Additive manufacturing footwear sole

Abstract

An article of footwear includes an additive manufactured sole. In some embodiments, an article of footwear may include a sole, an upper, and a bonding element coupling the sole to the upper. In some embodiments, the sole may include a three-dimensional mesh with a ground facing portion and a ledge formed on an upper side of the mesh. The ledge may include a continuous side surface coupled to the bonding element. In some embodiments, the sole may include an undulating underside including a plurality of ridges and a plurality of valleys located between the ridges. In some embodiments, the sole may include a continuous ground facing rim formed on a peripheral portion of an underside of the sole.

Description

Technical Field

[0001] The embodiments described herein generally relate to soles and sole features of footwear items. Specifically, the embodiments described herein relate to additive manufactured soles having features designed to couple to an upper and / or provide ground contact features. Background Art

[0002] Footwear generally includes a sole that provides support and cushioning for a wearer's foot and an upper that is attached to the sole and encloses the wearer's foot. The sole can be configured to provide desired comfort and performance characteristics to the wearer. The sole can be formed by molding a foam material, such as ethylene vinyl acetate (EVA), etc.

[0003] Runners and other athletes may desire footwear to have specific performance features to optimize their performance. Additionally, customization of the sole can allow for the footwear to be tailored to a specific athlete. Accordingly, there is a continuing need for soles that provide desired attributes and performance features. Summary of the Invention

[0004] A footwear item and components thereof according to the present invention can include one or more or a combination of the following features.

[0005] A first embodiment (1) of the present application relates to a footwear item including a sole, the sole including: a three-dimensional mesh extending from a toe region of the sole to a heel region, the mesh including: a grid structure including a plurality of interconnected unit cells, each interconnected unit cell including a plurality of struts defining a three-dimensional structure and a plurality of nodes, and one or more unit cells being connected at the nodes; a ground-facing portion including a plurality of traction elements and located at a lower side of the mesh opposite an upper side; a ledge formed at the upper side of the mesh and including a continuous side surface that faces the lower side and extends along at least one of an outer lateral side or an outer medial side of the mesh; an upper coupled to the mesh; and a bonding element extending between the ledge and the upper and coupling the ledge to the upper.

[0006] In a second embodiment (2), the mesh, the ledge, and the ground-facing portion according to the first embodiment (1) are integrally formed as a single piece.

[0007] In a third embodiment (3), an upper side of the mesh according to the first embodiment (1) or the second embodiment (2) includes an upper surface that is substantially smooth in surface profile.

[0008] In a fourth embodiment (4), continuous side surfaces of the ledge according to any one of the first embodiment (1) to the third embodiment (3) extend around a heel region of the sole from an outer lateral side of the mesh to an outer medial side.

[0009] In a fifth embodiment (5), the ledge according to any one of the first embodiment (1) to the fourth embodiment (4) further includes a solid top surface formed on an upper surface of an upper side of the mesh.

[0010] In a sixth embodiment (6), the coupling element according to any one of the first embodiment (1) to the fifth embodiment (5) is coupled to the continuous side surfaces of the ledge.

[0011] In a seventh embodiment (7), the ledge according to any one of the first embodiment (1) to the sixth embodiment (6) extends into a midfoot region of the mesh.

[0012] In an eighth embodiment (8), a lower side of the mesh according to any one of the first embodiment (1) to the seventh embodiment (7) includes a plurality of ridges and a plurality of valleys located between respective ridges, and a plurality of traction elements of the ground-facing portion are formed on each of the plurality of ridges.

[0013] In a ninth embodiment (9), each of the plurality of traction elements according to the eighth embodiment (8) includes a separate continuous surface layer that covers a part of each of the plurality of ridges.

[0014] In a tenth embodiment (10), a lower side of the mesh according to any one of the first embodiment (1) to the seventh embodiment (7) includes a ground-facing peripheral edge and an intermediate portion in the ground-facing peripheral edge, and a plurality of traction elements of the ground-facing portion are formed on the ground-facing peripheral edge.

[0015] In an eleventh embodiment (11), the intermediate portion according to the tenth embodiment (10) is recessed relative to the peripheral edge.

[0016] In a twelfth embodiment (12), the ground-facing peripheral edge according to the tenth embodiment (10) includes a continuous surface layer that extends around each of a toe region, a midfoot region, and a heel region of the sole, and a plurality of traction elements are formed on the continuous surface layer.

[0017] The thirteenth embodiment (13) of the present application relates to a sole for a footwear item, the sole comprising: a three-dimensional mesh extending from a toe region to a heel region of the sole, the mesh comprising: a grid structure including a plurality of interconnected unit cells, each interconnected unit cell including a plurality of struts defining a three-dimensional structure and a plurality of nodes, and one or more unit cells are connected at the nodes; a wavy underside including a plurality of ridges and a plurality of valleys between respective ridges, wherein the ridges are at least partially defined by one or more unit cells of the grid structure; and a plurality of traction elements formed on the plurality of ridges of the wavy underside of the mesh such that the plurality of traction elements face the ground.

[0018] In the fourteenth embodiment (14), the plurality of ridges according to the thirteenth embodiment (13) include a first ridge and a second ridge. A first height of the first ridge located in the toe region among the plurality of ridges is measured between a first peak of the first ridge and a bottom of an adjacent valley among the plurality of valleys. A second height of the second ridge located in the heel region among the plurality of ridges is measured between a second peak of the second ridge and a bottom of an adjacent valley among the plurality of valleys, and the second height is different from the first height.

[0019] In the fifteenth embodiment (15), the second height according to the thirteenth embodiment (13) is greater than the first height.

[0020] In the sixteenth embodiment (16), each of the plurality of traction elements according to any one of the thirteenth embodiment (13) to the fifteenth embodiment (15) includes a separate continuous surface layer covering a part of each of the plurality of ridges.

[0021] In the seventeenth embodiment (17), the continuous surface layer of each traction element according to the sixteenth embodiment (16) includes a ribbed traction texture.

[0022] In the eighteenth embodiment (18), at least one ridge located in the toe region of the sole among the plurality of ridges according to any one of the thirteenth embodiment (13) to the eighteenth embodiment (18) includes a flatter profile than at least one ridge located in the heel region of the sole among the plurality of ridges.

[0023] In the nineteenth embodiment (19), the sole according to any one of the thirteenth embodiment (13) to the eighteenth embodiment (18) further includes a plurality of connecting ribs formed on the wavy underside of the mesh and extending between adjacent traction elements of the plurality of traction elements.

[0024] The twentieth embodiment (20) of the present application relates to a sole for a footwear item, the sole comprising: a three-dimensional mesh extending from a toe region to a heel region of the sole, the mesh comprising: a grid structure including a plurality of interconnected unit cells, each interconnected unit cell including a plurality of struts defining a three-dimensional structure and a plurality of nodes, and one or more unit cells being connected at the nodes; and a continuous ground-facing edge formed on a peripheral portion of the underside of the mesh, wherein the continuous ground-facing edge extends around each of the toe region, midfoot region, and heel region of the sole, and the continuous ground-facing edge includes a plurality of traction elements formed on the ground-facing surface of the edge.

[0025] In the twenty-first embodiment (21), a depression is formed in the midfoot region of the intermediate portion between the ground-facing edges of the mesh according to the twentieth embodiment (20).

[0026] In the twenty-second embodiment (22), the plurality of traction elements according to the twentieth embodiment (20) or the twenty-first embodiment (21) form a ribbed traction texture.

[0027] In the twenty-third embodiment (23), the sole according to any one of the twentieth embodiment (20) to the twenty-second embodiment (22) further includes a plurality of connecting ribs formed on the wavy underside of the mesh and extending through the intermediate portion of the underside to connect the outer side of the ground-facing edge to the inner side of the ground-facing edge. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] The accompanying drawings, which are incorporated herein and form a part of the specification, illustrate the invention and, together with the description, further serve to explain the principles of the invention and enable a person skilled in the relevant art to make and use the invention.

[0029] Figure 1 A side view of a footwear item having a sole coupled to an upper by a coupling element is shown in accordance with some embodiments.

[0030] Figure 2 An exploded view of a footwear item including a sole, an upper, and a coupling element is shown in accordance with some embodiments.

[0031] Figure 3 A cross-sectional view of an assembled footwear item is shown in accordance with some embodiments, showing the sole coupled to the upper by a coupling element.

[0032] Figure 4A A side view of a sole is shown in accordance with some embodiments.

[0033] Figure 4B Shows Figure 4AA top - down flipped view of the sole shown.

[0034] Figure 5 A perspective top - view of a sole according to some embodiments is shown.

[0035] Figure 6 Shows Figure 5 A perspective bottom - view of the sole shown.

[0036] Figure 7 Shows Figure 5 A top - down flipped view of the sole shown.

[0037] Figure 8 Shows Figure 7 A cross - sectional view of the sole in along section line 8–8.

[0038] Figure 9 Shows Figure 7 A cross - sectional view of the sole in along section line 9–9.

[0039] Figure 10 A perspective bottom - view of a sole according to some embodiments is shown.

[0040] Figure 11 Shows Figure 10 A top - down flipped view of the sole shown.

[0041] Figure 12 Shows Figure 11 A cross - sectional view of the sole in along section line 12–12. Detailed Description

[0042] Reference will now be made in detail to the representative embodiments shown in the drawings. It should be understood that the following description is not intended to limit the embodiments to a preferred embodiment. On the contrary, the present invention is intended to cover alternatives, modifications, and equivalents that may be included within the spirit and scope of the described embodiments.

[0043] References in the specification to "one embodiment", "an embodiment", "exemplary embodiments", "some embodiments", etc., indicate that the described embodiments may include a particular feature, structure, or characteristic, but each embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, these phrases do not necessarily refer to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is considered within the knowledge of those skilled in the art to effect such feature, structure, or characteristic in connection with other embodiments, whether or not explicitly described.

[0044] The indefinite articles "a", "an", and "the" include plural referents unless expressly contradicted or the context clearly dictates otherwise.

[0045] The term "comprising" is an open transitional phrase. The list of elements following the transitional phrase "comprising" is a non-exclusive list, such that elements other than those specifically recited in the list may also be present.

[0046] As used herein, unless otherwise specified, references to "first," "second," "third," "fourth," etc. are not intended to denote order, or that a feature with a higher number requires a feature with a lower number. Additionally, unless otherwise specified, the use of "first," "second," "third," "fourth," etc. does not necessarily mean that the "first," "second," "third," "fourth," etc. features have different properties or values.

[0047] Footwear generally includes a sole formed from a molded material (e.g., injection molding or compression molding). In some cases, when the midsole is molded as one piece, the properties of the resulting midsole cannot be made to vary over different portions of the midsole. Thus, the molded midsole may include isotropic properties. However, in some cases, it may be desirable to provide a midsole having mechanical properties that vary over different regions or within different regions and / or vary according to the direction of loading of the midsole to improve the performance of the midsole and allow for customization of the performance of the midsole. For example, it may be desirable to provide a midsole having anisotropic properties that vary over different portions of the midsole in order to improve the performance of the midsole and allow for customization of the performance of the midsole.

[0048] Some embodiments described herein relate to footwear including a sole that includes a three-dimensional mesh to provide desired properties to the sole, such as ground contact properties and anisotropic properties. In some embodiments, the mesh can be customized to provide different characteristics in different regions of the sole. In some embodiments, the anisotropic properties can assist in guiding an athlete's foot during movement or can be used to guide a wearer's foot during daily use. Additionally, selective mechanical deformation of the mesh can be achieved to provide a stride length gain during the ground contact phase of walking or running. Some embodiments described herein relate to footwear articles or footwear components including an additively manufactured three-dimensional mesh. In some embodiments, the mesh can absorb midfoot and heel impact forces and convert vertical momentum into forward momentum by angularly offset mesh features arranged to convert a force applied along a desired direction into an angular rotation.

[0049] Some embodiments described herein relate to an article of footwear or a footwear component that includes a sole, the sole including a wavy or irregular bottom surface formed on a lower side of a mesh to provide a plurality of traction elements dispersed across the lower side of the sole. Accordingly, the footwear can be customized such that the mechanical properties obtained by the sole vary across or within different regions and / or vary according to the direction of midsole loading (e.g., anisotropic properties) to provide performance improvements. Some embodiments described herein relate to an article of footwear or a footwear component that includes an additive manufactured three-dimensional mesh. The additive manufacturing techniques described herein can produce footwear that includes customized properties generated by controlling the mesh geometry and dimensions.

[0050] Some embodiments described herein relate to an article of footwear or a footwear component that includes a sole, the sole including a substantially smooth or flat top surface. During the manufacture of the sole, the upper side of the sole can be coupled to a build plate or print head for additive manufacturing the sole. This manufacturing configuration allows additional degrees of freedom in the design and construction of the lower side of the sole. For example, as described herein, the lower side (ground-facing side) can be customized to meet a user's expectations for support or performance in the sole, and / or can include a wavy or irregular bottom surface as described herein. Additionally, the lower side (ground-facing side) can be designed to have peaks, valleys, and / or recesses as described herein. These peaks, valleys, and / or recesses can provide cushioning performance, performance, and / or weight reduction, among other things.

[0051] In addition to the customized bottom surface, the smooth top surface can also provide benefits in the assembly of the article of footwear. In some embodiments, the flat top surface can include a solid surface integrally formed thereon that increases the contact area for adhesion with other components of the article of footwear. In some embodiments, ledges can be formed in the smooth or flat top surface, the top surface including a large continuous surface area for adhesion with a bonding element that can, in turn, be coupled to the upper. This large continuous surface can increase the bond strength of the adhesion between the bonding element and the ledge of the sole as compared to the bond strength of the adhesion between the bonding element and the mesh pattern in the sole.

[0052] As used herein, the term three-dimensional network refers to a three-dimensional structure that includes a plurality of interconnected unit cells arranged in a network structure or a grid structure. The network or grid structure of the network includes interconnected structural members (struts) that define a plurality of unit cells. The structural members and the unit cells can be connected at nodes. For example, the interconnected structural members can be struts that are connected at nodes and define unit cells arranged in a grid configuration. In some embodiments, the plurality of interconnected unit cells can be arranged in a regular or repeating grid configuration. Exemplary grid structures include, but are not limited to, a basic cubic grid, a body-centered cubic grid, a face-centered cubic grid, and modified grids based on these grid types. Exemplary grid structures include, but are not limited to, the grid structures described in U.S. Application Nos. 17 / 069,623 and 18 / 313,135, which are incorporated herein by reference in their entirety.

[0053] The unit cells can have any of a variety of sizes and geometries. In addition, the unit cells within the three-dimensional network can be the same or different. Thus, the three-dimensional network can include unit cells of different sizes or geometries. The three-dimensional shape of the unit cell can be defined by a plurality of interconnected struts that are connected to each other at nodes. In such an embodiment, each unit cell can include a basic geometry defined by the struts. As used herein, "basic geometry" refers to the basic three-dimensional shape, connection, and arrangement of the struts that define the unit cell. The basic geometry of the unit cell can be, but is not limited to, a dodecahedron (e.g., rhombic), a tetrahedron, an icosahedron, a cube, a cuboid, a prism, or a parallelepiped. Each node can be connected to two or more struts. The struts can be arranged to provide a three-dimensional network with desired performance characteristics, and the three-dimensional network can include regions with struts of different densities.

[0054] In some embodiments, the interconnected unit cells can include a solid representation of a repeating implicit surface of the grid structure. In such an embodiment, the unit cell can include a "base surface geometry" defined by the underlying three-dimensional shape of the body, which is formed by one or more strips of material (walls) that are a solid representation of the implicit surface that defines the complete unit cell. In some embodiments, the implicit surface can be a periodic implicit surface such that the base surface geometry of each unit cell contacts the base surface geometry of at least some adjacent unit cells to create a grid. An example of a suitable periodic surface is a G-minimal surface (gyroid), but any type of suitable periodic surface can be used.

[0055] Here, an entity representation of an implicit surface refers to an entity object that follows the shape of the implicit surface. The actual implicit surface has no thickness, while the entity representation of the implicit surface has a thickness on one or both sides of the actual implicit surface in three-dimensional space. The thickness gives the volume of the entity representation, meaning the entity representation can be constructed from physical materials into a physical object. The added thickness can be uniform, or at least approximately uniform despite the presence of rounded corners or local deformations, and is thin compared to the overall dimensions of the implied surface being represented. In some embodiments, the relative density of the unit cell of the solid representation can be 5% to 30%, 5% to 40%, 10% to 25%, or 15% to 20%. As used herein, the term "relative density" refers to the percentage of the amount of the unit cell occupied by the solid material in the total volume of the unit cell.

[0056] In some embodiments, an implicit surface can be created using a combination of random Fourier series functions, where linear and / or non-linear coefficients and linear and non-linear variables within the sine and cosine terms in the x, y, and z spaces are iterated to generate the function. The resulting unit cell can have different planes of symmetry, e.g., in various examples, zero planes of symmetry, one plane of symmetry, or more than one plane of symmetry. The function can be derived in a manner that satisfies the periodicity of the unit cell. The criteria for selecting an applicable implicit surface within the design space domain can include any one or any combination of the number of terms in the equation, the number of connecting components, the edge boundary length, the surface area, and the volume fraction.

[0057] The sole of the footwear item described herein (e.g., sole 112) and any component of the sole footwear described herein can be formed by additive manufacturing, such as three-dimensional (3D) printing. Exemplary additive manufacturing techniques generally include, for example, selective laser sintering, selective laser melting, selective heat sintering, stereolithography, fused deposition modeling, or 3-D printing. Various additive manufacturing techniques related to footwear items are described, for example, in US2009 / 0126225, WO 2010 / 126708, US2014 / 0300676, US2014 / 0300675, US2014 / 0299009, US2014 / 0026773, US2014 / 0029030, WO 2014 / 008331, WO 2014 / 015037, US2014 / 0020191, EP2564719, EP 2424398, and US2012 / 0117825. In some embodiments, the additive manufacturing process can include a continuous liquid interface production process. For example, the additive manufacturing process can include a continuous liquid interface production process as described in U.S. Patent No. 9,453,142, issued on September 27, 2016, which is incorporated herein by reference in its entirety.

[0058] In some embodiments, 3-D printing for a sole or a component of a footwear item may include 3-D printing a sole or component in an intermediate green state, shaping the sole or component in the green state, and curing the green state into its final shape. In some embodiments, 3-D printing for a sole or a component of a footwear item may include 3-D printing a sole or component in an intermediate green state, expanding the green state, shaping the sole or component in the green state, and curing the green state into its final shape.

[0059] Techniques for producing intermediate green state objects from resins by additive manufacturing are known. Suitable techniques include bottom-up and top-down additive manufacturing commonly known as stereolithography. These methods are known and are described, for example, in U.S. Patent Nos. 5,236,637 to Hull, 5,391,072 and 5,529,473 to Lawton, 7,438,846 to John, 7,892,474 to Shkolnik, 8,110,135 to El-Siblani, U.S. Patent Application Publication No. 2013 / 0292862 to Joyce, and U.S. Patent Application Publication No. 2013 / 0295212 to Chen et al. The disclosures of these patents and applications are hereby incorporated by reference in their entireties.

[0060] In some embodiments, the additive manufacturing step may be performed by one of a family of methods sometimes referred to as continuous liquid interface production (CLIP). CLIP is known and is disclosed in, for example, U.S. Patent Nos. 9,211,678; 9,205,601; 9,216,546; and other documents; "Continuous Liquid Interface Production of 3D Objects" by J. Tumbleston et al. (Science 347, 1349 - 1352 (2015)); "Layerless Manufacturing by Continuous Liquid Interface Production" by R. Janusziewcz et al. (Proc. Natl. Acad. Sci. USA 113, 11703 - 11708 (Oct. 18, 2016)). Other examples of methods and apparatuses for performing specific embodiments of CLIP include, but are not limited to: Batchelder et al., U.S. Patent Application Publication No. US2017 / 0129169 (May 11, 2017); Sun and Lichkus, U.S. Patent Application Publication No. US2016 / 0288376 (Oct. 6, 2016); Willis et al., U.S. Patent Application Publication No. US2015 / 0360419 (Dec. 17, 2015); Lin et al., U.S. Patent Application Publication No. US2015 / 0331402 (Nov. 19, 2015); D. Castanon, U.S. Patent Application Publication No. US2017 / 0129167 (May 11, 2017); B. Feller, U.S. Patent Application Publication No. US2018 / 0243976 (published Aug. 30, 2018); M. Panzer and J. Tumbleston, U.S. Patent Application Publication No. US2018 / 0126630 (published May 00, 2018); K. Willis and B. Adzima, U.S. Patent Application Publication No. US2018 / 0290374 (Oct. 11, 2018); L. Robeson et al., PCT Patent Publication No. WO 2015 / 164234 (see also U.S. Patent Nos. 10,259,171 and 10,434,706); and C. Mirkin et al., PCT Patent Publication No. WO 2017 / 210298 (see also U.S. Patent Application No. US2019 / 0160733). The disclosures of these patents and applications are hereby incorporated by reference in their entirety.

[0061] Although stereolithography techniques such as CLIP may be preferred, it should be understood that other additive manufacturing techniques such as inkjet printing (see, for example, U.S. Patent No. 6,259,962 to Gothait and U.S. Patent Application No. US2020 / 0156308 to Ramos et al.) may also be used.

[0062] In any of the embodiments described herein, the mesh may be selected to provide the desired performance characteristics. The mesh can be customized to provide a higher stiffness-to-weight ratio to provide a lightweight midsole, control the shear stiffness of the midsole to allow or prevent midsole shear, and control energy return and damping.

[0063] Exemplary materials for the sole 112 and its components (such as the mesh 130) include, for example, but are not limited to, foams, rubbers, ethylene vinyl acetate (EVA), thermoplastic elastomers, thermoplastic polyurethanes (TPU), expanded thermoplastic polyurethanes (eTPU), expanded elastic polyurethanes, polyether block amides (PEBA), expanded polyether block amides (ePEBA), thermoplastic rubbers (TPR), and polyolefins such as polyethylene (PE), polystyrene (PS), polypropylene (PP), nylon (polyamide), carbon, graphene, carbon fiber, carbon nanotubes, fiber-reinforced polymers, mycelium, aluminum, steel, titanium, or any other suitable material.

[0064] Some embodiments described herein relate to an article of footwear that includes an upper 110, a sole 112, and a binding element 114 configured to couple the sole 112 to the upper 110, as Figure 1 shown. In some embodiments, the article of footwear 100 can be a footwear component, such as a sole or a midsole, or can be a complete article of footwear, such as a shoe, a sports shoe, a boot, or a splint, and other types of footwear. In Figure 1 and Figure 2 the illustrative embodiment shown, the binding element 114 overlaps a portion of the sole 112 and a portion of the upper 110 to connect the upper 110 and the sole 112 together. In some embodiments, the binding element 114 can increase the binding strength between the upper 110 and the sole 112. In some embodiments, the sole 112 can include a three-dimensional mesh 130 such that adjacent surfaces of the upper 110 in the article of footwear 100 are formed by a grid structure 140. In Figure 4A 、 Figure 4B and Figure 5 the illustrative embodiment shown, a ledge 134 is formed around the heel region 124 of the sole 112. The ledge 134 can provide a continuous surface for the binding element 114 to adhere to.

[0065] In some embodiments, the upper 110 may include a nonwoven, woven, or knitted textile material. In some embodiments, the upper 110 may include a knitted upper. The knitted upper may be formed by flat knitting or circular knitting. In some embodiments, the upper 110 may include a sock-type upper. Exemplary textile materials for the upper 110 include, but are not limited to, thermoplastic polyurethane (TPU), polyester, polyamide, polyethylene (PE), PE foam, polyurethane (PU) foam, nylon, ultra-high molecular weight polyethylene (e.g., (a type of ultra-high molecular weight polyethylene), carbon fiber, (a type of para-aramid), synthetic spider silk, cotton, wool, natural or artificial silk, polyethersulfone (PES), (polyether-polyurea copolymer) or a blend of two or more of these materials.

[0066] In some embodiments, sole 112 may include a three-dimensional mesh 130, a ground-facing portion 132, and a ledge 134, e.g. Figure 4A , Figure 4B and Figure 5 In some embodiments, the mesh 130, the ground-facing portion 132, and the ledge 134 can be integrally formed (e.g., integrally 3D printed) as a single piece of the sole 112. In some embodiments, at least two of the mesh 130, the ground-facing portion 132, and the protrusions 134 can be assembled and bonded together to form the sole 112. The sole 112 may include a toe region 120, a midfoot region 122, a heel region 124, a medial side 126, and a lateral side 128, for example Figure 4A and Figure 4B shown.

[0067] The three-dimensional mesh 130 may provide desired properties to the sole 112, such as anisotropic properties, and / or allow the sole 112 to be customized to provide different properties in different regions 120, 122, 124 of the sole 112. For example, selective mechanical deformation of the mesh 130 may provide stride length gains during the ground contact phase of walking or running, which may be optimized by selecting the geometry and size of the mesh 130. In addition, the mesh 130 may absorb midfoot and heel strike forces and convert vertical momentum into forward momentum through angular biasing features arranged to convert forces applied in a desired direction into angular rotation.

[0068] In some embodiments, the mesh 130 may be formed by any of the additive manufacturing (eg, three-dimensional (3D) printing) techniques described herein.

[0069] exist Figure 1 , Figure 2 , Figure 4A ,Figure 4B and Figure 5 In the illustrative embodiments shown, the mesh 130 may include a plurality of interconnected unit cells 140 arranged in a mesh structure or a grid structure. The plurality of unit cells 140 may be formed by a plurality of struts 142 connected together at a plurality of nodes 144. The plurality of struts 142 may be interconnected structural members that define a three-dimensional structure in the mesh 130 and may determine the desired properties of the sole 112. The plurality of struts 142 are connected at the plurality of nodes 144 and define the unit cells 140 of the mesh 130. In some embodiments, the plurality of interconnected unit cells 140 may be arranged in a regular or repeating grid configuration.

[0070] In some embodiments, the mesh 130 may include an upper side 150 and a lower side 152, such as Figure 4A - Figure 6 shown. The upper side 150 may include an upper surface 154 configured to contact the upper 110 when the footwear item 100 is assembled, and an upper peripheral edge 155 extending around the perimeter of the upper surface 154. In some embodiments, the upper surface 154 may include an upper peripheral edge 153 that forms a continuous surface around the peripheral edge 155 of the upper side 150. In some embodiments, a portion of the unit cell 140 may be exposed on the upper side 150 between the edges of the upper peripheral edge 153. In some embodiments, the upper surface 154 may include a generally smooth overall surface such that the plurality of struts 142 have a flat profile at the upper surface 154. In some embodiments, the upper surface 154 may include a shallow profile that follows the approximate shape of the user's foot. In some embodiments, the upper surface 154 may have a first radius in the toe region 120 and a second radius in the midfoot region 122. In some embodiments, the first radius may be approximately 410 mm. In some embodiments, the first radius may be greater than or equal to about 400 mm to less than or equal to about 420 mm. In some embodiments, the second radius may be approximately 100 mm. In some embodiments, the second radius may be greater than or equal to about 90 mm to less than or equal to about 110 mm. In some embodiments, the upper surface 154 may have a shape formed by a method as described in U.S. Application 17 / 419,601, the disclosure of which is incorporated herein by reference in its entirety.

[0071] In some embodiments, the upper peripheral edge 153 may include a toe guard 151 formed (e.g., integrally 3D printed) within the upper peripheral edge 153.

[0072] A ledge 134 may be formed on the upper side 150 of the sole 112 around the heel region 124, such as Figure 4B and Figure 5As shown. The ledge 134 can be configured to provide continuous surface areas 156, 158 for adhering to the bonding element 114. The ledge 134 can include a large continuous surface area for adhering to the bonding element 114. Compared to the bonding strength of the bond between the bonding element 114 and the plurality of interconnected unit cells 140 of the mesh 130, the continuous surface area of the ledge 134 can increase the bonding strength of the bond between the bonding element 114 and the ledge 134.

[0073] The ledge 134 can include a continuous side surface 156. In some embodiments, the ledge can include a solid top surface 158, such as Figure 4A , Figure 4B and Figure 5 as shown.

[0074] The solid top surface 158 can extend around the heel region 124 and along the upper surface 154 away from the upper peripheral edge 155. In some embodiments, the solid top surface 158 can be substantially perpendicular to the continuous side surface 156. In some embodiments, the solid top surface 158 can extend away from the continuous side surface 156 at an obtuse angle relative to the continuous side surface 156. In some embodiments, the solid top surface 158 can form a part of the upper peripheral rim 153. In some embodiments, the solid top surface 158 can extend beyond the upper peripheral rim 153 and be further away from the upper peripheral edge 155 than the upper peripheral rim 153.

[0075] The continuous side surface 156 can extend around the heel region 124 and away from the upper peripheral edge 155 along the outer medial side 126, the outer lateral side 128, or both to the lower ledge edge 189 of the ledge 134, such as Figure 5 as shown. In Figure 4B and Figure 5 the exemplary embodiments shown, the continuous side surface 156 extends along a portion of the medial side 126 and the lateral side 128 of the sole 112, from the heel region 124 of the sole 112 to the midfoot region 122. In some embodiments, the continuous side surface 156 can extend further along the medial side 126 than along the lateral side 128. In some embodiments, the continuous side surface 156 can extend further along the lateral side 128 than along the medial side 126. In some embodiments, when the sole 112 and the upper 110 are coupled together, the lower ledge edge 189 can be used to align, properly position, and / or orient the bonding element 114.

[0076] In some embodiments, the continuous side surface 156 extends a ledge distance 159 from the upper peripheral edge 155 between the upper side 150 and the lower side 152 to the lower ledge edge 189. In some embodiments, the ledge distance 159 can be greater than or equal to about 3 millimeters (mm) to less than or equal to about 15 mm from the upper peripheral edge 155. In some embodiments, the ledge distance 159 can be greater than or equal to about 5 mm to less than or equal to about 10 mm from the upper peripheral edge 155. In some embodiments, the ledge distance 159 can be about 10 mm from the upper peripheral edge 155. In some embodiments, the ledge distance 159 can be characterized as a portion of the distance between the upper side 150 and the lower side 152 of the sole 112. In some embodiments, the ledge distance 159 can be greater than or equal to about 10% to less than or equal to about 50% of the distance between the upper side 150 and the lower side 152 of the sole 112. In some embodiments, the ledge distance 159 can be greater than or equal to about 15% to less than or equal to about 40% of the distance between the upper side 150 and the lower side 152 of the sole 112.

[0077] In some embodiments, the continuous side surface 156 is a solid member that extends completely around the sole 112. In some embodiments, a plurality of through-holes 157 can be formed in the continuous side surface 156 along the inner side 126 and the outer side 128 of the sole 112. In some embodiments, the plurality of through-holes 157 can allow for venting during the manufacture of the sole 112 to increase the yield of the sole 112 and reduce defects. In some embodiments, the plurality of through-holes 157 provide venting during the manufacture of the sole 112, which can reduce the manufacturing lead time of the sole 112.

[0078] In Figure 1 - Figure 3In the illustrative embodiments shown, the upper 110 is connected to the sole 112 by a bonding element 114. In some embodiments, the bonding element 114 may be coupled to the sole 112 with an adhesive 116, such as epoxy, glue, or any other suitable adhesive. The bonding element 114 overlaps and adheres to a portion of the upper 110 with the adhesive 116 and overlaps and adheres to the ledge 134 of the sole 112 with the adhesive 116. The overlap of the bonding element 114 across the upper 110 and the ledge 134 of the sole 112 can help facilitate the attachment of the sole 112 to the upper 110. The ledge 134 can provide a greater adhesive contact area than the unit cell 140 of the mesh 130, thereby allowing an increase in the bonding strength between the bonding element 114 and the sole 112. In some embodiments, the bonding element 114 may include a patch strip. In some embodiments, the bonding element 114 may include a flange that couples the sole 112 to the upper 110. In some embodiments, the bonding element 114 may include a molded clip. Suitable materials for the bonding element 114 may include, but are not limited to, rubber, ethyl vinyl acetate (EVA), thermoplastic elastomer, thermoplastic polyurethane (TPU), expanded thermoplastic polyurethane (eTPU), expanded elastic polyurethane, polyether block amide (PEBA), expanded polyether block amide (ePEBA), thermoplastic rubber (TPR), and polyolefins such as polyethylene (PE), polystyrene (PS), or polypropylene (PP), nylon (polyamide), or foams including one or more of these materials. Additional suitable materials include graphene, carbon fiber, carbon nanotubes, fiber-reinforced polymers, mycelium, aluminum, steel, titanium, or any other suitable material. In some embodiments, the bonding element 114 may include a material that is partially or fully melted (e.g., by infrared welding) to join the upper 110 and the sole 112 together.

[0079] Exemplary instances of the assembly of the upper 110, sole 112, and bonding element 114 are shown in Figure 3 The upper 110 is fitted over the upper surface 154 of the mesh 130. The shape of the upper 110 in the portion adjacent the sole 112 may include a contour that conforms to the user's foot. This shape can create a gap 111 between the upper 110 and the sole 112. In some embodiments, the gap 111 is filled with the adhesive 116 and covered by the bonding element 114 during the construction of the footwear item 100. In some embodiments, the bonding element 114 may form the outermost surface of the footwear item 100 that extends between the overlapping portions of the upper 110 and the ledge 134.

[0080] In some embodiments, for example Figure 5 - Figure 9As shown, the lower side 152 of the mesh 130 may include a wavy surface such that the ground-facing portion 132 is formed on the lower side 152 of the mesh 130. In some embodiments, the lower side 152 of the mesh 130 may include a plurality of ridges 160 and a plurality of valleys 170 positioned between respective ones of the plurality of ridges 160. The plurality of ridges 160 are at least partially formed by one or more underlying unit cells 140 of the mesh 130. Similarly, the plurality of valleys 170 are at least partially formed by one or more underlying unit cells 140 of the mesh 130.

[0081] The plurality of ridges 160 can be dispersed on the lower side 152 in a uniform or non-uniform pattern. In some embodiments, the plurality of ridges 160 can be dispersed across the entire lower side 152 to provide support to desired portions of the user's foot. In some embodiments, the plurality of ridges 160 can be positioned to enhance the performance of the sole 112 for the user. In some embodiments, one or more of the underlying unit cells 140 for the plurality of ridges 160 can include selective mechanical deformation for each respective ridge 160 of the plurality of ridges 160. For example, the ridges 162, 164 can absorb impact forces and convert vertical momentum into forward momentum by angularly offset mesh geometries arranged to convert forces applied in a desired direction into angular rotation.

[0082] In some embodiments, the ground-facing portion 132 may include a plurality of traction elements 190 formed on each of the plurality of ridges 160, such as Figure 6 - Figure 9 shown. In some embodiments, each of the plurality of traction elements 190 can form a continuous surface layer 192 that covers a respective portion of each of the plurality of ridges 160. In some embodiments, each continuous surface layer 192 may extend over each respective ridge 160 and be configured to contact the ground during use. In such embodiments, the sole 112 may not have an outsole material disposed on the surface layer 192. In some embodiments, each continuous surface layer 192 can be integrally formed with the mesh 130 (e.g., integrally 3D printed).

[0083] In some embodiments, each continuous surface layer 192 may include a traction texture 194. In such embodiments, the traction texture 194 can be used to increase traction when the sole 112 contacts the ground during use. In Figure 6 and Figure 7In the illustrative embodiments, the traction texture 194 may include a ribbed traction texture that includes a plurality of contoured ribs. In some embodiments, the traction texture 194 may include concentric rib circles, overlapping rib circles, wavy ribs, or any other suitable geometry. In some embodiments, the traction texture 194 may correspond to the motion for which the footwear item 100 is used. For example, the traction texture 194 may be designed for running in a straight line, such as on a treadmill, or may include lateral features to improve traction when the user changes direction.

[0084] In some embodiments, the plurality of protrusions 160 may have different geometries across the sole 112. For example, the first protrusion 162 in the toe region 120 may differ in height, slope, and / or size compared to the second protrusion 164 in the heel region 124. In some embodiments, within the toe region 120, the plurality of protrusions 160 may differ in height, slope, and / or size. In some embodiments, within the midfoot region 122, the plurality of protrusions 160 may differ in height, slope, and / or size. In some embodiments, within the heel region 124, the plurality of protrusions 160 may differ in height, slope, and / or size.

[0085] In Figure 8 the illustrative embodiment shown, the first protrusion 162 has a first height 161. The first height 161 may be measured from the first peak 163 at the apex of the first protrusion 162 to the bottom 173 of an adjacent first valley 172 among the plurality of valleys 170. Similarly, the second protrusion 164 may have, for example Figure 9 the second height 165 shown. The second height 165 may be measured from the second peak 167 at the apex of the second protrusion 164 to the bottom 175 of an adjacent second valley 174 among the plurality of valleys 170.

[0086] In some embodiments, the second height 165 may be greater than the first height 161. In such embodiments, the second protrusion 164 may provide a greater cushioning depth in the heel region 124 of the sole 112. In such embodiments, the first protrusion 162 may provide a greater stiffness in the toe region 120 of the sole 112. In some embodiments, the second height 165 may be at least about 2 mm greater than the first height 161. In some embodiments, the first height 161 may be greater than the second height 165. In some embodiments, the first height 161 may be at least about 2 mm greater than the second height 165. In some embodiments, the first protrusion 162 and the second protrusion 164 may have equal heights 161, 165.

[0087] In some embodiments, the first height 161 can be greater than or equal to about 0 mm and less than or equal to about 12 mm. In some embodiments, the first height 161 can be greater than or equal to about 1 mm and less than or equal to about 12 mm. In some embodiments, the first height 161 can be greater than or equal to about 4 mm and less than or equal to about 10 mm. In some embodiments, the first height 161 can be greater than or equal to about 5 mm and less than or equal to about 7 mm.

[0088] In some embodiments, the second height 165 can be greater than or equal to about 5 mm and less than or equal to about 30 mm. In some embodiments, the first height 161 can be greater than or equal to about 7 mm and less than or equal to about 15 mm. In some embodiments, the first height 161 can be about 10 mm.

[0089] In some embodiments, the first ridge 162 can include a profile that is flatter than at least one of the plurality of ridges 160 located in the heel region of the sole 112 (e.g., ridge 164). In some embodiments, the second ridge 164 can have a steeper slope extending between the bottom 175 of the second valley 174 and the second peak 167 of the ridge 164, whereas the first ridge 162 can have a shallower slope extending between the bottom 173 of the first valley 172 and the first peak 163 of the ridge 162.

[0090] In some embodiments, the first ridge 162 can have a first tilt angle 166 on the inner side of the first ridge 162 that is between about 5 degrees and about 30 degrees relative to a plane 176 that is tangent to the peak 163 of the first ridge 162 and parallel to the substantially flat upper surface 154. In some embodiments, the first ridge 162 can have a second tilt angle 168 on the outer side of the first ridge 162 that is between about 5 degrees and about 30 degrees relative to the plane 176. In some embodiments, the first tilt angle 166 and the second tilt angle 168 can be different. In some embodiments, the first tilt angle 166 and the second tilt angle 168 can be equal.

[0091] In some embodiments, the second ridge 164 can have a third tilt angle 169 on the inner side of the second ridge 164 that is between 50 degrees and 85 degrees relative to a plane 177 that is tangent to the peak 167 of the second ridge 164 and parallel to the substantially flat upper surface 154. In some embodiments, the second ridge 164 can have a fourth tilt angle 171 on the outer side of the second ridge 164 that is between 50 degrees and 85 degrees relative to the plane 177. In some embodiments, the third tilt angle 169 and the fourth tilt angle 171 can be different. In some embodiments, the third tilt angle 169 and the fourth tilt angle 171 can be equal. Figure 8 and Figure 9Shows an example of the inclination angles 166, 168 of the first ridge 162 and the inclination angles 169, 171 of the second ridge 164.

[0092] In some embodiments, the first ridge 162 may have a relatively flat profile that has a continuous arc extending from an adjacent valley 172. In some embodiments, the second ridge 164 may include a composite profile that includes a steep side, an arcuate ground-facing region, and a radius connecting the steep side and the arcuate ground-facing region. For example, as Figure 8 and Figure 9 shown, the connecting radius of the second ridge 164 may be less than the average radius of the continuous arc of the first ridge 162.

[0093] In some embodiments, the first ridge 162 and the second ridge 164 may have a varying width from the outside to the inside, which may be a function of the ridge height, inclination angle, and / or radius. In some embodiments, the width of the ridge on the inner side 126 of the sole 112 may be greater than the width of the ridge on the outer side 128 of the sole 112. In some embodiments, the width of the ridge on the outer side 128 of the sole 112 may be greater than the width of the ridge on the inner side 126 of the sole 112. In some embodiments, the plurality of ridges 160 may be sized according to a gait pattern. In some embodiments, the plurality of ridges 160 may have a greater width in a region of the sole 112 where the user applies greater pressure according to the gait cycle or pattern. For example, the plurality of ridges 160 at the inner side 126 of the toe region 120 and the outer side 128 of the heel region 124 may be wider than the plurality of ridges 160 at the outer side 128 of the toe region 120 and the inner side 126 of the heel region 124.

[0094] In some embodiments, the continuous surface layer 192 covering the first ridge 162 may have a larger surface area than the continuous surface layer 192 covering the second ridge 164. In some embodiments, the continuous surface layer 192 covering the first ridge 162 may have a smaller surface area than the continuous surface layer 192 covering the second ridge 164.

[0095] In some embodiments, the underside 152 may include a plurality of connecting ribs 180 extending between the continuous surface layers 192 of the plurality of ridges 160, such as Figure 7As shown. The plurality of connecting ribs 180 may be integrally formed (e.g., integrally 3D printed) with the continuous surface layer 192. In some embodiments, the plurality of connecting ribs 180 may be integrally formed (e.g., integrally 3D printed) on the plurality of interconnected unit cells 140 of the mesh 130. In embodiments including the ribs 180, the plurality of connecting ribs 180 may tie adjacent traction elements 190 together via the continuous surface layer 192 such that the plurality of traction elements 190 can move together, or one traction element can resist the movement of another traction element. The connecting ribs 180 may include flat strips of material, each strip extending from a first continuous surface layer 192 to a second continuous surface layer 192. In some embodiments, the connecting ribs 180 may extend onto the inner side 126 and / or the outer side 128 and may be integrally formed with the upper peripheral edge 153 on the upper side 150.

[0096] In some embodiments, for example Figure 7 As shown in, the plurality of connecting ribs 180 may include a wavy or corrugated shape between adjacent traction elements 190. In some embodiments, the plurality of connecting ribs 180 may extend substantially linearly between adjacent traction elements 190. In some embodiments, the plurality of connecting ribs 180 may extend across the width of the sole 112 from the inner side 126 to the outer side 128.

[0097] In some embodiments, the plurality of connecting ribs 180 may extend across the length of the sole 112 from the toe region 120 to the heel region 124.

[0098] In some embodiments, the sole 112 may additionally include an outsole that is attached to each of the continuous surface layers 192 of the plurality of traction elements 190. In some embodiments, spacer material may be secured to the continuous surface layer 192 and / or the front toe portion 185 such that the outsole is attached to the spacer material rather than directly to the continuous surface layer 192 and / or the front toe portion 185. In such embodiments, the sole 112 may be connected to the outsole by any of a variety of methods, such as by stitching, bonding, or by other methods such as using an adhesive. The outsole may include a durable material, such as natural or synthetic rubber, etc.

[0099] Another embodiment of the sole 112 according to the present invention is shown in Figure 10 - Figure 12 as shown. Figure 10 - Figure 12 The sole 212 shown in is substantially similar to Figure 1 - Figure 9 the sole 112 shown and described herein. Thus, like reference numerals in the 200 series denote features common between the sole 112 and the sole 212. The description of the sole 112 is incorporated by reference into the sole 212, except where it conflicts with the specific description and drawings of the sole 212. For example, the sole 212 may include a ledge 134 and / or an upper peripheral edge 153.

[0100] In Figure 10 - Figure 12 In the illustrative embodiment shown, the sole 212 may include a three-dimensional mesh 230 and a continuous ground-facing peripheral edge 232. The mesh 230 can be formed in substantially the same manner as the mesh 130 and includes an upper side 250 and a lower side 252. The lower side 252 of the mesh 230 may include a peripheral portion 260, and the continuous ground-facing peripheral edge 232 may be formed on the peripheral portion 260. In some embodiments, the continuous ground-facing peripheral edge 232 may include a continuous surface layer 292 covering the underlying mesh 230 at the peripheral portion 260.

[0101] In some embodiments, the continuous surface layer 292 may extend around at least two of the toe region 220, the midfoot region 222, and the heel region 224 of the lower side 252 of the sole 212. In some embodiments, the continuous surface layer 292 may extend around each of the toe region 220, the midfoot region 222, and the heel region 224 of the lower side 252 of the sole 212.

[0102] In some embodiments, the unit cell 140 of the mesh 230 may be exposed on the lower side 252 in an intermediate portion 293 between the edges of the continuous surface layer 292 of the continuous ground-facing peripheral edge 232.

[0103] In some embodiments, for example Figure 10 - Figure 12 as shown, a recess 295 may be formed in the intermediate portion 293 of the lower side 252 of the mesh 230. In some embodiments, the recess 295 may be formed in the midfoot region 222 of the intermediate portion 293. The recess 295 extends into the sole 212 relative to the lower side 252 of the continuous ground-facing peripheral edge 232 and the continuous surface layer 292. In some embodiments, the recess 295 may be defined by a recessed area formed by the unit cell 140 of the mesh 230. In some embodiments, the recess 295 may be disposed in the midfoot region 222 between the inner and outer sides of the continuous surface layer 292 of the continuous ground-facing peripheral edge 232.

[0104] In Figure 12In the illustrative embodiment shown, the recess 295 has a depth 296. The depth 296 can be measured from the continuous surface layer surface 292 to the base 298 of the recess 295. In some embodiments, the depth 296 can be greater than or equal to about 2 mm to less than or equal to about 15 mm. In some embodiments, the depth 296 can be greater than or equal to about 5 mm to less than or equal to about 12 mm. In some embodiments, the depth 296 can be about 10 mm. In some embodiments, the recess 295 can include a maximum depth 296 that is greater than or equal to about 30% and less than or equal to about 70% of the total depth of the sole 212 at the recess 295.

[0105] In some embodiments, the continuous surface layer surface 292 can include a plurality of traction elements 294. In such embodiments, the traction elements 294 can be used to increase traction when the sole 212 contacts the ground during use, as shown. In some embodiments, for example Figure 10 and Figure 11 as shown, the plurality of traction elements 294 can include a ribbed traction texture that includes a plurality of contoured ribs. In some embodiments, the plurality of traction elements 294 can include concentric rib circles, overlapping rib circles, wavy ribs, or any other suitable geometry. In some embodiments, the plurality of traction elements 294 can correspond to the sport for which the footwear item 200 is used. For example, the plurality of traction elements 294 can be designed for running in a straight line, such as on a treadmill, or can include lateral features to improve traction when the user changes direction.

[0106] In some embodiments, the underside 252 can include a plurality of connecting ribs 280 that extend between the inner and outer sides of the continuous surface layer surface 292 of the continuous ground-facing peripheral edge 232, for example Figure 10 and Figure 11 as shown. In some embodiments, the plurality of connecting ribs 280 can be integrally formed (e.g., integrally 3D printed) with the mesh 230. In such embodiments, the plurality of connecting ribs 280 can be integrally formed on the plurality of interconnected unit cells 140 of the mesh 230. In some embodiments, the plurality of connecting ribs 280 can be integrally formed (e.g., integrally 3D printed) with the continuous surface layer surface 292.

[0107] In some embodiments, the plurality of connecting ribs 280 can extend across the middle portion 293 of the underside 252 and connect the opposite inner and outer sides of the continuous surface layer surface 292 together. In such embodiments, the plurality of connecting ribs 280 can resist deformation of one side of the peripheral edge 232 compared to the other side. In some embodiments, for example Figure 10 and Figure 11As shown, the plurality of connecting ribs 280 include a wavy or corrugated shape between adjacent sides of the continuous surface layer surface 292. In some embodiments, the plurality of connecting ribs 280 may extend substantially linearly between adjacent sides of the continuous surface layer surface 292. In some embodiments, the plurality of connecting ribs 280 may extend across the width of the sole 212 from the inner side to the outer side. The connecting ribs 280 may include flat strips of material, each extending from the inner side to the outer side of the continuous surface layer surface 292.

[0108] When a numerical range including an upper limit value and a lower limit value is cited herein, unless otherwise specified in a particular case, the range is intended to include its endpoints, as well as all integers and fractions within the range. When defining a range, the present invention is not intended to be limited to the specific values cited. In addition, when a quantity, concentration, or other value or parameter is given as a range, one or more ranges, or a list of upper limit values and lower limit values, this should be understood to specifically disclose all ranges formed by any pair of an upper limit or value of any range and a lower limit or value of any range, regardless of whether such pairs are separately disclosed. Finally, when the term "about" is used to describe a value or endpoint of a range, the present invention should be understood to include the specific value or endpoint mentioned. Whether or not the numerical value or endpoint of the range is recited as "about", the numerical value or endpoint of the range is intended to include two embodiments: one modified by "about" and one not modified by "about".

[0109] As used herein, the term "about" means a value within ±10% of the stated value. For example, about 10% can include any percentage between 9% and 11%.

[0110] It should be understood that the detailed description section, rather than the summary and abstract sections, is intended to explain the present invention. The summary and abstract sections may set forth one or more, but not all, of the exemplary embodiments contemplated by the inventors, and thus are not intended to limit the present invention in any way.

[0111] The foregoing description of specific embodiments will so fully reveal the general nature of the present invention that others can, by applying knowledge within the skill of the art, readily modify and / or adapt these specific embodiments for various applications without undue experimentation and without departing from the general concept of the present invention. Therefore, such adaptations and modifications are intended to be within the meaning and range of equivalents of the disclosed embodiments based on the teachings and guidance presented herein. It should be understood that the language or terminology of this specification is for the purpose of description and not of limitation, such that the terminology or wording of this specification is to be interpreted by those skilled in the art in light of the teachings and guidance herein.

[0112] The breadth and scope of the present invention should not be limited by any of the above exemplary embodiments.

Claims

1. An article of footwear comprising: A sole comprising: A three-dimensional mesh extending from a toe region to a heel region of a sole, the mesh comprising: a lattice structure comprising a plurality of interconnected unit cells, each interconnected unit cell comprising a plurality of struts defining a three-dimensional structure and a plurality of nodes at which one or more unit cells are connected; a ground-facing portion comprising a plurality of traction elements and located at a lower side of the web opposite the upper side; and a ledge formed on an upper side of the mesh and comprising a continuous side surface extending toward the lower side and along at least one of an outer side or an outer side of the mesh; an upper coupled to the mesh; and A binding element extends between the ledge and the upper and couples the ledge to the upper.

2. The article of footwear according to claim 1, wherein: The mesh, the ledge and the ground facing portion are integrally formed as a single piece.

3. The article of footwear according to claim 1, wherein: The continuous side surface of the ledge extends from an outer lateral side to an outer medial side of the web around a heel area of ​​the sole.

4. The article of footwear according to claim 3, wherein: The ledge further includes a solid top surface formed on an upper surface of an upper side of the mesh.

5. The article of footwear according to claim 1, wherein: The coupling element is coupled to a continuous side surface of the ledge.

6. The article of footwear according to claim 1, wherein: The underside of the mesh includes a plurality of ridges and a plurality of valleys between the ridges. Wherein, a plurality of traction elements of the ground facing portion are formed on each of the plurality of protrusions.

7. The article of footwear according to claim 6, wherein: Each of the plurality of traction elements includes a separate continuous skin layer that covers a portion of each of the plurality of protuberances.

8. The article of footwear according to claim 1, wherein: The lower side of the mesh includes a peripheral edge facing the ground and a middle portion of the peripheral edge facing the ground. Wherein, the plurality of traction elements of the ground-facing portion are formed on the ground-facing peripheral edge.

9. The article of footwear according to claim 8, wherein: The middle portion is recessed relative to the peripheral edge facing the ground.

10. The article of footwear according to claim 8, wherein: The ground-facing peripheral rim includes a continuous surface covering that extends around each of the toe region, the midfoot region, and the heel region of the sole, and a plurality of traction elements are formed on the continuous surface covering.

11. A sole for an article of footwear, the sole comprising: A three-dimensional web extending from the toe area to the heel area of ​​the sole, said web comprising: a lattice structure comprising a plurality of interconnected unit cells, each interconnected unit cell comprising a plurality of struts defining a three-dimensional structure and a plurality of nodes at which one or more unit cells are connected; a corrugated underside comprising a plurality of ridges and a plurality of valleys between the ridges, wherein the ridges are at least partially defined by one or more unit cells of the grid structure; and A plurality of traction elements are formed on the plurality of ridges on the corrugated underside of the web such that the plurality of traction elements face the ground.

12. The shoe sole according to claim 11, wherein: a first ridge of the plurality of ridges located in the toe region has a first height measured between a first peak of the first ridge and a bottom of an adjacent valley of the plurality of valleys, a second ridge of the plurality of ridges located in the heel region has a second height measured between a second peak of the second ridge and a bottom of an adjacent valley of the plurality of valleys, The second height is different from the first height.

13. The shoe sole according to claim 12, wherein: The second height is greater than the first height.

14. The shoe sole according to claim 11, wherein: Each of the plurality of traction elements includes a separate continuous skin layer that covers a portion of each of the plurality of protuberances.

15. The shoe sole according to claim 14, wherein: The continuous surface layer of each traction element includes a ribbed traction texture.

16. The shoe sole according to claim 11, wherein: At least one of the plurality of ridges located in a toe region of the sole includes a flatter profile than at least one of the plurality of ridges located in a heel region of the sole.

17. The shoe sole according to claim 11, wherein: The sole further includes a plurality of connecting ribs formed on the contoured underside of the web and extending between adjacent ones of the plurality of traction elements.

18. A sole for an article of footwear, the sole comprising: A three-dimensional mesh extending from a toe region to a heel region of a sole, the mesh comprising: a lattice structure comprising a plurality of interconnected unit cells, each interconnected unit cell comprising a plurality of struts defining a three-dimensional structure and a plurality of nodes at which one or more unit cells are connected; and a continuous ground-facing edge formed on a peripheral portion of the underside of the web, wherein the continuous ground-facing edge extends around each of a toe region, a midfoot region, and a heel region of the sole, and Wherein the continuous ground-facing edge includes a plurality of traction elements formed on a ground-facing surface of the edge.

19. The shoe sole according to claim 18, wherein: A depression is formed in the midfoot region of a middle portion between successive ground-facing edges of the web.

20. The shoe sole according to claim 18, wherein: The sole further includes a plurality of connecting ribs formed on the undulating underside of the web and extending across a middle portion of the underside to connect an outer side of the continuous ground facing edge to an inner side of the continuous ground facing edge.

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