direction of the vector during peak loads on the sole of the foot at that location, while filtering out magnitude and direction results during low load periods of a touchdown event. In alternative embodiments, no correction factors are required.

[0209] Once the performance metric vector has been generated, the information can be utilized to determine structural characteristics of at least a portion of a sole of an article of footwear for a user based on the performance metric. For example, for embodiments where footwear is to be customized to improve traction during ground contact events, the performance metric vector can be used to orient and distribute traction elements on the surface of an outsole or ground contacting midsole portion of the shoe (or portion thereof), with the size, shape, and / or distribution of the traction elements dependent on the magnitude of the performance metric vector in a specific area of ​​the outsole. Fig. 16B and Fig. 16C An example outsole for an article of footwear can be seen in Fig.16A The performance metric vector 240 customizes the pulling element 245 .

[0210] exist Fig. 16B In the embodiment, the pulling elements 245 are arranged in a regular pattern that corresponds to the positions of the pressure sensor elements 180 utilized during the measurement of the input parameter. Fig. 16C In the embodiment shown in FIG. 1 , the pulling elements 245 may be located in any regular or irregular pattern, regardless of the specific location of the pressure sensor element 180 utilized during measurement of the input parameter.

[0211] The traction elements 245 may be asymmetrically configured such that they include a leading edge 250 and a trailing edge 255, and when the traction elements are oriented such that the leading edge 250 is perpendicular to the direction of the performance metric vector, the traction provided by the traction elements 245 is optimized, thereby providing a customized and optimized traction effect in the direction that is most important to the performance of a particular athlete. FIG. 17A to FIG. 18 Various example directionally oriented traction elements 245 are shown in , with each traction element 245 having a preferred orientation in which the leading edge 250 (elongated edge or point) is oriented in the direction of a performance metric vector for a particular athlete.

[0212] Various embodiments of traction element 245 may include undercut 257 designed to create a sharper leading edge 250, thereby improving traction in the direction facing leading edge 250. The size and shape of undercut 257 may also influence and control the flexibility of traction element 245 during ground interaction, with larger undercut 257 creating a thinner and, therefore, more flexible traction element 245 (for the same configuration of angled back 259). Certain embodiments of traction element 245 may include angled back 259, which may potentially reduce the traction generated by traction element 245 in the direction facing angled back 259. As a result, traction may be tailored to create greater traction in specific directions (e.g., directions associated with ground interaction at various locations on the foot during a foot strike event), while reducing traction, and therefore friction, in directions where high traction is not desired and, in fact, may be detrimental to performance. Careful shaping of traction element 245 may also allow for minimization of material used (and, therefore, minimization of the weight of material required) without compromising the performance of traction element 245 .

[0213] In one embodiment, traction elements 245 may be customized such that the size of traction elements 245 varies depending on the size and / or direction of the performance metric vector in that region. Alternatively or additionally, the number of traction elements 245 may vary depending on the size and / or direction of the performance metric vector in that region, e.g., a greater number of traction elements 245 are clustered in regions where the performance metric vector size is high. In various embodiments, the outsole may be customized using any appropriately distributed traction elements, tread patterns, and / or spike patterns, and traction element / tread / spiked orientations, shapes, and / or configurations, depending on the specific performance characteristics required for the sporting activity in question and / or the aesthetic and / or performance preferences of the athlete.

[0214] Various embodiments of the present invention may include processing input parameter information to obtain different and / or additional methods for customizing performance metric information for shoes. For example, instead of providing a separate performance metric vector at each measurement location on the sole of the foot, the information may be averaged over several predetermined regions (e.g., heel region, midfoot region, and forefoot region) with different performance metric vectors, and thus having traction elements of different sizes and orientations for each different region, and traction elements of the same orientation and size distributed throughout each region. For example, this may be achieved by estimating the center of pressure for the time step using the raw pressure distribution data in each time step, and then generating a vector using the center of pressure data for each time step, so as to provide a center of pressure vector for the foot landing of an individual athlete. Like distributed pressure data, center of pressure data may be greatly different for different athletes, and therefore may provide valuable distinguishing information to allow customization of footwear for a specific athlete.

[0215] exist FIG. 19A to FIG. 21B Example schematic center of pressure vectors 250 for various foot strike types can be seen in FIG. Fig.19A and Fig.19B ), those with the middle part of the foot touching the ground ( Fig. 20A and Fig. 20B ) and front-foot striker ( Fig.21A and Fig. 21B ) shows the center pressure vector 250, along with a representative force vector 230 and a total pressure measurement 255. Fig.22A and Fig. 22B An example region 260 can be seen in which a performance metric vector for each location along the pressure center vector 250 is utilized during the customization process. Fig.22A shows a sole 265 divided into eight separate regions 260, the eight separate regions 260 being evenly divided along the length of the sole 265, and Fig. 22B Seven regions 260 of varying lengths and shapes are shown covering a sole 265. In various embodiments, any distribution of regions 260 may be utilized depending on the level of customization desired.

[0216] In one embodiment, the performance metric information (e.g., the performance metric vector) may be further analyzed to determine the distribution details of the traction elements within the outsole. Example geometric and mathematical modeling techniques that may be used to analyze the input parameters and / or performance metric information to design customized footwear elements may include, but are not limited to, circle filling, Delaunay triangulation, and / or Voronoi decomposition (or Voronoi tessellation / Voronoi diagram).

[0217] like Fig.23A The illustrated example analysis method includes the use of circle filling, whereby the arrangement of equal or unequal sized circles 280 on a given surface (e.g., a shoe sole 265) can be optimized so that no overlap occurs and all circles 280 are in contact with each other. The number of circles, the size of the circles (uniform or different in size), and the local distribution of the circles can be controlled according to the specific requirements of the system. In one embodiment, performance metric information (e.g., the size of the performance metric vector at various locations throughout the sole) can be used as an input to the circle filling algorithm, and the size of the performance metric vector in a given area controls the size and / or number of circles 280 in that area. Using control inputs, such as, but not limited to, the number of circles 280 to be distributed throughout the sole 265 and / or the maximum and minimum sizes of the circles to be distributed throughout the sole 265 as additional inputs allows the circle filling algorithm to process the performance metric information to generate an optimized distribution of traction elements 245 based on specific inputs provided by, for example, traction elements 245 positioned at the center of each circle 280.

[0218] like Fig. 23B Another analysis method shown includes using Delaunay triangulation to distribute traction elements 245 at optimal locations within sole 265 through optimized triangulation of input parameter data and / or performance metric data. In this analysis method, the original input parameter data and / or performance metric data can be used to form a plurality of triangles 285 that are optimally distributed throughout sole 265, after which traction elements are located at the central vertices of each triangle 285. Another related analysis method includes using Voronoi thinning, which is a method of dividing space into a plurality of regions in which a plurality of points (also referred to as seeds, locations, or generators) are predefined and in which the algorithm results in the generation of a plurality of Voronoi vertices or nodes 290 using the seed points, which represent points that are equidistant from three (or more) locations. Using input parameter data and / or performance metric data as control elements of the Voronoi refinement algorithm allows for the formation and distribution of Voronoi cells 295 (areas between nodes) that can be optimized to identify locations for pulling elements 245 .

[0219] In addition to using the experimental data representing the performance characteristics of the foot and / or the physical characteristics of the user's foot as input parameters, the preference based on aesthetics and / or performance of the athlete can be used to help customize footwear. For example, the importance of factors such as, but not limited to, the size, distribution and shape of traction elements, the required traction level, the durability of footwear, the flexibility of footwear, and / or the weight of footwear can be different according to different athletes. As a result, one embodiment of the present invention allows the athlete to control the design of customized footwear according to the relevant importance of each controllable input parameter based on user preference or selection criteria. In this embodiment, the sole customized with the benchmark of traction elements is formed using experimental performance data and / or physical characteristics data, and the traction elements are distributed to optimize the traction for a specific user. Then, this benchmark customization can be modified, for example, by reducing the size of traction elements and / or forming a cavity between traction elements to reduce weight (when the traction of low weight ratio improvement is more important for athletes), to meet user preferences, or to change the shape, size and distribution of traction elements, wherein a specific traction element type is considered to be more comfortable, better in performance and / or more aesthetically pleasing for athletes. In one embodiment, different traction elements and spike shapes may be selected based on the foot conditions and surface, weather conditions, and / or the sport being performed. Additionally, since running in a straight line and running around a curve produce different performance metrics for an athlete and each shoe of the athlete, the athlete may select as input parameters the degree to which the traction element distribution and orientation are weighted by the straight line running input parameter data and the curve running input parameter data. In one embodiment, different performance requirements and traction requirements may be desired or preferred for different competitions (e.g., for sprints, medium distance events, long distance events, hurdle race events, etc.).

[0220] In one embodiment, the shoe may be adapted to receive a removable and interchangeable outsole element (e.g., an outsole spike plate) or ground contacting midsole element, thereby allowing the traction of the shoe to be adjusted by replacing the outsole element according to the athlete's specific requirements. For example, an athlete may have several different outsole elements customized for various weather conditions, underfoot conditions, competitions, and other relevant parameters, with the athlete freely selecting the most suitable spike plate for a specific event.

[0221] In one embodiment, the customized physical characteristics of the outsole of the footwear may include, or consist essentially of, a tread pattern, with the specific pattern shape and orientation customized to meet the specific performance metric information and user preference information of a specific athlete.

[0222] In one embodiment, weight can be reduced by removing material from carefully selected areas of the outsole by forming cavities or voids. The voids can be strategically placed to be located only in areas where less traction is needed (such as in the midfoot area for heel strikers) and / or in areas where adding the voids will not adversely affect the structural integrity of the outsole. The formation of voids and / or cavities can also create areas of increased flexibility, which can have a beneficial effect on the performance of footwear for certain athletes.

[0223] exist FIG. 24A to FIG. 24C , and more specifically, example configurations of outsole plates for track spike shoes are shown. Each of the three plates shown is generated from the same input parameters and performance metrics, with variations in the finished design and configuration based on selections of different user preferences. Fig.24A In an embodiment, for example, plate 300 is designed with regularly distributed traction elements 305 and voids 310, with the size of each traction element 305 being based on the size of the performance metric data in that area. In addition, user preferences are set so that traction becomes a relatively important factor and weight reduction is less important, thereby generating a greater number of traction elements 305 and a smaller number of weight-saving voids 310.

[0224] exist Fig. 24B In the embodiment of , plate 315 is designed with an irregular distribution of traction elements 320 and voids 310, the size of traction elements 320 is directly related to the magnitude of the performance metric in that area, and the emphasis is placed on low weight and higher flexibility, thereby creating a greater number of voids, especially in the midfoot area 325. Fig.24C In the embodiment of FIG. 3 , plate 330 is designed with irregularly distributed traction elements 335 that are grouped together in a tighter formation in areas where the performance metric data magnitude is high (such as in central portion 340 of forefoot region 345 ).

[0225] exist FIG. 25A to FIG. 25E Other examples of variations in custom designs based on variations in user preference criteria for a single set of input parameters and performance metrics can be seen in . For example, Fig.25A and Fig.25B Two plates (350, 355) are shown with the same input parameters and performance metrics, but plate 350 is designed to reduce weight (by increasing the distribution and size of voids 310, particularly within the outer edge 365 of the forefoot region 370 and midfoot region 360 where the performance metric data is lower in size), while plate 355 is designed with traction set as a more important parameter than weight reduction (thereby producing fewer voids 310 and more traction elements 380).

[0226] Similarly, Fig.25C and Fig.25D Shows the Figure 5A and Fig.25B The same input parameters and performance metrics have different design configurations of the plate (400, 405), the size of the traction element 380 of the plate (400, 405) is limited to a set size, which is larger than the set size in Fig.25A and Fig.25B The embodiment of the invention allows for smaller dimensions and traction elements 380 to be grouped more closely together in areas with large performance metric data sizes. Again, the plates (400, 405) are designed to have the same characteristics, but the emphasis of plate 400 is on low weight rather than high traction, while plate 405 emphasizes traction to a greater extent than plate 400, thereby creating fewer voids 310.

[0227] Fig.25E Shows the use of Figure 5A and Fig.25D Another configuration of outsole plate 410 designed for the same input parameters and performance metrics. In this embodiment, selection criteria have been set to reduce the number of traction elements 380, but allow the size of traction elements 380 to be significantly increased in areas corresponding to the larger performance metric results. Again, selection criteria have been set to reduce weight by increasing void 310 distribution and size, particularly in midfoot region 360 and outer edge 365 of forefoot region 370 where the performance metric data is lower in size. In various alternative embodiments, the distribution of traction elements 380 and voids 310 may be controlled by a number of selection criteria related to a number of performance and aesthetic aspects, such as, but not limited to, the size, shape, distribution, number, and / or size variation of traction elements and / or voids.

[0228] In one embodiment, FIG. 24A to FIG. 25E As shown, the sole plate including traction elements may be formed as a plate-like structure with traction elements extending from the plate and voids or cavities formed in certain portions of the plate. FIG. 26A to FIG. 31B As shown, the sole plate can be formed into a plurality of traction elements having a mesh structure of interconnecting elements (e.g., rods) 415 that connect the traction elements. In another alternative embodiment, the plate can be formed in an appropriate manner to have the desired structural requirements to meet the performance needs of the wearer.

[0229] Fig.26A and Fig.26BShown are plates (420, 425) designed using the same user selected criteria (e.g., traction element shape, size, distribution, etc.) and the same plate structure (having rods 415 connecting the various traction elements 430 in a mesh or lattice structure) but utilizing input parameters (e.g., pressure data and force data) and performance metrics (e.g., input data analyzed and processed based on a pre-selected algorithm) from two different athletes. As can be seen, due to the different input parameters generated by the different athletes, the algorithm used to process the input parameters, even for the same user selected criteria, produces different traction element 430 distributions. The addition of a mesh structure with rods 415 or other elongated elements allows for the incorporation of structural elements designed to provide controlled stability, flexibility / stiffness, support, and / or protection depending on the shape, thickness, and orientation of the elongated elements.

[0230] In one embodiment, an outsole plate for a track spiked running shoe may be formed with mounting elements that allow removable spikes to be mounted to the plate to provide additional traction in addition to the traction elements formed integrally with the plate. These mounting elements may be of any size, shape, and configuration depending on the specific spikes and spike configuration desired. In various embodiments, any number of spikes may be mounted to the plate, with many track runners utilizing 3, 4, 5, or 6 spikes. Fig. 27 An example outsole plate 440 for a running shoe with spikes having mounting elements 445 for running spikes is shown in FIG.

[0231] In one embodiment, the plate may be formed to result in different ground interactions between the ground and the left and right shoes as the athlete runs around a curve. Fig.28A and Fig.28B 29A and 29B , the different input parameters (e.g., pressure data and force data) for each foot result in different traction element 460 configurations for each plate. In one embodiment, a pair of shoes specifically adapted for running around a curve may include a customized sole plate and a specially designed and possibly customized upper, such as that described in U.S. Patent Publication No. 2010 / 0229426, the entire disclosure of which is incorporated herein by reference. Fig.29B Another pair of outsole plates (462, 465) designed based on input parameters obtained during curve running can be seen in Fig.28A and Fig.28B The results are calibrated based on different sole plate shapes and input parameters for different athletes. In various embodiments, the processing algorithm can be designed to distribute traction elements and / or voids in the surface of any shape of plate or outsole depending on the specific shape of the shoe.

[0232] exist FIG. 30A to FIG. 31B FIG. 4 shows a pair of outsole plates (470, 475) using input parameter measurements taken during straight-line running, in plan and perspective view. Figure 2 The left foot plate 470 and the right foot plate 475 are shown. Fig.31A and Fig.31B As shown in , the plates (470, 475) may be formed as a generally flat structure with traction elements 480 extending therefrom. In alternative embodiments, such as in Fig. 27 In the sole plate 440 shown in the figure, the plate can be manufactured as a curved or angled profile to allow the plate to cooperate with the sole or its portion (e.g., an outsole with a curved or angled lower surface profile). In various alternative embodiments, any suitable shape of the sole plate or outsole element can be designed.

[0233] In one embodiment of the present invention, the input parameters may be utilized to determine a performance metric that may be used to design a custom midsole or custom midsole component (e.g., a heel pad and / or a forefoot insert component) in addition to or in lieu of a ground contacting structure having traction elements. FIG. 32A to FIG. 32C An example midsole designed by analyzing pressure and force measurement input parameter data can be seen in FIG. In this embodiment, midsole 500 is formed as a lattice or mesh structure with a plurality of elongated elements 505 extending between nodes 510. The distribution of elongated elements 505 and nodes 510 in the lattice structure is determined by performance metric data obtained from the input parameters of a specific athlete and the selection criteria of the athlete. More specifically, elongated elements 505 and nodes 510 can be arranged to provide areas where support increases or decreases, cushioning increases or decreases, and / or stability increases or decreases in different regions of midsole 500.

[0234] exist FIG. 32A to FIG. 32C In embodiments, the lattice structure is arranged so that more nodes 510 and shorter elongated elements 505 are positioned in areas having high performance metrics, thereby providing additional structural support in these areas, such as in a central forefoot region 515 proximate the location of the metatarsal heads of the athlete 520. In various embodiments, the properties of the lattice structure may be controlled by specifying various aspects of the lattice structure, such as, but not limited to, the length of each elongated element 505, the thickness of each elongated element 505, the density of each elongated element 505, and / or the material(s) used for each elongated element 505. Additionally, properties such as, but not limited to, the size, shape, density, and / or material(s) of the nodes 510 may also be controlled to ensure that specific performance characteristics of the midsole 500 are met. FIG. 32A to FIG. 32CIn the embodiment of the present invention, the elongated elements 505 and the nodes 510 form a triangular structure, in alternative embodiments, any suitable structural form can be utilized. In one embodiment, the elongated elements 505 and the nodes 510 form a plurality of polyhedral shapes, such as, but not limited to, tetrahedrons (i.e., polyhedrons with four triangular faces), cubes, octahedrons, dodecahedrons, icosahedrons, etc. For example, the midsole 500 or portions thereof can be formed by an array of elongated elements 505 forming a plurality of tetrahedral shaped "units". The relative sizes, shapes, and structural properties of these units can vary throughout the midsole 500 to impart different structural properties to different areas of the shoe.

[0235] Such as FIG. 32A to FIG. 32C The benefit of the lattice structure for athletes may be that it allows for custom design of sole components (e.g., midsoles or midsole elements) to meet the performance requirements of athletes while also minimizing weight by allowing for an open mesh structure with open cavities between elongated elements 505 and nodes 510. In one embodiment, the lattice structure can remain an open structure. In an alternative embodiment, materials (e.g., lightweight foams) can be injected into the lattice structure to fill the open cavities, thereby providing additional structural support.

[0236] In one embodiment, the performance metric data may be processed by mathematical algorithms such as, but not limited to, circle filling, Delaunay triangulation, volume meshing, and / or Voronoi decomposition to form a design for the midsole lattice structure. Fig.32D An example structural configuration for a midsole using Voronoi decomposition to analyze athlete performance metric data is shown in Fig.33 52 is a graph showing the performance metric data used to calculate the midsole mesh used in this analysis, represented as a scalar hexahedral pressure map distribution. In this embodiment, the pressure distribution within a volume representation of the sole of the article of footwear is represented by a contour map 527, with high pressure areas 528 and low pressure areas 529 distributed around the volume based on pressure measurements taken for a particular athlete.

[0237] exist FIG. 34A to FIG. 34FAnother example midsole designed and constructed according to the methods and systems described herein is shown in FIG. In this embodiment, the midsole 530 includes a forefoot region 535 having a warped toe portion 540, a midfoot region 545, and a heel region 550. The midsole 530 also includes an upper surface 555 for engaging the upper of the shoe and a lower surface 560 for engaging the outsole of the shoe and / or providing a ground contact surface (no need to provide additional one or more outsole elements). The midsole 530 also includes a sidewall 565, which can be exposed when assembled into a finished shoe, or can be fully or partially covered by a transparent or opaque covering element when assembled into the finished shoe. The structure of the midsole 530 includes a plurality of elongated elements 570 connected at a plurality of nodes 575, and the combined elongated elements 570 and nodes 575 form a plurality of open triangular structural segments 580. As discussed above, the specific arrangement of elongated elements 570 and nodes 575 may be customized based on specific performance metrics for a given athlete so that midsole 530 provides customized cushioning, support, and flexibility (as well as other possible performance advantages) for the specific athlete.

[0238] In various embodiments, after formation, any suitable skin, covering, and / or encapsulation may be added to the structure to provide an outer surface covering for the structure or a portion thereof. This may provide protection to the structure, prevent the structure from becoming clogged with mud, water, etc., provide additional structural properties to the structure, and / or provide a unique aesthetic element to the structure. The skin / cover may be made of any suitable material, such as, but not limited to, thermoplastic polyurethane (TPU), thermoplastic elastomer (TPE), and / or a knitted, woven, or non-woven fabric.

[0239] The upper surface 555 may be bonded, stitched, or otherwise attached to the upper of the shoe, and, for example, to a strobel board for the upper of the shoe. In certain embodiments, an insole may be placed above the midsole 530 in a finished shoe to provide a separate layer between the midsole 530 and the foot of the wearer of the shoe. In certain embodiments, in addition to or in lieu of a separate insole component, a strobel board positioned above the upper surface 555 to which the upper surface 555 is attached provides a layer of material between the midsole 530 and the foot of the wearer of the shoe. In alternative embodiments, the upper surface 555 is attached to the upper only at the edges, with no strobel board, insole, or other layer of material between the midsole 530 and the foot of the wearer of the finished shoe.

[0240] exist FIG. 34A to FIG. 34FIn the embodiment of, upper surface 530 comprises a plurality of holes 585, these holes 585 can reduce the weight of midsole 530, and provide air permeability between midsole 530 and the upper of shoe. Hole 585 can be arranged as any specific pattern, and can be any appropriate shape, and this depends on the concrete performance, air permeability and weight requirement of footwear. In one embodiment, the position, size and shape of hole 585 can be determined based on the concrete performance metric of athlete, thereby providing customized air permeability and load distribution plate. In one embodiment, upper surface 555 may not have any holes 585 therein, for example, this may be useful for providing the extra surface area that upper can be bonded thereto, and in the embodiment that does not expect or need extra air permeability (for example, in waterproof footwear), it may also be useful. In one embodiment, the profile of the shape of upper surface 555 can be specifically constructed for the foot shape of a given athlete, thereby providing tailor-made for the athlete.

[0241] The lower surface 560 of the midsole 530 includes a plurality of flat lower contact surfaces 590 which, in various embodiments of the invention, may provide a surface to which one or more outsole elements may be secured (e.g., by bonding) or which may provide a direct ground contact surface for the midsole 530. The shape, size, and configuration of these lower contact surfaces 590 may be standardized or may be customized by analyzing and applying input parameters, performance metrics, and / or selection criteria for individual athletes. In alternative embodiments, the lower surface 560 may be a solid, void-free surface. Fig.35 5, includes a midsole 530 having a plurality of traction elements 595 extending from a bottom surface 560. In this embodiment, a bottom surface 600 of the traction elements 595 provides a direct ground contacting surface for the midsole 530, thereby allowing the midsole 530 to function without the addition of additional outsole elements.

[0242] In one embodiment, the insole for the shoe can be designed using input parameters and algorithms, the insole is customized for the specific physical characteristics of the athlete, and the structure of the insole is designed to provide customized experience and / or performance characteristics to the athlete. In alternative embodiments, the method and system described herein can be used to design and manufacture any outsole, midsole and / or insole structure and parts, such as, but not limited to, the entire outsole, midsole and / or insole, insert, which is placed in the outsole, midsole and / or insole (for example, in the forefoot, midfoot and / or heel of the shoe, and / or in the medial, lateral and / or central part of the shoe. In one embodiment, in addition to the customized sole element, or in place of the customized sole element, the method and system described herein can be used to form a customized upper and / or upper portion.

[0243] exist Fig.35 A to Fig.35 E shows an example shoe 610, which includes a sole 615 and an upper 620 that are manufactured into a single integral structure according to the methods and processes described herein. In this embodiment, the sole 615 includes a midsole 625 formed by a plurality of adjacent circular elements 630, and the circular elements 630 are spaced apart to form an open mesh structure. The upper 620 is integrally formed with the sole 615 to create the overall structure forming the shoe 610, and the upper 620 includes a mesh-like portion 635 that forms a link of most of the upper 620, which includes a tongue 640, and a support element 645 provides additional structural support in high strain areas (e.g., in the midfoot region 650 and the heel region 655). In an alternative embodiment, the overall structure of customization can only form the specific area of ​​the sole and / or upper of the shoe, and additional materials and structural elements are attached to the customized structure. In various embodiments, the shoe 610 can be constructed with any appropriate closure mechanism, which is formed along the upper and / or sole element or attached to the shoe after formation. In one embodiment, both sides of the hook and loop arrangement may be formed during an additive manufacturing process, and the resulting hook and loop structure may be separated after manufacturing to provide a closure mechanism.

[0244] In one embodiment, the upper or portion(s) thereof may be formed by the methods described herein (e.g., by additive manufacturing), and thereafter, the upper or portion(s) thereof may be heat welded, fused, bonded, or otherwise attached to fabric or other material to form a finished part. In one embodiment, a flat upper shell for the upper may be formed by additive manufacturing, and thereafter, the upper shell may be heat pressed (or otherwise bonded or attached) to fabric to form a finished upper. In one embodiment, a forming die / heat press form may be formed (with or separate from the upper shell), which may then be used to ensure that the structural definition of the upper shell (e.g., raised portions) is not lost during the heat pressing process.

[0245] Utilize method and process described herein, can customize the sole 615 of shoe 610 and / or any element of upper 620 based on athlete's concrete input parameter, performance metric and / or selection criteria, to produce fully customized shoes.For example, can customize the position, size, shape, pattern, structure and material property of support element 645 based on athlete's input parameter, to provide the support member that especially satisfies athlete's running way, foot shape, performance requirement and aesthetic requirement.In addition, can also customize based on athlete's input parameter, such as but not limited to, the key elements such as position, size, shape, pattern, structure and material property of grid-like part 635, to provide the support member that especially satisfies athlete's running way, foot shape, performance requirement and aesthetic requirement.In alternative embodiment, the element of sole 615 and / or upper 620 can be formed with any suitable open or closed structure with any suitable size (for example, shape and size), structure, material property (for example, density), to produce the concrete performance and aesthetic requirement of individual athlete.

[0246] In various embodiments, any sensor and measurement value described herein can be used to provide appropriate input parameters, which depend on the specific requirements of the athlete for customizing the entire shoe 610, or customize the sole 615 and / or the upper 620 (or, its limited area) separately. The factors that the shoe can be customized for include, but are not limited to, the performance and technique of the athlete, the body structure of the athlete's foot, injury prevention and / or protection, weight considerations, support considerations, and / or aesthetic considerations. In an exemplary embodiment, during the measurement of input parameters, a stress / strain gauge can be placed on the upper of the athlete's shoe to identify the area of ​​the upper that is subjected to high and low stress / strain during the gait cycle of the individual athlete, and the algorithm and method described herein use this information to identify the area of ​​the upper that needs more support for the athlete and the upper area that does not need too much support (and, therefore, these areas can be constructed by lighter and / or more flexible materials and / or material structures).

[0247] In an alternative embodiment, stress / strain data may be collected by scanning the foot / shoe during physical activity using an optical camera (or other appropriate scanning or measurement techniques), with markings on the foot / shoe providing identification of the relative positioning of various parts of the foot and changes in that relative positioning over time. Analysis of changes in relative position may be used to calculate stress and strain at various regions of the shoe / foot during physical activity.

[0248] exist FIG. 37A to FIG. 37DIn another example, the midsole 500 can be seen to be formed using the method and materials described herein. In this embodiment, the midsole 500 is formed as a lattice or a mesh structure, which has a plurality of elongated elements 505 extending between nodes (connection positions) 510. In one embodiment, the distribution of elongated elements 505 and nodes 510 in the lattice structure can be determined by the performance measurement data obtained by the selection criteria of the input parameters from the specific athlete (or athlete's group) and the athlete (or athlete's group). Alternatively, the lattice structure can be formed more generally to provide standardized support and performance requirements for a class of athletes. In this embodiment, the lattice structure (or, volume grid structure) is made up of arrays, and the array comprises a series of tetrahedrons, and the tetrahedron comprises the hexagonal unit 705 of shared adjacent elements. In this embodiment, the structure is formed by connecting the center point of each face of the tetrahedron to the midpoint of each side.

[0249] In various embodiments, polyhedrons or any suitable size, shape and structural relationship can be utilized to form a grid of cells that provide desired levels of support, flexibility, cushioning and other structural, performance and / or aesthetic parameters to different areas of a shoe sole or portion thereof based on performance and aesthetic considerations. Example polyhedrons that can be used to form structural features of a midsole include, but are not limited to, tetrahedrons, truncated tetrahedrons, cubes, truncated cubes, dodecahedrons, truncated dodecahedrons, octahedrons, truncated octahedrons, higher order polyhedrons or truncated polyhedrons, and / or prisms with any suitable number of sides (e.g., triangular prisms, pentagonal prisms, hexagonal prisms or higher order prisms). In one embodiment, the entire midsole or portion thereof can be formed from a single polyhedral structure (if desired, different sizes, element thicknesses, etc. are used to impart different structural properties to different areas). In another embodiment, multiple different polyhedrons can be included in a single midsole (or portion thereof). Such structures may also be utilized to form other portions of shoes (eg, shoe uppers or portions thereof) and / or sports apparel, sports protection / pads, and / or sports equipment, or portions thereof.

[0250] In one embodiment, Fig.37DAs shown, the bottom (or, lower) surface 560 of the midsole 500 may include one or more indentations 718 in which ground contacting elements (e.g., outsole elements) or other structural features may be placed. Other possible structural features may include, but are not limited to, cushioning elements, traction elements, protective elements (e.g., plates), flexion control elements, performance monitoring sensors, etc. In various embodiments, one or more indentations or cavities may be located at any portion of the midsole (e.g., in the central region, on the upper or lower surface, on the medial and / or lateral sides, and / or in the forefoot, midfoot, and / or heel regions) to provide a location for placing one or more structural features. In one embodiment, traction elements may be built directly into the midsole, thereby completely or partially eliminating the need for an additional separate outsole element.

[0251] exist Fig.38A and Fig.38B Another example midsole formed using the methods and materials described herein can be seen in . In this embodiment, a cell structure 720 is formed by installing elongated elements 505 from the center of a tetrahedral element and connecting them together at nodes 510 at each corner. Fig.39A and Fig.39B Another example midsole is shown in FIG. , which includes square cells 725 forming a warped square grid, which are interlaced with an intermediate layer of polyhedral cells 730.

[0252] Another example of a midsole 500 may be formed from a plurality of polyhedrons (tetrahedrons in this case) having circular elements 735 (or rings) forming the faces of the tetrahedrons, such as Fig.40A and Fig.40B The size and thickness of these rings 735 can vary across the volume of the midsole 500 to impart different structural properties to different areas thereof. FIG. 41A to FIG. 42 , another midsole formed of a plurality of polyhedrons (in this case, cubes) having circular elements 735 (or, rings) forming the faces of the cubes is shown in . In addition to size and thickness variations, the rings 735 may vary in shape (from circular to elliptical or other curved shape of any suitable geometry) to impart different structural properties to different areas thereof.

[0253] In one embodiment, the lower surface 560 of the midsole 500 includes positioning elements 740 on or in which ground contacting elements (e.g., outsole elements) or other structural elements can be positioned and attached. For example, these positioning elements 740 can provide a stable structure to which outsole elements can be permanently (or removably) attached and retained. In one embodiment, one or more plates 745 can be integrally formed with (or attached to) the midsole 500 to provide additional structure and support to the upper surface 555 and / or lower surface 560 of the midsole 500. Fig.42 An example plate 745 covering the entire upper surface 555 of the midsole 500 is shown in Fig.50 5 shows a plate 745 comprising a strip of material extending around the periphery of the upper surface 555 of the midsole 500. The plate 745 can provide cushioning and protection for the wearer's foot and / or provide a firm surface to which the upper of the shoe can be adhered or otherwise attached.

[0254] exist Fig.43A and Fig.43B Another example midsole according to one embodiment of the present invention is shown in FIG. In this embodiment, oval shapes 750 are formed and connected together to form a midsole 500. Fig.44 Another embodiment is shown in , which includes a plurality of elliptical elements 750, which are located at each face of a tetrahedral unit and connected together by a common wall structure 755 to form an open array of structural elements.

[0255] In one embodiment, a unit in the midsole 500 may be formed by a plurality of adjacent triangular elements 760, such as Figures 45 to 50 As shown, the triangular elements form the faces of the array of tetrahedral structural elements. In various embodiments, the triangles or any other shapes may have sharp or rounded corners. In one embodiment, in certain areas of the midsole 500, the elongated elements may be arranged in a generally vertical arrangement to provide additional structural stability to the midsole 500 (e.g., to reduce / prevent shearing during loading). In addition, as discussed above, the size of the elongated elements 505 forming the cells may be varied across the midsole 500, for example, areas requiring greater structural support (such as, under the athlete's forefoot) may have smaller cells 762 with shorter elongated elements 505 (such as Fig.47B shown).

[0256] In one embodiment, the shape of midsole 500 may be based on scanned data of an athlete's foot shape. Fig.45 An example midsole 500 having an upper surface 555 that generally conforms to the shape of a player's foot can be seen.

[0257] In various embodiments, the elongated element can be straight or curved, and can have any appropriate length, thickness and orientation to impart desired structural properties to various regions of the midsole. The thickness can be constant, or can change in the length of the elongated element. The orientation of one or more elongated elements can be generally vertical or at an acute angle to the vertical. The elongated element can be angled in a generally longitudinal direction (relative to the direction of the shoe sole) or in a generally lateral direction, or at any angle between these two directions. For example, the elongated element can be arranged in an orientation relative to the direction of the main load placed on the midsole at this position during sports.

[0258] In one embodiment, structural elements, such as elliptical elements 770, may be arranged to form faces of a larger structural unit, such as, but not limited to, FIG. 51A to FIG. 52 In various embodiments, the elongated elements and / or ellipsoidal elements may be arranged in any suitable manner to create an array of structural units that provide any suitable structural properties to the midsole.

[0259] Various embodiments of midsole structures described herein may include an array of structural units that are warped or otherwise adjusted to create regions of different density, directional strength, etc. to impart different structural properties to different regions of the midsole. Fig.53 An example warped array can be seen having regions of lower density 780 (formed by increasing the length of the elongated elements 505 and thereby increasing the size of the resulting cells 782) and regions of higher density 785 (formed by decreasing the length of the elongated elements 505 and thereby decreasing the size of the resulting cells 787).

[0260] In one embodiment, a grid or array of elements may be used to form a foot shape, which may be used, for example, to form an upper or portion of an upper for an article of footwear and / or to form a last used in manufacturing footwear. These foot models 790 may have a hollow interior, or a structured or partially structured interior. FIG. 54A to FIG. 55B An example foot model including a plurality of elongated elements 505 forming a chainmail-type structure is shown in Fig.56A and Fig.56B A foot model can be seen in FIG. 5 including a plurality of elongated elements 505 forming an array of hexagonal and pentagonal cells 795. In alternative embodiments, any suitable structure or combination of structures may be utilized to form the foot model.

[0261] In various embodiments, these structures can be formed from a generally hard and inflexible material (e.g., when forming a shoe last for manufacturing purposes), or can be formed from a flexible and / or elastic material (e.g., when forming an upper or portion thereof for footwear). In one embodiment, structures, such as portions of an upper and / or other shoe elements (e.g., a sole element, or a combination of sole and upper elements), can be formed in a fully or partially collapsed or flattened state and then unfolded to form a finished part. This can be particularly beneficial for, for example, additive manufacturing, where forming an object into a collapsed state allows for a significant reduction in volume requirements during manufacturing, thereby allowing significantly more parts to be manufactured in a single manufacturing run. In one embodiment, a shoe element or any other structure (e.g., protective clothing or padding, athletic equipment, etc.) can be manufactured from a flexible material that elastically deforms into a finished part after initial forming (e.g., by pre-forming elastic deformation stresses in the formed structure to automatically deform when constructed or when the structure is released from a manufacturing mold, powder bed, etc.). Alternatively or additionally, the structure may be formed from a material that permits plastic deformation after initial formation to reshape the structure into a desired shape.

[0262] In one embodiment, a structure (e.g., a shoe sole and / or upper) may be formed, for example, by additive manufacturing techniques, with one or more hinges or other deformable structural elements allowing the component to be formed in a bent or collapsed state and then deformed to form the finished structure. In another embodiment, the structure may be formed with an internal cavity into which a bladder may be placed after initial formation in a collapsed state to "expand" the structure to the finished size.

[0263] In one embodiment, a midsole 800 for an article of footwear may be formed from a plurality of separate structural elements 805 connected by a plurality of coupling elements 810. Figure 57 to Figure 58EAn example coupling system and a midsole 800 formed by a plurality of structural elements 805 and coupling elements 810 can be seen in FIG. In this embodiment, the coupling elements 810 can be flexible, elastically or plastically deformable, and / or can provide some degree of give within the structural elements 805 (e.g., by being loose enough to allow relative movement between adjacent structural elements 805) to provide a midsole 800 with a controlled degree of flexibility and maneuverability. The structural elements 805 are formed as hollow wall elements with openings into which the coupling elements 810 extend. The coupling elements 810 are formed as curved elongated elements extending between adjacent structural elements 805 to form a lock-mail type coupling arrangement. In alternative embodiments, the structural elements 805 and the coupling elements 810 can take appropriate forms and can utilize any appropriate form of structure that provides relative movement of the connection between adjacent structural elements. In one embodiment, the structural elements 805 can be formed as an integral structure with the coupling elements 810. In another embodiment, the structural elements 805 and the coupling elements 810 can be separate interconnecting elements. Structural elements 805 and coupling elements 810 may be utilized to form a sole and / or upper of a shoe, or portions thereof, or portions of sports apparel, sports equipment, or protective equipment / pads.

[0264] In one embodiment, the size and shape of structural elements 805 and / or coupling elements 810 can vary so that different areas of midsole 800 have structural elements 805 with different shapes, sizes, and / or structural properties. FIG. 58A to FIG. 58E The embodiment includes a toe portion 815 with smaller structural elements 805, a forefoot region 820 with larger structural elements 805, and a heel region 830 and a midfoot region 825 with intermediate-sized structural elements 805, the variation in size allowing four structural elements 805 to span the width of the midsole throughout its length. In alternative embodiments, any suitable number of elements may span the width of the structure, and the number and arrangement of elements may vary in its length and / or width.

[0265] Providing relative motion between structural elements 805 allows midsole 800 to be manipulated after formation to allow the shape and size of midsole 800 to be adjusted, thereby allowing a single structure to fit feet of various sizes and shapes. For example, a midsole 800 that can expand and contract in width and / or length can be adjusted to fit a variety of shoe sizes. Fig.58B and Fig.58C As shown, the midsole 800 can be adjusted to have a first length L(1) and width W(1) to fit a first shoe size, or it can be expanded to provide a second length L(2) and width W(2) to fit a second shoe size. Allowing this adjustment will allow a single structure to cover a large number of different foot sizes, foot widths, and foot shapes.

[0266] Additionally, allowing relative movement of structural element 805 allows midsole 800 to be manufactured into a first configuration (e.g., flat, such as Fig.58D ), and then reshaped into a final curved configuration (e.g., curved along at least a portion of the longitudinal extent, such as Fig.58E This can be particularly beneficial for additive manufacturing, for example, where forming the midsole 800 in a flat state (and, after forming, only adding curvature to the structure) potentially allows for a significant reduction in volume requirements during manufacturing, thereby allowing significantly more parts to be manufactured in a single manufacturing run.

[0267] The midsole 800 may be locked into the finished shape by any suitable method. For example, the midsole 800 may be formed into the desired form and then treated by any suitable chemical or thermal treatment to fuse the structural elements 805 and the coupling elements 810 into a locked arrangement. Alternatively or additionally, a foam, adhesive, or other material may be poured into the midsole 800 to hold the midsole 800 in its desired shape.

[0268] exist Figures 59A to 59E 855, which has cleated traction elements for use, for example, in soccer, football, rugby, or other sports requiring cleats. In these embodiments, the size, shape, and arrangement of cleated traction elements 850 can be arranged on outsole plate 855 in any suitable manner to provide the structure, performance, and / or aesthetic properties required by the wearer. In one embodiment, the positioning, orientation, and structural characteristics of cleated traction elements 850 can be customized to the requirements of the athlete based on utilizing the methods and systems described herein.

[0269] In one embodiment, the cross-section of the cleated traction element 850 can be generally circular, for example, Fig.59E Alternatively, the cleated traction element 850 may be ribbed to create multiple extensions extending from a central core, such as Fig.59D (which shows a cleated traction element 850 having a 3-sided ribbed structure). In alternative embodiments, any suitable cross-sectional cleat shape may be utilized, including, but not limited to, oval cleats, blade-shaped cleats, or triangular cleats. These cleats may or may not taper, and may extend at generally 90° or at an acute angle relative to the base.

[0270] In one embodiment, a sole structure (e.g., an outsole plate or midsole element) may include one or more flex grooves to provide controlled flexibility in specific areas of the sole structure. For customized footwear, the positioning of these flex grooves may be based on scanned foot data and / or performance data of an athlete, for example.

[0271] exist FIG. 60A to FIG. 60E 8 shows an outsole plate 855 for a cleated sole structure having flex grooves 860. Flex grooves 860 divide outsole plate 855 into a plurality of regions: a medial forefoot region 865, a lateral forefoot region 870, a medial midfoot region 875, a lateral midfoot region 880 (which extends into a lateral heel region 885), and a medial heel region 890. In alternative embodiments, any suitable arrangement of the separated regions may be utilized depending on the athlete's physiology, the performance requirements of the shoe, and / or aesthetic considerations.

[0272] In one embodiment, the traction elements may be divided into primary traction elements and one or more groups of secondary traction elements, with one or both of the primary traction elements and / or the secondary traction elements being positioned, sized, and / or shaped based on biometric and / or performance data from the athlete. FIG. 60B to FIG. 60E A variety of different outsole plates 855 are shown, Fig.60B A plate with only the primary traction element 900 is shown, and Figures 60C to 60E Various configurations of primary traction elements 900 and secondary traction elements 905 are shown. Fig.60E It is also shown that FIG. 60B to FIG. 60D The main traction elements 900 utilized in the embodiment of the present invention have different shapes of the main traction elements 900.

[0273] In one embodiment, performance and / or biometric information may be utilized to generate a grid of polygonal shapes based on measured and processed athlete data within which customized cleats may be positioned. Fig.61A 8 and 9. An example outsole plate 855 with a mapping / grid structure 910 superimposed thereon can be seen in FIG. In this embodiment, edges 915 of the grid elements correspond to edges of cells 925 on outsole plate 855 in which cleated traction elements 920 may be positioned. The size (e.g., height) and shape of cleated traction elements 920 may be based on processing of performance and / or biometric information from an athlete, as described herein.

[0274] As described herein, various methods of processing athlete data may be utilized when calculating a traction element configuration and location customized for a specific athlete. FIG. 62A to FIG. 62DSeveral example processing methods for, for example, cleated traction elements are shown in . These figures show different traction element configurations that can be formed from a single data set depending on the specific filtering, processing, and other analysis tool selections.

[0275] Fig.62A The placement of studded traction elements 850 on outsole plate 855 is shown based on direct averaging and simple weighting of all data during the entire athletic movement session. Fig.62B The placement of cleated traction elements 850 on outsole plate 855 is shown based on the filtered data set, using only a maximum of 10% of the data samples at a given location to form the cleated traction element 850 configuration at that location. Fig.62B The arrangement of the cleated traction elements 850 on the outsole plate 855 is shown based on a zoning approach to data processing, with data in different areas (or regions) of the outsole plate 855 being processed independently based on identification of the primary performance requirements for each area (e.g., longitudinal or lateral support, ground contact or toe-off support, etc.). Fig.62D Shows the Fig.62C Weighted filtering of the zoned data of 850, the placement of cleated traction elements 850 on outsole plate 855, using data at points close to the points of interest to smooth the data transitions between zones. In alternative embodiments, any other suitable processing and analysis techniques may be utilized, if appropriate.

[0276] exist Figures 63A to 63G An example method for designing an outsole plate 940 having traction elements 945 with cleats is shown in . In this embodiment, biometric and performance data of an athlete is collected and used to determine the preferred cleat 945 location, size and shape on the surface of an outsole plate 940 for a shoe (such as a soccer shoe / boot). This data can also be used to determine the preferred structure for the plate 940 to provide superior flexibility, support and stability customized for the athlete.

[0277] exist Figures 63A to 63G In an embodiment, the data used in the custom design process includes biometric data related to the geometry of the athlete's foot (e.g., foot scan data 950 obtained by optically scanning the geometry of the foot), and in addition, pressure data 955 associated with the distribution of pressure under the foot during physical exercise and force vector data 960 associated with the direction and magnitude of force between the foot and the ground during physical exercise are used to provide a cleat configuration particularly relevant to the athlete. In alternative embodiments, additional and / or different biometric and / or performance data may be used in the customization process.

[0278] In one embodiment, the athlete can perform many different sports (e.g., straight running, curve running, jumping, cutting in, turning, kicking, etc.), and all these different data sets are incorporated into the data processing algorithm. The data for different sports can be weighted based on the dominance of specific sports for athlete performance and / or athlete preference. For example, an athlete (e.g., English soccer player) may want or need specially designed shoes for maximizing straight-line speed, and another athlete may want or need shoes designed for enhancing cutting speed and / or stability. Data can also be weighted or otherwise filtered to ensure that the result will not be overly dependent on a data set and movement to the detriment of other data sets and movement, thereby forming a shoe that provides customized support for various sports.

[0279] The processed data is then used to form an array 965 of desired cleat 945 locations, sizes, and orientations, such as Fig.63D The data is then further processed to determine locations on the outsole plate 940 where a greater or lesser degree of flexibility (e.g., longitudinal, lateral, and / or torsional flexibility) is desired, where a greater or lesser degree of stiffness is desired, where a greater or lesser degree of structural support is required, and where a greater or lesser degree of protection is required. The data can then be used to form an integral, multi-component structure that provides both customized traction control and structural support for the athlete. For example, the data can be used to form a primary grid component 970 that includes a customized array of traction elements (e.g., Fig.63E ), the secondary lattice component 975 comprises a lattice or mesh of a support structure designed to provide customized flexibility, rigidity, structural support and protection (such as Fig.63F The two lattice components may then be combined together to form a final outsole plate 940 design that provides a structure that is particularly suited to the performance and biometric needs of an athlete.

[0280] In various embodiments, any suitable combination of traction elements, flexible elements (e.g., flex grooves), support elements, etc., may be incorporated into shoe elements. These elements may be customized for a specific athlete (based on analysis of that athlete's biometric and performance data), or they may be designed to provide a more general, average structure based on analysis of multiple athletes playing a specific sport or series of sports.

[0281] In one embodiment, the traction elements may be formed as generally hollow structures to reduce the material required for manufacture and to reduce the weight of the board. Fig.64A and Fig.64B9 shows an example sole plate 978 for a cleated shoe having a plurality of hollow cleated traction elements 980, with a web of structural stabilizing elements 985 extending within the hollow interior 990 of each cleated traction element 980. Structural stabilizing elements 985 may be used to provide structural support to cleated traction elements 980 and may take any suitable form, in alternative embodiments, hollow cleated traction elements 980 themselves may be sufficiently structurally stable and solid, thereby eliminating the need for structural stabilizing elements 985. In one embodiment, a material (e.g., foam, rubber, or another suitable material) may be inserted into the hollow cleated traction elements 980 to provide stability to the elements and / or provide cushioning and / or other structural benefits to sole plate 978.

[0282] In Figures 66a to Fig.66D 1000 is a shoe that is used, for example, in soccer with a traction element having cleats. In this embodiment, a shoe (or boot) 1000 includes an upper 1005 and a sole 1010, wherein the sole 1010 includes a sole plate 1015 having a bottom surface 1020 suitable for ground engagement and an upper surface facing the interior of the shoe 1000. As is known in the art, the sole 1010 can be fixedly attached to the upper 1005 in any suitable manner. The sole 1010 can include additional elements, such as, but not limited to, an insole (e.g., a foam insole) positioned between the sole plate 1015 and the wearer's foot. An example insole element with a selected cushioning element is described in U.S. Patent Application No. 14 / 620,539 filed on February 12, 2015, the entire disclosure of which is incorporated herein by reference.

[0283] Upper 1005 includes an instep portion 1022, which includes a tongue 1025 and a lacing system 1030. In an alternative embodiment, a burrito-style tongue (such as in Fig.67A and Fig.67BThe upper 1005 includes an outer layer having different textures and / or cushioning properties in different locations, and the different textures provide different performance characteristics at associated locations of the upper 1005 to improve the performance of the shoe 1000 by providing optimized traction, cushioning, and rebound / energy return properties to the wearer depending on the specific sport being played (e.g., playing soccer with the shoe 1000). For example, providing increased cushioning to specific areas of the upper 1005 (e.g., by using foam material in those areas and, for example, in the medial midfoot section of the shoe) can allow the wearer to better control a ball being passed to him or her (the cushioning properties of the material in that area dissipates the ball's energy and thereby eases control of the ball when it reaches the foot), while providing higher energy return / reduced cushioning to other areas can improve the rebound characteristics of that area of ​​the shoe 1000 and thereby increase force transfer between the foot and the ball during a kicking motion (e.g., hitting a target), where maximum energy transfer and, thereby, maximum ball speed can be advantageous.

[0284] In Figure 66A and Fig.66B The upper 1005 shown in FIG. 1 includes a first upper portion 1035 covering a majority of a lateral midfoot region 1040, a lateral forefoot region 1045, a central forefoot region 1050, and a medial midfoot region 1055, and a second upper portion 1060 having a different texture positioned in a medial forefoot region 1062. In one embodiment, the second upper portion 1060 can be formed from the same material as the first upper portion 1035, and can be formed, for example, as an integral material portion with the first upper portion 1035, wherein the different texture is applied to the second upper portion 1060 by applying a texture mechanism (e.g., surface texture, surface roughening, surface smoothing, applying heat to mold and cure material, applying additional material or chemical treatment (such as adhesive material) to the outer surface, etc.). In an alternative embodiment, the second upper portion 1060 can be formed from a different material than the first upper portion 1035. In one embodiment, three or more different upper portions can be utilized, each having its own combination of texture / traction and cushioning properties.

[0285] The second upper portion 1060 shown in Figure 66A includes a plurality of regularly distributed parallel ridges 1065 and indentations 1070, wherein the ridges extend at an angle of approximately 45° to the longitudinal axis of the shoe 1000 (i.e., the axis extending longitudinally from the front to the rear along the shoe). In alternative embodiments, the ridges 1065 can extend at an angle between approximately 10° and approximately 80°, or more specifically between approximately 30° and approximately 60°, or even between approximately 40° and approximately 50°. The ridges 1065 can be generally straight or curved in any suitable manner. The ridges 1065 can have any suitable width and height, and can have a width of between approximately 1 mm and approximately 10 mm, and for example, between approximately 4 mm and approximately 8 mm (e.g., approximately 6 mm) in one embodiment, and a height of between approximately 0.1 mm and approximately 3 mm, and for example, between approximately 0.5 mm and 1.5 mm (e.g., approximately 1 mm). The indentations 1070 between the ridges 1065 can have the same width as the ridges 1065, or can have a smaller or larger width. In one embodiment, the indentations 1070 can have a width that is approximately half the width of the ridges 1065. In alternative embodiments, the ridges 1065 and indentations 1070 can be larger or smaller and have any suitable ratio of sizes as appropriate for a particular embodiment.

[0286] In an alternative embodiment, the second upper portion 1060 can have any suitable texture, such as, but not limited to, a cross-hatched pattern, a plurality of discrete protrusions and / or indented elements, a rough or smooth surface (relative to the surrounding outer surface) and / or a tacky surface. Providing ridges 1065 and / or other textures on areas such as the second upper portion 1060 provides customized traction between the outer surface of the upper 1005 and the ball controlled and kicked by the athlete. This can be beneficial when, for example, the ball is given appropriate spin, wherein different surface textures interact with the ball in different ways to give different spins to the ball. By providing the upper 1005 with a plurality of different upper portions 1035, 1060, each with different textures and cushioning properties, the shoe 1000 can be adapted to provide a unique combination of ball interaction zones for the athlete, wherein the properties of each region are customized for the preferences of a particular athlete or a group of athletes.

[0287] The first upper portion 1035 and / or the second upper portion 1060 can be made from any suitable material and can be formed from a multi-layer material assembly, for example, having a textile inner layer (in FIGS. 66A and Fig.66B The shaded base layer as viewed through the hexagonal holes 1075 in FIG. 66A and FIG. Fig.66B 66A and 66B) and a fabric outer layer (shown in FIG. 66C and FIG. 66C) with holes 1075 therein. Fig.66BThe fabrics on the inner and outer layers may include, or consist essentially of, a breathable or non-breathable woven, nonwoven, knitted or otherwise constructed mesh material formed from any suitable natural or synthetic material. The middle layer may be formed from a foam material, a non-foam material, or a fabric. An example middle foam layer may be made from, for example, a foam material manufactured by Chung Liang Industrial Co., Ltd. of Taichung City, Taiwan. In one embodiment, the upper material and / or any one or more layers of the multi-layer material assembly can be formed with holes or other structural elements therein, such as by perforating or cutting the material, or by molding, knitting, weaving, or otherwise forming a material layer with holes and / or other structural features therein. In various embodiments, the holes can be sized, shaped, and / or oriented to provide a selected degree of breathability, unidirectional or multi-directional stretch, cushioning, and / or support.

[0288] As shown, the foam middle / centering layer includes a plurality of regularly distributed polygonal holes 1075 (and, in this case, hexagonal holes) that form regularly spaced indentations in the first upper portion 1035, thereby providing breathability and forming a regular texture in the first upper portion 1035. The holes 1075 can have a width (from straight side to straight side of the hexagonal cross-section) of between about 1 mm and about 10 mm, and for example, between about 4 mm and about 8 mm (e.g., about 6 mm). In alternative embodiments, the holes 1075 can be larger or smaller as appropriate for a particular embodiment. In alternative embodiments, the holes 1075 can be generally circular, oval, or have any other suitable cross-section. For example, as in Fig.67A and Fig.67B The shoe 1000 shown in the figure includes an upper 1005, which has a first upper portion 1035 including a multi-layer material component, wherein the multi-layer material component has a foam intermediate layer including regularly distributed oval holes 1075, and the first upper portion 1035 extends over a lateral forefoot area 1045, a central forefoot area 1050, a medial forefoot area 1062 and a medial midfoot area 1055.

[0289] The depth of the holes 1075, and therefore the depth of the texture on the first upper portion 1035, depends on the thickness of the foam material in the middle layer and the extent to which the outer layer extends into the holes 1075. Therefore, careful selection of the thickness of the foam middle layer is required to ensure proper cushioning and traction characteristics for the first upper portion 1035, wherein thicker foam layers provide greater cushioning and greater texturing. In one embodiment, the foam middle layer can have a thickness between about 0.5 mm and about 2 mm, although thinner and thicker middle layers may be utilized depending on the specific performance characteristics required.

[0290] In addition to the structural features provided by first upper portion 1035 and second upper portion 1060, upper 1005 can include additional structural features. For example, as shown in FIGS. 66A and 66B, Fig.66B As shown in , upper 1005 can include heel portion 1080 incorporating heel pad 1085 (e.g., a cushioned heel pad) and constructed heel counter 1090. In addition, additional material layers can be positioned to the interior or exterior of the surface of upper 1005 (or within the multi-layer material portion) at one or more areas of upper 1005 to provide additional structural support and other performance characteristics to shoe 1000 as appropriate. For example, in Fig.67A and Fig.67B The shoe 1000 shown in the drawing includes: a fourth material layer 1095, which provides additional structural support to the wearer's midfoot in the lateral midfoot area 1040, the medial midfoot area 1055 and the instep area 1022; and a second upper portion 1060 in the midfoot area, which has a surface texture different from that of the surrounding material portions (wherein the fourth material layer 1095 extends over the first upper portion 1035 in the medial midfoot area 1055 and over an additional, or third upper portion 1110 in the lateral midfoot area 1040, and the third upper portion 1110 extends over the lateral midfoot area 1040 and around the heel area 1080). The fourth material layer 1095 can be formed from any suitable breathable or non-breathable woven, nonwoven, knitted or otherwise constructed mesh material (and, for example, a lightweight, high strength to weight ratio synthetic nonwoven material having less elasticity than surrounding materials to provide more support in the midfoot region).

[0291] In one embodiment, as in Fig.67A and Fig.67B, fourth material layer 1095 includes one or more spaces 1105 and, for example, elongated holes that can be positioned and oriented to allow fourth material layer 1095 to stretch more in one direction than in another direction. For example, by orienting spaces 1105 so that they extend in a direction generally from sole 1010 toward lace 1030, fourth material layer 1095 can provide a greater degree of support in that direction (thereby supporting lacing system 1030) while still allowing a greater degree of flexibility along the longitudinal axis of shoe 1000. In various embodiments, the size, shape, and orientation of spaces 1105 within any material layer can be selected to provide any suitable stretch, support, and breathability properties, depending on the area covered by the material layer and the specific performance characteristics required.

[0292] The specific configurations of upper portions and the specific configurations of traction / texture, cushioning, energy return, and support properties provided by these different upper portions can be selected based on the general design requirements of an athlete or group of athletes, or can be determined based on analysis of one or more experimental data sets to provide configurations specifically tailored to an athlete or group of athletes and / or type of sport and game, as described herein. For example, physical and / or optical measurements of stress and / or strain at different portions of the shoe can be used to determine optimal areas for positioning and orienting material portions, while measurements of the interaction between a soccer ball and the shoe when handling and kicking the ball (e.g., measurements of the spin and velocity of the ball, pressure and / or force measurements on the foot, etc. for different ball impacts) can be used to determine the appropriate distribution of traction / texture and cushioning properties in different areas of the foot.

[0293] In one embodiment, biometric data and / or performance data related to one or more athletes performing specific sports strategies (e.g., running turns, etc.) and kicking sports (e.g., shooting, passing, stopping the ball, etc.) can be used to determine the distribution of materials on the upper 1005 to best support a specific type of athlete or a specific type of sports performance. The specific data used can be based on performance characteristics related to player position (e.g., goalkeeper, defender, midfielder, or forward), performance level (e.g., beginner, intermediate, or expert), and / or game type (e.g., speed-based, power-based, precision-based, etc.). The positioning, orientation, and selection of materials, material properties, and material processing in each area of ​​the upper 1005 can then be appropriately selected for the specific performance required.

[0294] exist Fig.66C and Fig.66D 66A and Fig.66B1000. The sole plate 1015 includes a plurality of traction elements that are shaped, oriented, and arranged to provide optimized performance characteristics for the soccer shoe 1000 based on specific design considerations. More specifically, the sole plate 1015 includes a first sole portion 1115 that includes a plurality of first traction elements 1120 having a distal end 1125 and a sidewall 1130 formed by a plurality of extensions 1135 extending from a central core 1140 (and, in this case, three extensions arranged in a generally triangular arrangement). In alternative embodiments, the traction elements 1120 can have any size, shape, and orientation, and be distributed in any suitable manner, as described herein.

[0295] The sole plate 1015 also includes a second sole portion 1145 with four second traction elements 1155, 1160 having distal ends 1125 and sidewalls 1130 having generally hexagonal cross-sections. In alternative embodiments, the second sole portion 1145 can include a greater or lesser number of traction elements, and the traction elements can have any size, shape, and orientation, and be distributed in any suitable manner, as described herein. For example, in one embodiment of the present invention, one or more of the second traction elements, and / or one or more of the first traction elements 1120 can have a circular, oval, or polygonal cross-section (e.g., a triangle, square, rectangle, pentagon, hexagon, or higher order polygon), and can have any suitable height and cross-sectional area.

[0296] As shown, second sole portion 1145 extends over a medial portion of a lower surface of sole plate 1015 proximate a medial midfoot region 1055 and a medial forefoot region 1062 of sole plate 1015, and more specifically, over at least a first metatarsal region of sole plate 1015. Sole plate 1015 includes three second traction elements 1155 arranged in a generally triangular pattern proximate the first metatarsal region, with a fourth second traction element 1160 positioned forward of the three second traction elements 1155 in medial forefoot region 1062 of plate 1015 (and, e.g., proximate edge 1165 of sole plate 1015).

[0297] The traction elements can be configured symmetrically or asymmetrically as desired. In addition, the traction elements can have different heights and sizes, or all have the same height and / or size, and can taper at any suitable angle. Each of the traction elements in first sole portion 1115 and second sole portion 1145 can be oriented to optimize its traction characteristics for the desired performance requirements of shoe 1000, as described herein.

[0298] The second sole portion 1145 can extend between about 50% and about 80% of the width of the sole plate from the medial side edge to the central area. The second sole portion 1145 includes a first edge 1165 close to the edge of the sole plate, a second edge 1170 extending from the edge of the sole plate to the central area of ​​the sole plate in the forefoot, and a third edge 1175 extending from the edge of the sole plate to the central area of ​​the sole plate from the midfoot area, wherein the second edge 1170 and the third edge 1175 converge and meet in the central area 1178 of the sole plate 1015. In an alternative embodiment, the second sole portion 1145 can extend over any suitable width of the sole plate 1015 and have any suitable shape. In one embodiment, the first sole portion 1115 and the second sole portion 1145 are separated by one or more flex grooves. The flex groove can also be positioned at any suitable position in the first sole portion 1115 and / or the second sole portion 1145.

[0299] In one embodiment, first sole portion 1115 is formed of a different material than second sole portion 1145, where, for example, first sole portion 1115 is formed of nylon and second sole portion 1145 is formed of thermoplastic polyurethane (TPU). In one embodiment, second sole portion 1145 is bonded to, co-molded with, or mechanically attached to the lower surface of first sole portion 1115 (so that second sole portion 1145 is below first sole portion 1115). In an alternative embodiment, first sole portion 1115 may have a cutout portion into which second sole portion 1145 can be inserted, so that second sole portion 1145 is not located below first sole portion 1115, but is instead placed on the lower surface of shoe 1000 beside it.

[0300] The traction element can be formed of any suitable material, and for example can have a base portion integrally formed from the same material as that used in the sole portion, the traction element extending from the base portion, wherein the end portion (close to the distal end 1125) is made of metal (e.g., aluminum or steel) or TPU. In one embodiment, each of the traction elements has an end formed of the same material (e.g., TPU). In an alternative embodiment, different traction elements in the first sole portion 1115 and / or the second sole portion 1145 can have ends formed of different materials. For example, one embodiment of the present invention can include a traction element with a metal end in an area with high wear (e.g., around the metatarsal ball of the wearer's foot), while the traction element has a TPU end in an area with lower wear. The end can be co-molded with the base and sole plate area of ​​the traction element, or connected (by bonding or mechanical attachment-e.g., threaded connection) after the molding of the bottom plate.

[0301] In various embodiments, the sole plate 1015 can include any suitable number and arrangement of plate portions, wherein, for example, different regions provide different degrees of stiffness, torsional stability, flexibility, and / or directional or non-directional traction. Additional stiffness can be provided, for example, by support elements (e.g., elongated strips of material extending from or through the bottom plate) extending over appropriate regions of the sole 1010. For example, a torsional support rod 1180 can be positioned through the midfoot region to provide support and torsional control in that region. In alternative embodiments, the support elements can be placed and oriented in any suitable location on the sole 1010.

[0302] Providing different areas of sole plate 1015 with different sole materials and configurations, and providing different cleats / traction elements extending therefrom, can create a shoe sole having beneficial performance characteristics that vary from one area to another depending on the sport being played. Fig.66C and Fig.66D The sole plate 1015 shown in the figure includes a second sole portion 1145 positioned near the first metatarsal region, which has a generally smooth cleat / traction element (e.g., a circular or hexagonal cross-section cleat), which is configured to interact with the ground to provide appropriate linear traction, but allows the shoe to rotate relatively easily when embedded in the ground, so as to allow the wearer to pivot quickly and easily when most of the weight is on the metatarsal ball of the foot (i.e., in the area close to the first metatarsal head). For example, in sports that require rapid changes in direction, this can be particularly beneficial. However, by placing and orienting the first traction element 1120 that depends on the direction in the first sole portion 1115 away from the metatarsal ball of the foot, the wearer can obtain additional traction when more parts of the foot are on the ground (e.g., during the push-off / lift-off movement of the gait cycle). Depending on the requirements of the wearer, combining different traction elements in such an appropriate arrangement allows the shoe 1000 to support both rapid turning movements and sharp acceleration movements.

[0303] Another sole plate 1015 for a soccer boot / shoe 1000 is provided on Figures 67C to 67E In this embodiment, sole plate 1015 again includes first sole portion 1115 and second sole portion 1145, but wherein the traction elements in the first sole portion have the same general configuration as the traction elements in the second sole portion (i.e., with a central core and three ribs extending therefrom), with the size, shape, and orientation varied as appropriate to optimize the traction properties of shoe 1000 in this area.

[0304] In this embodiment, second sole portion 1145 includes a plurality of secondary traction elements 1190, wherein secondary traction elements 1190 are smaller in size than the primary traction elements in the first and second sole portions. Secondary traction elements 1190 are connected by a plurality of interconnected elongated elements 1195 and provide additional traction in this area of ​​sole plate 1015. In alternative embodiments, any suitable configuration of secondary traction elements 1190 and / or tread elements can be utilized to support traction in different areas of the shoe. For example, in Fig.67E , secondary traction elements 1190 can extend outwardly to medial edge 1197 of sole plate 1015 to provide traction for the shoe even during high-angle cutting movements where only medial edge 1197 of shoe 1000 contacts the ground, and extend across the entire medial forefoot area of ​​sole plate 1015 to provide additional traction during toe-off.

[0305] Figures 67C to 67E The sole plate of the shoe also includes a raised structural support element 1200 in the midfoot area of ​​the sole plate 1015 to provide appropriate stiffness and torsion control for the midfoot area. Here, the structural support element 1200 is formed by a plurality of interconnected elongated elements 1205 forming a truss-like structure. The raised structural support element 1200 can be hollow or solid, depending on the required support and weight requirements of the shoe. In one embodiment, the structural support element 1200 can include a protrusion 1210 at the connection area between the interconnected elongated elements 1205 (and / or elsewhere on the structural support element 1200) to act as an additional traction element to provide additional traction for the shoe.

[0306] The customized footwear elements described herein may be manufactured by any suitable manufacturing technique (such as, but not limited to, injection molding, blow molding), or using rapid manufacturing (additive manufacturing) techniques (such as, but not limited to, selective laser sintering (SLS), fused deposition modeling, stereolithography, layered solid manufacturing, or inkjet-based additive manufacturing), or any suitable computer-controlled manufacturing technique (including layered addition / deposition of materials).

[0307] In one embodiment, the customized footwear components described herein can be manufactured by using SLS manufacturing methods and tools. SLS is an additive manufacturing technology that uses a high-power laser (e.g., a carbon dioxide laser) to fuse small particles of plastic, metal (direct metal laser sintering), ceramic or glass powder into blocks with a desired three-dimensional shape. By scanning the cross-section generated by the 3-D digital description of the part on the surface of the powder bed (e.g., from a CAD file or scanned data), the laser selectively fuses the powder material. After scanning each cross-section, the powder bed is lowered by a layer thickness, a new layer of material is applied on the top, and the process is repeated until the part is completed. SLS manufacturing allows the use of various plastics, ceramics and / or metals to form each component. Example materials that can be used for the manufacture of footwear components include, but are not limited to, polymers and, for example, semi-crystalline polymers such as, but not limited to, nylon (amino compounds), thermoplastic polyurethanes (TPU), thermoplastic elastomers (TPE), polyether block amides (PEBA) and / or polyesters. Other materials may include or consist essentially of shape memory plastics, thermoplastic elastomers (TPE's) such as styrene-butadiene-styrene (SBS), ethylene vinyl acetate (EVA), and / or rubbers such as butadiene rubber. Example metals include materials such as, but not limited to, aluminum, titanium, stainless steel, nickel alloys, cobalt-chromium alloys, maraging steels, shape memory alloys (such as, but not limited to, nickel titanium), or other alloys. In one embodiment, additional filler materials, such as, but not limited to, nylon or carbon fiber or glass fiber, may be added to the base material to modify the properties of the finished part. Example thermoplastic materials for use in SLS additive manufacturing and methods of making parts using these materials are disclosed in U.S. Patent Nos. 6,110,411 to Clausen et al. and 8,114,334 to Martinoni et al., the entire disclosures of both patents are incorporated herein by reference.

[0308] SLS provides a rapid method of manufacturing parts by projecting a laser beam with a desired energy onto a bed of particles of a selected material to form a three-dimensional object in a layer-by-layer manner without the need to form a mold for the part. In addition, SLS allows the formation of complex, monolithic structures that cannot be manufactured by conventional molding techniques. For example, an outsole including an integral traction element with an undercut portion would be extremely difficult to manufacture by conventional injection molding or blow molding manufacturing processes, but is easily manufactured using SLS or other additive manufacturing methods. In one embodiment of the present invention, an exemplary SLS machine that can be used to manufacture customized parts is a P 395 Selective Laser Sintering system manufactured by EOS GmbH Electro Optical Systems of Krailing, Germany.

[0309] Another advantage of utilizing rapid manufacturing techniques such as SLS is the ability to form structures having different layers formed of different materials, for example, an outsole structure having a substrate formed of a first material and an integral traction element formed of a second material. Additionally, by carefully controlling the properties of the laser utilized in SLS manufacturing, such as the laser power and the speed of the laser's scanning trajectory, the density and other structural properties of the materials used to construct a customized component can be carefully controlled over different areas of the structure. For example, this allows a lower density substrate (and therefore, lighter and more flexible) to have a higher density traction element (and therefore, increased strength and stiffness). This also allows different portions of a single structure (e.g., different traction elements within a single structure and / or different portions within a single substrate) to be formed with different density, strength, and / or stiffness properties.

[0310] SLS manufacturing also provides a method of manufacturing customized footwear elements significantly faster than traditional molding techniques, at least because there is no need to make a mold before forming the customized footwear element itself. In one embodiment, the entire customization process, from obtaining input parameters to providing a finished part to an athlete, can be performed in just a few hours, or possibly less. As a result, SLS manufacturing and other related additive manufacturing (or 3D printing) technologies provide an efficient method of manufacturing customized parts and / or multiple customized parts (whether customized or designed for a wide range of users) having structures that are difficult or impossible to manufacture using traditional molding techniques.

[0311] In one embodiment, additional materials, such as, but not limited to, pigments and / or UV stabilizers, may be added to the powdered material utilized in the additive manufacturing process to provide colored parts and / or parts that avoid color changes (e.g., fading or yellowing) over time when exposed to UV light. Pigments, UV stabilizers, and / or other additives may be added during extrusion of the material before the material is powdered, or added to the powdered material in liquid or powder form. In alternative embodiments, color may be added to the structure after the part is formed by spraying, dipping, or any other suitable coating technique. The color may be provided by any suitable pigment, ink, or other colorant(s) or chemical(s).

[0312] Other additives that may be added during the manufacturing process may include, but are not limited to, antioxidants, antistatic agents, and / or brighteners (e.g., fluorescent whitening agents). Example antioxidants may include, but are not limited to, aromatic amines, phenols, phosphites and phosphonites, thiosynergists, hindered amine stabilizers, hydroxylamines, benzofuranone derivatives, and / or acryl-modified phenols. Example antistatic agents may include, but are not limited to, fatty acid esters, ethoxylated alkylamines, diethanolamides, and / or ethoxylated alcohols. Example fluorescent whitening agents may include, but are not limited to, bisbenzoxazoles, phenylcoumarins, and / or bis(styryl)biphenyls.

[0313] In one embodiment, a leveling agent such as, but not limited to, powdered Cab-O- Fumed silica (e.g., available from Suite 1300, Boston, MA 02210, USA)

[0314] The Cab-O- PS 530 (fumed silica) can be added to the powder material to improve the flowability of the material during deposition of the material in a powder bed within an additive manufacturing system, for example, as described in U.S. Pat. No. 6,110,411 to Clausen et al., the entire disclosure of which is incorporated herein by reference.

[0315] In one embodiment, the component may be formed from a material that chemically reacts with another material upon exposure to the other material to expand or foam it to an increased final size after formation. For example, the component may be formed from a material that expands upon exposure to a liquid (e.g., water) such that after being formed in a reduced state, the component may be expanded to its final state by exposure to the liquid.

[0316] In one embodiment, a foaming agent may be added to the manufacturing material (either during extrusion of the raw material(s) or during or after powderization of the raw materials). As a result, a part may be formed by additive manufacturing that includes a foaming agent designed to foam and expand the part as soon as the part is exposed to controlled conditions (e.g., controlled heat and pressure conditions), such as within a post-processing mold or oven. As a result, a part may be formed by additive techniques at reduced dimensions, after which the foaming agent within the part is activated to produce the final foamed part. This may allow objects to be formed by additive manufacturing techniques at reduced dimensions, which allows for a significant reduction in volume requirements during manufacturing, after which the part is expanded to its desired dimensions by activating the foaming agent, thereby allowing significantly more parts to be manufactured in a single manufacturing run. Foaming a part by activating a foaming agent after the part is formed by additive manufacturing may also form a part having different structural properties (e.g., reduced density, increased cushioning, etc.) than a part that could be formed by additive manufacturing alone. The blowing agent may include or consist essentially of any suitable type of physical blowing agent known to those of ordinary skill in the art, such as, but not limited to, nitrogen, carbon dioxide, hydrocarbons (e.g., propane), chlorofluorocarbons, inert gases, and / or mixtures thereof. In an exemplary embodiment, the blowing agent includes nitrogen or consists essentially of nitrogen. Example blowing agents and methods of use are described in U.S. Patent Publication No. 2012-0196115A1, the entire disclosure of which is incorporated herein by reference. An example blowing agent used with the methods and systems described herein is an endothermic blowing agent, such as, but not limited to, Kycerol 91 or Kycerol 92 formed by modifying sodium bicarbonate. Another example blowing agent that can be used includes a thermally expandable microcapsule having a liquefied blowing agent (e.g., a liquefied hydrocarbon) encapsulated by a shell layer (e.g., an acrylic copolymer). An example of such a blowing agent is Cellcom-CAP / 170K.

[0317] The use of SLS or other additive manufacturing techniques allows for the formation of unique structures and combinations of structures that are difficult or impossible to form using traditional manufacturing techniques. Such structures may, for example, include multiple individual components that are simultaneously formed in an integral state during SLS manufacturing to produce interlocking multi-part structures (such as having FIG. 58A to FIG. 58E The midsole of the structural elements and the connecting elements shown). Fig.65 , an example structure is shown including a shoe 994 having an upper 995 and a plurality of sole elements 996 formed within an interior 997 of the upper 995. In this embodiment, the sole element 996 includes a plurality of traction elements 998 that extend through openings 999 in the upper 995 to form a ground contacting surface for the shoe 994.

[0318] In one embodiment, manufacturing using SLS allows for measuring or selecting input parameters remotely (e.g., at a sports facility, in a store, or even at home), so that the input parameters are analyzed remotely or at the user's location (by using a design program adapted to allow the user to design the footwear component itself using the input parameters and various selection criteria), or at the manufacturing facility when input parameter data from the user / athlete is received. The analysis tool may include an algorithm for converting a design based on performance metrics and user preferences into a computer-readable file (e.g., a CAD file) that can be sent directly to the SLS machine to form a customized component. The analysis tool may, for example, include a program or application (App) that can be stored on a PC or portable electronic device and can send input parameters, user selection criteria, performance metric information, and / or final design information to a manufacturing tool via a wireless or wired network for construction of a customized footwear component. As a result, an athlete can remotely create a custom design, send the design to a manufacturing tool, and have the component manufactured and sent back to the user in a short period of time. The measurement tools (e.g., measurement devices, such as pressure sensor arrays, and / or body scans and / or measurement tools) can be located at a shoe store, at a sports facility or event, and / or at home, while the manufacturing tools (e.g., SLS machines) can be located at a shoe store, at a sports facility or event, and / or at a remote manufacturing location. Alternatively, a user can build a customized footwear element at home using a portable consumer additive manufacturing tool.

[0319] In one embodiment, the part or parts formed by the manufacturing process and, for example, by SLS, can be post-processed to provide additional aesthetic and / or structural properties. Such post-processing may include painting the part and / or coating the part with a material that supports or modifies the structural properties of the part, infusing the part with one or more materials, filling a cavity in the part with one or more materials, and / or encasing the part in a covering material.

[0320] In one embodiment of the invention, multiple predetermined footwear options can be provided, rather than providing individually customized footwear for each individual athlete, the athlete selects the most appropriate option according to their specific needs and characteristics. For example, multiple data sets of athlete data (for example, pressure data and force data) can be classified into multiple predetermined categories, and these categories are determined by the following characteristics: such as, but not limited to, foot landing position (for example, heel landing, mid-foot landing or forefoot landing), pronation / supination level, straight running or curve running, etc. In this embodiment, the athlete can select pre-manufactured or post-manufactured "customized" shoes based on the category or multiple categories that the athlete is suitable for. In a specific embodiment, a limited number of different options can be provided for shoes, wherein traction elements are set specifically for heel landing, mid-foot landing and / or forefoot landing.

[0321] One embodiment of the present invention allows to utilize method and algorithm described herein to design and manufacture clothing and / or equipment for athletes and other users.For example, the measured value of individual's physical characteristics can be used to customize design clothing items such as but not limited to, protective helmets, protective clothing for upper and / or lower body (for example, shirts and / or trousers comprising protective materials or sleeves and / or wrappings comprising protective materials for being placed on the limbs and / or torso of the wearer), protective pads, etc. The relevant performance measured values ​​of the athlete for carrying out sports activities can also be included in the input parameters to ensure that clothing provides required protection without sacrificing performance.For example, the measured values ​​of the shape and size of the athlete's head can be used as the input parameters of the method for designing a customized helmet for the athlete, in one embodiment, the input parameters can include the measured values ​​of the athlete's motion (for example, the rotation of the neck and / or the neck shape changes due to the flexion of the neck muscles), and the measured values ​​can be used for further customizing the helmet to limit the impact of the helmet on the wearer's athletic ability, without damaging the protection provided. In one embodiment, customized pads (e.g., shoulder pads, elbow pads, torso pads, forearm pads, shin pads, hip pads, etc.) can be provided to athletes by measuring the physical characteristics of the body part in need of protection and / or taking measurements related to the movement of the body part during the athletic activity for which the pad is designed. Customized helmets, apparel, and / or pads may be beneficial for sports such as, but not limited to, lacrosse, football, ice hockey, field hockey, rugby, soccer, baseball, softball, martial arts, and / or boxing.

[0322] In one embodiment, footwear and blades for skating (e.g., in ice hockey, speed skating, or ice dancing) may be customized for a particular skater based on the wearer's physical characteristics and / or the wearer's performance characteristics (e.g., related to the wearer's skating posture and / or the particular movements performed by the wearer during their particular sporting activity). Because manufacturing methods (such as, but not limited to, SLS) allow components to be manufactured from a number of materials, including both plastics and metals, multiple components of the skate may be custom manufactured, including, but not limited to, the blade, blade attachment, sole, and / or upper.

[0323] One embodiment of the present invention allows the design and manufacture of athletic equipment (or, elements thereof), such as, but not limited to, lacrosse heads, lacrosse nets, golf clubs, tennis rackets, clamping elements for any part of athletic equipment, lacrosse sticks (and, for example, heads and / or clamping portions thereof), using the user's physical characteristics and / or the user's performance characteristics (e.g., by measuring forces, pressures, stresses, strains and / or flexion of the athletic equipment during a specific athletic performance of a sporting activity) using the methods and algorithms described herein.

[0324] It should be understood that alternative embodiments, and / or materials used in the construction of an embodiment or an alternative embodiment may be suitable for all other embodiments described herein.

[0325] Without departing from the spirit or essential characteristics of the present invention, the present invention may be implemented in other specific forms. Therefore, the foregoing embodiments are considered to be illustrative in all respects, rather than to limit the present invention described herein. The scope of the present invention is therefore indicated by the appended claims rather than the foregoing description, and all changes within the meaning and scope of the equivalent schemes of the claims are intended to be included therein.

Claims

1. A sole plate for an article of footwear, comprising: A lower surface adapted for ground contact, the lower surface comprising: a first sole portion including a plurality of first traction elements, the first traction elements including a distal end and a sidewall, the sidewall including three tapered extensions extending from a central core in a generally triangular arrangement; a second sole portion including three second traction elements arranged in a generally triangular pattern proximate a first metatarsal region of a foot of a wearer of the article of footwear and a fourth second traction element positioned in a medial forefoot region of the foot of the wearer of the article of footwear, the second traction element having at least one geometric feature that differs in at least one respect from a corresponding geometric feature of the first traction element, wherein the forefoot region of the second sole portion proximate the lower surface extends from a medial side edge of the sole plate to a central region of the sole plate; a torsion support bar positioned in the midfoot area; wherein the second sole portion extends from the medial side edge to the central region over a maximum of between about 50% and about 80% of the width of the sole plate; wherein the first sole portion and the second sole portion are separated by one or more flexion grooves; and Wherein, the second sole part comprises: a first edge proximate to an inner edge of the sole plate; a second edge extending from the medial edge of the sole plate to a central region of the sole plate; and A third edge extends from the medial edge of the sole plate to the central region of the sole plate, wherein the second edge and the third edge converge and meet in the central region of the sole plate.

2. The sole plate according to claim 1, wherein: The orientation of at least one first traction element in a first area of ​​the first sole portion is different than the orientation of at least one first traction element in a second area of ​​the first sole portion.

3. The sole plate according to claim 1, wherein: The second traction element includes a distal end and a sidewall including a generally hexagonal cross-section.

4. The sole plate according to claim 1, wherein: The second traction element includes a distal end and a sidewall including at least one of a generally circular cross-section, a generally oval cross-section, and a generally polygonal cross-section including at least one of a triangular, square, rectangular, pentagonal, or hexagonal polygon.

5. The sole plate according to claim 1, wherein: The three second traction elements arranged in the generally triangular pattern have generally the same height.

6. The sole plate according to claim 1, wherein: The first sole portion includes a first material, and the second sole portion includes a second material different from the first material.

7. The sole plate according to claim 6, wherein: The first material comprises nylon and the second material comprises thermoplastic polyurethane.

8. The sole plate according to claim 1, wherein: The first sole portion is at least one of bonded to the second sole portion and co-molded with the second sole portion.

9. The sole plate according to claim 1, wherein: The first traction element includes a triangular cross-section.

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