Sole with co-molded grid structure and solid region, shoe with sole and manufacturing method

Abstract

A sole for an article of footwear includes a plurality of portions including at least a first portion and a second portion. The first portion includes a grid structure having a plurality of unit cells. The plurality of unit cells may include a first subset of unit cells and a second subset of unit cells different from the first subset of unit cells. The second portion includes a solid material that at least partially encapsulates one or more unit cells of the first subset of unit cells.

Description

Technical Field

[0001] The embodiments described herein relate to co-molded articles. Specifically, the embodiments described herein relate to shoe soles having a co-molded grid structure and solid regions. 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 surrounds the wearer's foot. The sole can be configured to provide desired comfort and performance characteristics to the wearer. The sole can be made by molding a foam material. Making the sole by molding can be inexpensive, but the ability of the molding method to provide customized performance characteristics for the sole may be limited.

[0003] Competitive athletes such as runners and basketball players may desire that the footwear have specific performance characteristics to optimize their performance. Additionally, customization of the sole can allow for the footwear to be customized to fit a specific athlete. Accordingly, there is a continuing need for soles that provide desired properties and performance characteristics and methods of making such soles. Summary of the Invention

[0004] Some embodiments described herein relate to a sole for a footwear item, wherein the sole includes a grid structure having a plurality of unit cells. The plurality of unit cells includes a first subset of unit cells and a second subset of unit cells that is different from the first subset of unit cells. The sole further includes a second portion that includes a solid material, wherein the solid material at least partially encapsulates one or more of the unit cells of the first subset of unit cells.

[0005] In any of the various embodiments described herein, the grid structure can define channels that at least partially extend through the grid structure. In some embodiments, the solid material can be disposed within the channels defined by the grid structure. In some embodiments, the first subset of unit cells can define the channels.

[0006] In any of the various embodiments described herein, the first portion can include the toe region of the sole and the second portion can include the heel region of the sole.

[0007] In any of the various embodiments described herein, the first portion can include the upper region of the sole and the second portion can include the lower region of the sole.

[0008] In any of the various embodiments described herein, the solid material can include a foam material.

[0009] In any of the various embodiments described herein, the solid material may not contact the second subset of unit cells.

[0010] In any of the various embodiments described herein, the first subset of unit cells may have grid parameters different from those of the second subset of unit cells. In some embodiments, the unit cell density of the first subset of unit cells is greater than the unit cell density of the second subset of unit cells. In some embodiments, the cell surface openings of the first subset of unit cells are smaller than the cell surface openings of the second subset of unit cells. In some embodiments, each of the plurality of unit cells includes a plurality of interconnected struts, wherein the strut thickness of the first subset of unit cells is greater than the strut thickness of the second subset of unit cells.

[0011] Some embodiments described herein relate to a method of forming a sole for a footwear item, wherein the method includes: disposing a grid structure having a plurality of unit cells in a mold cavity defining a sole shape. The plurality of unit cells includes a first subset of unit cells and a second subset of unit cells different from the first subset of unit cells. The method further includes flowing a solid material into the mold cavity such that the solid material at least partially encapsulates one or more unit cells of the first subset of unit cells.

[0012] In any of the various embodiments described herein, the method of forming the sole may further include controlling the flow of the solid material into the first subset of unit cells by adjusting one or more of the molding temperature or molding pressure.

[0013] In any of the various embodiments described herein, the grid structure may be formed by an additive manufacturing method.

[0014] In any of the various embodiments described herein, the first subset of unit cells may have grid parameters different from those of the second subset of unit cells. In some embodiments, the unit cell density of the first subset of unit cells may be greater than the unit cell density of the second subset of unit cells. In some embodiments, the cell surface openings of the first subset of unit cells may be smaller than the cell surface openings of the second subset of unit cells. In some embodiments, each of the plurality of unit cells may include a plurality of interconnected struts, wherein the strut thickness of the first subset of unit cells may be greater than the strut thickness of the second subset of unit cells.

[0015] In any of the various embodiments described herein, flowing the solid material into the mold cavity includes expanding an expandable foam material in the mold cavity.

[0016] Some embodiments described herein relate to a molded article having a first portion including a grid structure having a plurality of unit cells. The plurality of unit cells includes a first subset of unit cells and a second subset of unit cells different from the first subset of unit cells. The sole further includes a second portion including a foam material that at least partially encapsulates one or more of the unit cells of the first subset of unit cells. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] 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.

[0018] Figure 1 A side perspective view of a footwear article according to one embodiment is shown, the sole of the footwear article having a grid structure and a solid region.

[0019] Figure 2 Shows Figure 1 A bottom view of the footwear article.

[0020] Figure 3 A side perspective view of a sole having a grid structure and a solid region according to one embodiment is shown.

[0021] Figure 4 A perspective view of a grid structure disposed in a mold for forming a co-molded sole according to one embodiment is shown.

[0022] Figures 5A - 5D A method for manufacturing a sole having a grid structure and a solid region according to one embodiment is shown.

[0023] Figure 6 A cross-sectional side view of a mold forming a sole having a grid structure and a solid region during the molding process is shown.

[0024] Figures 7A - 7C A method for manufacturing a co-molded article having a grid structure with channels and a solid region is shown.

[0025] Figures 8A - 8B A plan view of a portion of a grid structure having first and second unit cell subsets according to an embodiment is shown.

[0026] Figures 9A - 9D A method for manufacturing a footwear article according to one embodiment is shown. DETAILED DESCRIPTION

[0027] Reference will now be made in detail to representative embodiments shown in the accompanying drawings. It should be understood that the following description is not intended to limit the embodiments to one 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.

[0028] References in the specification to "one embodiment", "an embodiment", "exemplary embodiment", "some embodiments", etc., indicate that the described embodiment 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 affect such feature, structure, or characteristic in connection with other embodiments, whether or not explicitly described.

[0029] The indefinite articles "a", "an", and "the" include plural referents unless explicitly contradicted or the context clearly dictates otherwise.

[0030] The terms "comprising" and "including" are open transitional phrases. The list of elements following the transitional phrase "comprising" or "including" is a non-exclusive list such that elements other than those specifically recited in the list may also be present.

[0031] As used herein, unless otherwise specified, references to "first", "second", "third", "fourth", etc. are not intended to denote an order, or that a feature with a higher number requires a feature with a lower number. Moreover, 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.

[0032] Footwear generally includes a sole formed of a molded material. However, the ability to customize the properties or performance characteristics of the resulting sole by molding may be limited.

[0033] To provide improved performance and cushioning characteristics, footwear has been developed that includes a grid structure in the sole. By varying the grid pattern and parameters, such as factors like the shape and size of the unit cells of the grid structure, the use of the grid structure allows for further adjustment of the characteristics of the footwear at specific locations. The footwear can be customized such that the mechanical characteristics obtained by the sole vary across different regions or within different regions and / or vary according to the direction of midsole loading (e.g., anisotropic characteristics) to provide performance improvements.

[0034] While combining solid molded components and a grid structure can provide improved customization, there are difficulties in combining the grid structure with the molded component. The grid structure can be manufactured in a first process, and the molded component can be molded in a second process. Then a third process is needed to connect the molded component and the grid structure. The need for separate processes to form the grid structure and the molded component and then connect the two components increases the difficulty, time, and cost of manufacturing the sole.

[0035] In addition, in some cases, the grid structure and the solid component are joined by an adhesive. However, using an adhesive to connect the grid structure and the solid component has many disadvantages. Using an adhesive can form a relatively weak connection, and thus during the use of the sole, especially when there is a bending moment, the connection points between the grid structure and the solid component may be subjected to considerable stress. The adhesive may also degrade or weaken due to temperature changes, exposure to excessive water, or exposure to a soap solution. The adhesive also adds weight to the sole, which is particularly undesirable for the performance of the footwear. The adhesive may also contain non-environmentally friendly adhesive chemicals. Therefore, there is a need for improved soles and methods of forming soles incorporating a grid structure and a solid component.

[0036] Some embodiments described herein relate to a sole that includes a grid structure and a solid region formed by co-molding the grid structure with a solid material. During the molding process, the solid material can at least partially enter the grid structure. In this way, the resulting molded article can include a solid region mechanically bonded to the grid structure without using an adhesive. In addition, co-molding the grid structure and the solid region can simplify manufacturing by combining the grid structure and the solid region in the same process of forming the solid region.

[0037] In addition, the inventors have found that the degree to which the solid material enters the grid structure during the molding process can be controlled by adjusting the parameters of the grid structure. In this way, the underfoot characteristics of the sole, such as softness, responsiveness, stiffness, and energy return, can be adjusted.

[0038] As used herein, the term "grid structure" refers to a three-dimensional structure that includes a plurality of unit cells. The grid structure includes interconnected structural members that define the 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.

[0039] The unit cells can have any one of a variety of sizes and geometries. Additionally, the unit cells within the lattice structure can be the same or different. Thus, the lattice structure can include unit cells of different sizes or geometries. The three-dimensional shape of a 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 have 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 a unit cell can be, but is not limited to, a dodecahedron (e.g., a rhombic dodecahedron), 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 lattice structure with desired performance characteristics, and the lattice structure can include regions with struts of different densities.

[0040] In some embodiments, the interconnected unit cells can include a solid representation of the repeating implicit surface of the lattice 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 the solid representation of the implicit surface defining 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 lattice. An example of a suitable periodic surface is the G-minimal surface (gyroid), but any type of suitable periodic surface can be used.

[0041] Herein, a solid representation of an implicit surface refers to a solid object that follows the shape of the implicit surface. The actual implicit surface has no thickness, while the solid 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 solid representation, meaning that the solid representation can be constructed from physical material as 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 implicit surface being represented. In some embodiments, the relative density of the solid representation of the unit cell 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 volume of the unit cell occupied by the solid material.

[0042] In some embodiments, implicit surfaces can be created using combinations of random Fourier series functions, where linear and / or non-linear coefficients and linear and non-linear variables within sine and cosine terms in the x, y, and z spaces are iterated to generate the functions. The resulting unit cells 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 functions can be derived in a manner that satisfies the periodicity of the unit cells. Criteria for selecting an applicable implicit surface within a 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 lengths, the surface area, and the volume fraction.

[0043] The lattice structure can be formed by additive manufacturing (e.g., 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 articles are described, for example, in US 2009 / 0126225, WO 2010 / 126708, US2014 / 0300676, US2014 / 0300675, US2014 / 0299009, US2014 / 0026773, US2014 / 0029030, WO 2014 / 008331, WO 2014 / 015037, US2014 / 0020191, EP 2564719, EP 2424398, and US 2012 / 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 September 27, 2016, which is incorporated herein by reference in its entirety.

[0044] In some embodiments, the 3-D printed lattice structure can include 3-D printing a lattice in a green state, shaping the lattice structure in the green state, and curing the green state into its final shape. In some embodiments, the 3-D printed lattice structure can include 3-D printing a lattice structure in an intermediate green state, swelling the intermediate green state, shaping the lattice structure in the green state, and curing the green state into its final shape.

[0045] Techniques for producing an intermediate green state object from a resin 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 No. 5,236,637 to Hull, U.S. Patent Nos. 5,391,072 and 5,529,473 to Lawton, U.S. Patent No. 7,438,846 to John, U.S. Patent No. 7,892,474 to Shkolnik, U.S. Patent No. 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.

[0046] In some embodiments, the additive manufacturing step can 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 entireties.

[0047] Although stereolithography techniques such as CLIP may be preferred, it should be understood that other additive manufacturing techniques such as jet 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.

[0048] A variety of materials can be used for additive manufacturing of lattice structures, including, for example, but 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), or polypropylene (PP), or combinations of any of these materials, as well as other materials. Additional materials for forming lattice structures can include polyamides (nylons), carbon and carbon allotropes (such as graphene, carbon nanotubes, and carbon fibers), fiber-reinforced polymers, biocompatible materials (such as mycelium), and metals (such as aluminum, steel, or titanium, etc.), and combinations thereof.

[0049] In any of the embodiments described herein, the lattice structure can be selected to provide desired performance characteristics. The lattice structure 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.

[0050] As used herein, the terms "solid region" or "solid component" refer to a portion of a sole or other article that is not defined by a lattice structure. Thus, a "solid region" or "solid component" includes the overall volume or structure defined by a solid, non-lattice structure. A solid region or solid component can be without a lattice structure. Unless specifically described otherwise in connection with an embodiment herein, a solid region or solid component can be without openings or gaps defining unit cells. A solid region or solid component can be formed from a solid material, such as a foam material or an expanded foam material. The solid material can include one or more of ethylene vinyl acetate (EVA), thermoplastic polyurethane (TPU), or expanded TPU (e-TPU), polyether block amide (PEBA), and can include particles of EVA, TPU, or e-TPU, or any combination of these materials, as well as other materials. Additional materials for forming lattice structures can include polyamides (nylons), carbon and carbon allotropes (such as graphene, carbon nanotubes, and carbon fibers), fiber-reinforced polymers, biocompatible materials (such as mycelium), and metals (such as aluminum, steel, or titanium, etc.), and combinations thereof. A solid region or solid component can be formed by molding, such as by injection molding, transfer molding, or compression molding, as well as other molding methods. In embodiments having multiple solid regions or components, each solid region or component can be formed from the same material or can be formed from different materials, depending on the desired characteristics of the sole.

[0051] As discussed herein, in an "interface region", a "solid region" or "solid component" can be formed (e.g., co-molded) with a grid structure. In the interface region, the solid material of the solid region or solid component can completely or partially encapsulate the unit cells of the grid structure. The solid material of the solid region or solid component can completely or partially fill the unit cells of the grid structure to completely or partially fill the space within the unit cells. The unit cells of the grid structure can be completely or partially embedded in the solid material of the solid region or the solid components in the interface region. In some embodiments, an article can include a plurality of separate interface regions.

[0052] Within the interface region, one or more rows or columns of unit cells can be completely or partially encapsulated within the solid material of the solid region or solid component. In some embodiments, the interface region can include a plurality of consecutive rows or columns of unit cells that are completely or partially encapsulated by the solid material of the solid region or solid component.

[0053] In some embodiments, the interface region can include a first subset of unit cells as described herein, a second subset of unit cells as described herein, or both a first subset of unit cells as described herein and a second subset of unit cells as described herein. As described herein, the solid material of the solid region or solid component can completely or partially encapsulate the first subset of unit cells. Additionally, as described herein, the solid material of the solid region or solid component can completely or partially encapsulate a portion of the second subset of unit cells. In some embodiments, the interface region can surround all of a portion of a channel formed in the grid structure as described herein. In such embodiments, the solid material of the solid region or solid component can completely or partially encapsulate the unit cells (e.g., one or more unit cell rows) that define the channel and are located within the interface region.

[0054] Some embodiments described herein relate to a sole for a footwear article that includes a first portion having a grid structure and a second portion including a solid region. The grid structure can form all or a portion of one or more of the toe region, midfoot region, or heel region of the sole. Similarly, the solid region can form all or a portion of one or more of the toe region, midfoot region, or heel region of the sole. Together, the grid structure and the solid region can form all or a portion of the toe region, midfoot region, and heel region of the sole.

[0055] The lattice structure can include a first subset of unit cells and a second subset of unit cells. The first subset of unit cells can include first lattice parameters, and the second subset of unit cells can include second lattice parameters different from the first lattice parameters. The lattice parameters can include one or more of unit cell density, strut thickness, wall thickness of an implicit surface unit cell, number of struts forming a unit cell, unit cell surface openings, or unit cell geometry, etc. These lattice parameters can be selected to control the flow of solid material into the lattice structure, for example to allow solid material to enter some parts of the lattice structure but not others.

[0056] Some embodiments described herein relate to a method for manufacturing a sole of a footwear item, the method including manufacturing a lattice structure. The lattice structure can be formed by an additive manufacturing process. The lattice structure can be inserted into a mold cavity of a mold. In such an embodiment, a molding material is inserted into the mold cavity and the molding material can be molded such that the molding material at least partially encapsulates one or more cells of the lattice structure. In some embodiments, the lattice structure and the solid regions are mechanically bonded to each other without using adhesives or other fasteners.

[0057] Figure 1 A footwear item 100 is shown in accordance with one embodiment. The footwear item 100 can include a sports shoe or other athletic footwear, such as a running sports shoe, a basketball sports shoe, a soccer sports shoe, a spiked shoe, a walking shoe, or a boot. The footwear item 100 can include non-athletic footwear, including shoes, sandals, skates, loafers, or mules, and other footwear items.

[0058] The footwear item 100 includes an upper 120 and a sole 140. The upper 120 is configured to cover a portion of a wearer's foot and can securely accommodate and position the foot relative to the sole 140. The upper 120 can define an opening 122 for receiving the wearer's foot into the footwear 100. The upper 120 can include laces or other fastening systems for adjusting the fit of the upper 120 and securing the upper 120 to the wearer's foot. The upper 120 can define eyelets for receiving the laces. The upper 120 can have an elastic or stretchable structure to stretch to conform to and secure the footwear 100 to the wearer's foot. In some embodiments, the upper 120 can have a sock-like construction.

[0059] The upper 120 can be formed as one or more components fixed together or can be formed as a single piece. In some embodiments, the upper 120 can be manufactured separately from the sole 140 and fixed to the sole 140 in a separate process. The upper 120 can be fixed to the sole 140 by stitching, adhesives, seam tapes, or other types of fasteners and fastening methods and combinations thereof. In some embodiments, the upper 120 or a portion thereof can be manufactured integrally with the sole 140. In some embodiments, the upper 120 can be formed by an additive manufacturing method. In such embodiments, the upper 120 or a portion thereof can be molded together with the sole 140, as described in further detail herein.

[0060] The upper 120 can include natural materials, synthetic materials, or combinations thereof. The upper 120 can include one or more layers and can be a single layer or can have a multi-layer structure. The upper 120 can include knitted materials, woven materials, non-woven materials, etc., and combinations thereof. The knitted material can be formed by a knitting method, such as by flat knitting or circular knitting, and can be formed by warp knitting or weft knitting. The knitted material can be formed from one or more yarns, and each yarn can include one or more filaments or fibers. The yarn can include elastic yarns, shrink yarns, melt yarns, or monofilaments, as well as other types of yarns. The upper 120 can include thermoplastic yarns. The thermoplastic yarn can include a core of non-thermoplastic material surrounded by a shell of thermoplastic material, or a core of thermoplastic material surrounded by a shell of non-thermoplastic material, or the yarn can be formed entirely of thermoplastic material.

[0061] The sole 140 can include one or more of an insole, a midsole, and an outsole. The sole 140 can include one or more parts. At least one part includes a grid structure 160. In some embodiments, multiple parts of the sole 140 can include the grid structure 160. At least a portion of the sole 140 includes a solid region 180. In some embodiments, multiple parts can be the solid region 180. In some embodiments, the solid region 180 can be without a grid structure. The solid region 180 can be formed by molding. The grid structure 160 and the solid region 180 are mechanically joined to each other at an interface region 170, such as by co-molding, as described in further detail herein.

[0062] In Figure 1 embodiments, the footwear 100 is shown as having a sole 140 that has a first part 142 and a second part 144. The first part 142 includes the grid structure 160. The second part 144 includes the solid region 180. However, it will be understood that the sole 140 can include additional parts that include additional grid structures or additional solid regions.

[0063] Figure 1 The bottom view of the footwear 100 inFigure 2 is shown. The sole 140 may include an inner side 141 opposite to an outer side 143. The sole 140 may include a heel region 145, a midfoot region 147, and a toe region 149. The grid structure 160 may be disposed at any one or a combination of the heel region 145, the midfoot region 147, and the toe region 149, and may be disposed at the inner side 141, at the outer side 143, or both, and may extend completely from the inner side 141 to the outer side 143 or partially from the inner side 141 to the outer side 143, or vice versa. The grid structure 160 may be disposed at an upper portion of the sole 140 facing the upper shoe 120, or at the bottom of the sole 140, and may extend completely or partially from the upper portion of the sole 140 to the bottom.

[0064] The solid region 180 may be disposed at any position not occupied by the grid structure 160. Thus, the solid region 180 may be similarly disposed at any one or a combination of the heel region 145, the midfoot region 147, and the toe region 149, and may be disposed at the inner side 141, at the outer side 143, or both, and may extend completely from the inner side 141 to the outer side 143 or partially from the inner side 141 to the outer side 143, or vice versa. The solid region 180 may be disposed at an upper portion of the sole 140 facing the upper shoe 120, or at the bottom of the sole 140, and may extend completely or partially from the upper portion of the sole 140 to the bottom. In some embodiments, the solid region 180 may form the remainder of the sole 140 not formed by the grid structure 160 and the interface region 170.

[0065] In Figure 2 the illustrated embodiment, the grid structure 160 is disposed at the heel region 145. The grid structure 160 extends towards the midfoot region 147 and transitions to the solid region 180 at the interface region 170 in the midfoot region 147. The grid structure 160 extends from the upper portion of the sole 140 to the bottom of the sole 140 (see Figure 1 ), and extends from the inner side 141 to the outer side 143. The solid region 180 is disposed at the midfoot region 147 and the toe region 149. The solid region 180 extends from the upper portion of the sole 140 to the bottom of the sole 140, and extends from the inner side 141 to the outer side 143.

[0066] The sole 240 according to one embodiment is in Figure 3As shown. The sole 240 includes a first portion 242 having a grid structure 260 and a second portion 244 having a solid region 280. The grid structure 260 is disposed on the bottom 246 of the sole 140 and is disposed at each of the toe region 249, the midfoot region 247, and the heel region 245. The grid structure 260 extends from the medial side to the lateral side. The solid region 280 is disposed at the upper portion 248 of the sole 240 and is disposed at each of the toe region 249, the midfoot region 247, and the heel region 245. The solid region 280 extends from the medial side to the lateral side.

[0067] In some embodiments, the solid region 280 may extend into and at least partially fill a portion of the grid structure 260 in one or more interface regions 270. The solid region 280 may at least partially fill one or more unit cells of the grid structure 260 in the (one or more) interface regions 270. As described in further detail herein, the solid region 280 may additionally fill one or more channels formed in the grid structure 260 adjacent to the interface region 270. In Figure 3 it, the solid region 280 fills the channels formed in the grid structure 260 such that the solid region 280 extends from the upper portion 248 through the channels of the grid structure 260 toward the bottom 246 of the sole 240. This may help to secure the solid region 280 to the grid structure 260, help to provide the desired performance characteristics for the sole 240, or help with both.

[0068] It can be understood that Figures 1 - 3 is an example of the soles 140, 240 having a combination of grid structures 160, 260 and solid regions 180, 280, and other arrangements are possible and within the scope of the present invention. For example, the grid structure may be disposed on the medial side of the sole, while the solid region may be disposed on the lateral side of the sole in one or more of the heel region, the midfoot region, and the toe region. Additionally, the sole may include multiple grid structures, such as a first grid structure at the heel region and a second grid structure at the midfoot region, and may include multiple solid regions, such as a first solid region at the toe region and a second solid region at the midfoot region.

[0069] The soles having a grid structure and a solid region described herein may be formed by co - molding. The mold 310 may define a mold cavity 312 having the desired shape of the sole, such as Figure 4 shown. The grid structure, such as the grid structure 160, the grid structure 260, or the grid structure 360, may be inserted into the mold 310 at the desired location. For example, in Figure 4In this case, the grid structure 360 is configured to form the heel portion of the sole and is disposed in the heel portion of the mold cavity 312. A solid material, such as a foam material, is introduced under heat and / or pressure into the desired locations of the mold cavity 312 to fill or at least partially fill the remaining portion of the mold cavity 312 not occupied by the grid structure 360.

[0070] The solid material can be introduced into a portion of the mold cavity 312 not occupied by the grid structure 360. The solid material can flow within the mold cavity 312 to take the shape of the mold cavity and encounter the grid structure 360 at the interface region as described herein. The solid material can enter the grid structure 360 to a certain extent such that the grid structure 360 and the solid material are mechanically bonded in the interface region, as described in further detail herein. Flowing the solid material within the mold cavity 312 at least partially encapsulates one or more unit cells (e.g., one or more unit cells of the first subset of unit cells as described herein) within the solid material. In some embodiments, flowing the solid material within the mold cavity 312 can include expanding an expandable material within the mold cavity 312. In some embodiments, the expandable material can be an expandable foam material. Once the solid material is cooled or cured, the resulting co-molded sole can be removed from the mold 310.

[0071] The grid structure (e.g., grid structure 360) as described herein can be made of a material different from the solid material. The grid structure can be made of a material that does not melt or deform under the molding conditions of the solid material, such as at the molding temperature and / or pressure, such that the grid structure maintains its shape and configuration throughout the molding process.

[0072] An exemplary method of molding a sole 512 for a footwear item is shown in Figures 5A - 5D In Figure 5A In step 510 shown, a grid structure 502 having a desired shape and configuration is provided. The grid structure 502 can generally correspond to the shape of the sole or a portion thereof. The grid structure 502 can define one or more openings or channels 504 as described herein. The channels 504 can facilitate the flow of molding material into the openings or channels 504 of the grid structure 502. In some embodiments, in some embodiments, the channels 504 can alternatively receive one or more reinforcement elements prior to molding. The grid structure 502 can be manufactured by an additive manufacturing process as described herein.

[0073] In Figure 5B In step 520 shown, the grid structure 502 is disposed in a mold 506 that includes a mold cavity 507 that defines the desired shape of the sole 512. In Figure 5CIn step 530 as shown, the mold 506 can be closed, for example, by setting the upper mold 508 on the lower mold 509. Before and / or after the mold 506 is closed, solid material can be introduced into the mold cavity 507. In some embodiments, the mold 506 can include one or more ports into which the solid material can be injected or poured. The solid material can fill a portion of the mold cavity not occupied by the grid structure 502 and flow into the unit cells in one or more interface regions of the grid structure 502, as described herein. In Figure 5D In step 540 as shown, the mold 506 can be opened and the molded sole 512 including the co-molded grid structure 502 and the solid region 505 can be removed from the mold.

[0074] A cross-section of the grid structure and the solid material in a mold according to some embodiments is shown in Figure 6 In Figure 6 , the mold 610 includes an upper mold 614 and a lower mold 616 that form a mold cavity 612 defining the shape of the sole 640. The grid structure 660 is disposed at a desired location in the mold cavity 612 to form a portion of the resulting sole 640. Solid material is introduced into the mold cavity 612, for example, through one or more ports of the mold 610, and fills a portion of the mold cavity 612 not occupied by the grid structure 660.

[0075] The solid material 680 meets the grid structure 660 at the interface region 670. The solid material 680 at least partially encapsulates one or more unit cells 662 of the grid structure 660 in the interface region 670. The grid structure 660 can be configured to allow the solid material 680 to penetrate the grid structure 660 to a desired extent as described herein. For example, the solid material 680 can enter and can partially or completely fill one or more unit cells 662 at the surface of the grid structure 660. In this way, the solid region 680 and the grid structure 660 are mechanically bonded to each other. The mechanical bond can allow the sole 640 to be formed without the use of adhesives or other fasteners. Bonding the grid structure 660 and the solid material 680 during molding can also eliminate the need for subsequent steps to bond the solid region to be formed by molding to the grid structure, and instead integrally bond the grid structure to the solid region during the molding of the solid region.

[0076] In some embodiments, the grid structure can be designed to control the inflow of solid material into the grid structure. For example, in embodiments with solid materials that are relatively viscous during molding, the solid material may not easily flow into the small or narrow channels of the grid structure. Thus, by varying the geometry and dimensions of the unit cell, the inflow of solid material into the grid structure during molding can be precisely controlled. In some embodiments, the inflow or flow of solid material within the grid structure can be inhibited by adjusting one or more grid parameters. In some embodiments, the inflow of solid material into or within the grid structure can be inhibited by: (i) increasing the unit cell density of the grid structure, defined as the number of unit cells per unit volume, (ii) increasing the thickness of the struts of the unit cells forming the grid structure, (iii) reducing the size of the unit cell surface openings of the grid structure, (iv) adjusting the unit cell geometry, (v) increasing the thickness of the walls of the unit cells forming the grid structure, (vi) increasing the number of struts forming the unit cells, or any combination of two or more of (i)–(vi). Similarly, in some embodiments, the inflow of solid material into or within the grid structure can be facilitated by adjusting one or more grid parameters. In some embodiments, the inflow of solid material into or within the grid structure can be facilitated by: (i) decreasing the unit cell density of the grid structure, defined as the number of unit cells per unit volume, (ii) decreasing the thickness of the struts of the unit cells forming the grid structure, (iii) increasing the size of the unit cell surface openings of the grid structure, (iv) adjusting the unit cell geometry, (v) decreasing the thickness of the walls of the unit cells forming the grid structure, (vi) decreasing the number of struts forming the unit cells, or any combination of two or more of (i)–(vi). In some embodiments, increasing or decreasing the thickness of the walls forming the unit cells can include increasing or decreasing the relative density of the implicit surface unit cells.

[0077] In addition, the extent to which solid material enters the grid structure can also be controlled based on molding parameters such as molding temperature, pressure, and molding time, as higher temperature, higher pressure, and longer molding time can allow the molding material to enter the grid structure to a greater extent. Thus, the grid parameters can be selected together with the molding parameters to customize the extent to which solid material enters the grid structure during molding.

[0078] As used herein, the thickness of a strut may be defined by the "effective diameter" of the strut, but this term should not be construed as requiring the strut to have a circular shape. Alternatively, the strut may have a non-circular cross-sectional shape, and in such an embodiment, the term effective diameter is intended to refer to the largest cross-sectional dimension of the cross-sectional shape. For example, the thickness or effective diameter of a strut having a square cross-sectional shape will be the diagonal dimension across the square. As another example, the effective diameter of a strut having an elliptical cross-sectional shape will be the length of the major axis of the ellipse. For a strut having an effective diameter that varies along the length of the strut (e.g., an hourglass shape), the effective diameter is the minimum effective diameter. The cross-sectional shape of the strut is the shape of the strut in a cross-section perpendicular to the length of the strut between two nodes in the grid structure.

[0079] Figure 7A Exemplary grid structure 760 showing a first subset 765 of unit cells and a second subset 766 of unit cells is shown. The first subset 765 may have one or more grid parameters that are different from the grid parameters of the second subset 766. As Figure 7A shown, the first subset 765 has a greater cell density relative to the second subset 766, having more unit cells per unit volume. However, the first subset 765 may differ from the second subset 766 with respect to different grid parameters and may have a greater strut thickness, a different number of struts per unit cell, a greater wall thickness, a smaller cell surface opening, or a different geometry, etc.

[0080] In Figure 7A it, the first subset 765 is disposed along a first face 761 of the grid structure 760 where the solid material inserted into the mold 790 interfaces with the grid structure 760 at the interface region 770. The relatively high unit cell density of the first subset 765 can help to limit the flow of the solid material into the grid structure 760 during molding. In some embodiments, the solid material may enter and partially encapsulate one or more unit cells of the first subset 765, but may not enter or encapsulate the unit cells 766 of the second subset 766.

[0081] In some embodiments, for example Figure 7AAs shown, the grid structure 760 can define one or more channels 764. In some embodiments, the channels 764 allow for the incorporation of reinforcing elements 795, such as one or more rods, bars, or plates, into the grid structure 760 and the resulting molded article. In some embodiments, the (one or more) reinforcing elements 795 can include handles or torsion bars. In some embodiments, the (one or more) reinforcing elements can be made of polyamide (nylon), carbon and carbon allotropes (such as graphene, carbon nanotubes, and carbon fibers), fiber-reinforced polymers, biomaterials (such as mycelium), and metals (such as aluminum, steel, or titanium, etc.) and combinations thereof. In such embodiments, one or more of the reinforcing elements 795 can be fully or partially embedded within a solid material that fills the channels 764.

[0082] The channels 764 can allow solid material to flow into the channels 764 during molding. This can help further promote the bonding and connection of the grid structure 760 with the solid material by allowing the solid material to enter the unit cells of the grid structure 760 at the interface region 770 located around the channels 764. In some embodiments, this can help further promote the bonding and connection of the grid structure 760 with the solid material by allowing the solid material to enter additional unit cells of the grid structure 760 and unit cells within the grid structure 760 in addition to entering the unit cells at the first face 761. The channels 764 can further provide desired performance characteristics to the resulting molded article. This allows for further adjustment of the performance and characteristics of the sole by allowing portions of the grid structure 760, namely the locations corresponding to the channels 764, to include solid material and / or reinforcing elements therein.

[0083] The channels 764 can extend partially or fully through the grid structure 760 and can extend from a first face 761 of the grid structure to a second face 762. Alternatively, the channels 764 can extend from the first face 761 into the interior of the grid structure 760 without reaching the other face, such that the inner end of the channels 764 is enclosed by the grid structure 760. The channels 764 can be linear or can be curved or meandering. The channels 764 can have a constant effective diameter or can taper or expand along their length. Additionally, the channels 764 can be a single flow path or can have a branched configuration defining multiple flow paths through the grid structure 760. The channels 764 are shown as having a generally circular cross-sectional area. However, the channels 764 can have other cross-sectional areas, such as triangular, square, rectangular, or elliptical cross-sectional areas, etc.

[0084] For example, in Figures 7A - 7C a method of manufacturing a molded article including a grid structure according to some embodiments is shown. For example, Figures 7A - 7C the method shown can be used to manufacture sole 140, sole 240, or sole 512.

[0085] In step 710, a grid structure 760 having a channel 764 is provided. In some embodiments, in step 710, a reinforcing element such as a rod, bar, or plate may be inserted into the channel 764. Then, in step 720, the grid structure 760 is placed in a mold cavity 792 of a mold 790 that defines the shape of the desired article, and a solid material 780 is introduced into the mold cavity. During molding, the solid material 780 fills the portion of the mold cavity 792 not occupied by the grid structure 760 and also flows into the channels 764 of the grid structure 760 within one or more interface regions 770. During molding, the solid material 780 at least partially encapsulates one or more unit cells of the grid structure 760, such as at a first face 761 of the grid structure 760. In step 730, the resulting co-molded article 770 is removed from the mold 790. The resulting molded article 750 includes a first portion having the grid structure 760 and a second portion having the solid material 780. The solid material 780 may fill the channels 764 of the grid structure 760 to provide the desired properties to the resulting molded article 750 and facilitate the connection and fixation of the grid structure 760 and the solid material 780.

[0086] Figure 8A An exemplary grid structure 860 including a plurality of unit cells 862 is shown. According to some embodiments, the grid structure 860 may include a first subset 870 of unit cells and a second subset 880 of unit cells. As used herein, a "subset" of unit cells may refer to a continuous or contiguous plurality of interconnected unit cells. For example, a subset may refer to unit cells arranged along a row or column of the grid structure, or in contiguous rows and / or columns. The first subset 870 may have a first grid parameter, and the second subset 880 may have a second grid parameter different from the first grid parameter. As discussed herein, grid parameters may include unit cell density, strut thickness, number of struts in each unit cell, size of the unit cell surface openings, unit cell geometry, and wall thickness of the unit cell, etc.

[0087] In some embodiments, the grid parameter may be the unit cell density, where the unit cell density is defined as the number of unit cells per unit volume, e.g., the number of unit cells in 1 cm 3 In some embodiments, the first subset 870 may have a first unit cell density, and the second subset 880 may have a second unit cell density different from the first unit cell density. In some embodiments, as Figure 8AAs shown, the first unit cell density of the first subset 870 is greater than the second unit cell density of the second subset 880. In some embodiments, the first unit cell density of the first subset 870 can be at least 10% greater than the second unit cell density of the second subset 880. In some embodiments, the first unit cell density of the first subset 870 is less than the second unit cell density of the second subset 880. In some embodiments, the first unit cell density of the first subset 870 can be at least 10% less than the second unit cell density of the second subset 880.

[0088] The first subset 870 with a relatively high unit cell density can be used to limit the extent to which solid material can flow into the first subset 870 during molding. The first subset 870 can be configured such that solid material can enter the relatively dense first subset 870 only to a limited extent and can partially encapsulate one or more unit cells of the first subset 870 during molding. However, the relatively high density of the first subset 870 can prevent the solid material from flowing deeper into the grid structure 860 beyond the first subset 870, e.g., into the second subset 880. As a result, the solid material may not contact or enter the second subset 880.

[0089] The first subset 870 with a relatively low unit cell density can be used to facilitate the flow of solid material into the first subset 870 during molding. The first subset 870 can be configured such that solid material can enter the relatively open first subset 870 to completely or partially encapsulate one or more unit cells of the first subset 870 during molding. However, the relatively high density of the second subset 880 can inhibit or prevent the solid material from flowing deeper into the grid structure 860 beyond the first subset 870. As a result, the solid material may not completely or partially encapsulate the cells of the second subset unit 880.

[0090] In some embodiments, the first subset 870 with a relatively high unit cell density can be disposed at a face of the grid structure 860 configured to interface with the solid material at an interface region during molding to limit the extent of solid material flowing into the grid structure 860. However, in some embodiments, the first row of the grid structure 860 at a face of the grid structure 860 can include the second subset 880 with a relatively low unit cell density, and the first subset 870 with a relatively high unit cell density can be disposed as the second row or the third row or more rows such that solid material can flow into the first row of the grid structure 860 formed by the second subset 880, and the further flow of the solid material into the grid structure 860 is then restricted or constrained by the first subset 870 disposed at the second row. In such embodiments, the first subset 870 can be used as a barrier or sieve to slow down or stop the flow of solid material into the grid structure 860.

[0091] In addition, in asFigure 8A In some of the illustrated embodiments, the grid structure 860 can define one or more channels 890. The channels 890 can be the same as or similar to the channels 764 described herein. The channels 890 can have an effective diameter D3 that is larger than the effective diameter D1 of the unit cells of the first subset 870 of the grid structure 860 or the effective diameter D2 of the unit cells of the second subset 880. Due to the relatively large effective diameter D3 of the channels 890, solid material can flow into the channels 890 more easily during molding than into the relatively smaller unit surface openings of the unit cells of the first and second subsets 870, 880. After molding, the channels 890 can be completely filled with solid material.

[0092] As used herein, the effective diameter of a unit cell is defined as the largest cross-sectional dimension of the volume occupied by the unit cell. For example, for a cubic unit cell, the effective diameter is the diagonal dimension of the square cross-section spanning the volume of the cubic unit cell.

[0093] In some embodiments, all or a portion of the perimeter 891 of the channels 890 can be defined by the first subset 870, as shown, for example, Figure 8A in the figures. As described above, the first subset 870 can be configured to control or limit the extent to which solid material enters the grid structure 860. The second subset 880 can be connected to the first subset 870 around the perimeter 891 of the channels 890. For example, the first subset 870 can include the first row of the grid structure 860 that defines the channels 890, and the second subset 880 can include the second row of the grid structure 860 that is spaced from the channels 980 by the first subset 870. However, it should be understood that in alternative embodiments, the first subset 870 can include multiple consecutive rows, e.g., the first three rows of the grid structure 860, and the second subset 880 can include the rows of the grid structure 860 that are beyond the first subset 870, e.g., the fourth row, the fifth row, etc. All or a portion of the first subset 870 can be located in the interface region as described herein. In some embodiments, a portion of the second subset 880 can be located in the interface region.

[0094] In some embodiments, the second subset 880 can form the remainder of the grid structure 860 that is not formed by the first subset 870. In some embodiments, the second subset 880 can have grid parameters that are selected to provide desired performance characteristics for the grid structure 860, while the first subset 870 can have grid parameters that are selected to control or limit the flow of solid material into the grid structure 860.

[0095] During molding, solid material can flow into and fill the channel 890. The solid material can enter the first subset 870 and can at least partially encapsulate one or more unit cells of the first subset 870. In embodiments where the first subset 870 restricts the flow of solid material into the grid structure 860, the solid material does not flow beyond the first subset 870 and into the second subset 880, such that the solid material does not contact the second subset 880.

[0096] Figure 8B An exemplary grid structure 860' with a plurality of unit cells 862' is shown. The grid structure 860' includes a first subset 870' of unit cells, a second subset 880' of unit cells, and a channel 890' having a channel perimeter 891'. Each unit cell of the first subset 870' is formed by a plurality of interconnected struts 874', and each unit cell of the second subset 880' is formed by a plurality of interconnected struts 884'. In contrast Figure 8A to this, the first and second subsets 870', 880' may have the same unit cell density. Alternatively, in Figure 8B one embodiment, the first subset 870' may have a first strut thickness and the second subset 880' may have a second strut thickness different from the first strut thickness.

[0097] In some embodiments, the first strut thickness may be greater than the second strut thickness. In some embodiments, the first strut thickness may be at least 10% greater than the second strut thickness. In such embodiments, the first subset 870' with the higher strut thickness provides a relatively small unit surface opening 864' through which the solid material can flow. Thus, the first subset 870' can limit the extent to which the solid material can flow into the grid structure 860'.

[0098] In some embodiments, the first strut thickness may be less than the second strut thickness. In some embodiments, the first strut thickness may be at least 10% less than the second strut thickness. In such embodiments, the first subset 870' with the smaller strut thickness provides a relatively large unit surface opening 864' through which the solid material can flow. Thus, the first subset 870' can facilitate the extent to which the solid material can flow into the grid structure 870'.

[0099] Although Figure 8B shown changing the strut thickness to change the unit surface opening 864', the size of the unit surface opening 864' can additionally or alternatively be changed by changing the unit cell density of the first subset 870' or the second subset 880' of unit cells, or by changing the geometry of the first subset 870' or the second subset 880' of unit cells.

[0100] As described above with respect toFigure 8A The discussion regarding the functionality and arrangement of the grid structure 860 and the first and second subsets 870, 880 also applies to the grid structure 860' and the first and second subsets 870', 880' because the grid parameters, such as unit cell density or strut thickness, can be selected to limit or facilitate the flow of solid material through the grid structure during molding.

[0101] It should be understood that the first and second subsets of the grid structure can differ in one or more grid parameters. For example, the first subset can differ from the second subset in both strut thickness and unit cell density. It should also be understood that the grid structure can have additional subsets of unit cells, such as a third unit cell subset, a fourth unit cell subset, etc. Such additional subsets can also have grid parameters that are different from the first and second subsets.

[0102] An exemplary method of forming a footwear article having a grid structure and a solid region is shown in Figures 9A - 9D . In step 910, the grid structure 960 and the mold insert 906 are placed in a mold 902 that defines the shape of the sole and upper of the footwear article 908. The mold is filled with the solid material described herein. After molding is complete, in step 920, the mold is opened, for example, by separating the upper mold 903 from the lower mold 904. In some embodiments, the lower mold 904 can define a portion of the sole of the footwear article, and the upper mold 903 can define all or a portion of the upper of the footwear article. The mold insert 906 can define all or a portion of the foot cavity for receiving the wearer's foot within the footwear article. In some embodiments, the mold insert 906 can be configured to provide the shape of the upper of the footwear in combination with the upper mold 903 and also define all or a portion of the foot cavity for receiving the wearer's foot within the footwear article.

[0103] In step 930, the mold insert 906 is removed from the mold 902. Then in step 940, the co-molded footwear article 908 is removed from the mold 902.

[0104] The shoe 908 includes an upper 901 integrally formed with a solid region 907 of the sole 905. The upper 901 and the solid region 907 of the sole 905 are formed of molded solid material. The solid region 907 of the sole 905 is mechanically bonded to the grid structure 960 at the interface region 970. As Figure 9D shown, the grid structure 960 forms the lower portion of the sole 905.

[0105] While the embodiments described herein relate primarily to articles of footwear and methods of manufacturing articles of footwear, the present invention is not limited solely to footwear, and the principles and methods described herein can be applied to manufacturing other co-molded articles having a grid structure and solid regions. Such articles can be used, for example, in sports equipment or apparel, and other applications. For example, the co-molded articles described herein can be used in shock pads, and such pads can be integrated into clothing and protective equipment, such as clothing and equipment that can be worn or used by, for example, hockey players, football players, baseball catchers, referees, roller skaters, skateboarders, skiers, and snowboarders. Exemplary articles of clothing and protective equipment can include helmets, gloves, elbow pads, shin guards, shoulder pads, padded shirts, padded pants or shorts, and other padded clothing,

[0106] It should be understood that the detailed description section, rather than the summary and abstract sections, is intended to be used to interpret the present application. The summary and abstract sections may set forth one or more, but not all, exemplary embodiments contemplated by the inventors, and thus are not intended to limit the present invention in any way.

[0107] The foregoing description of the specific embodiments will so fully reveal the general nature of the 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. It should be understood that the language or terminology herein 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.

[0108] The breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments.

Claims

1. A sole for a footwear article, the sole comprising: comprising a first portion of a grid structure, the grid structure comprising a plurality of unit cells, wherein the plurality of unit cells comprises a first subset of unit cells and a second subset of unit cells different from the first subset of unit cells; as well as A second portion includes a solid material, wherein the solid material at least partially encapsulates one or more unit cells of the first subset of unit cells.

2. The sole according to claim 1, wherein: The lattice structure defines a channel that extends at least partially through the lattice structure.

3. The sole according to claim 2, wherein: The solid material is arranged in channels defined by the grid structure.

4. The sole according to claim 3, wherein: A first subset of the unit cells defines the channel.

5. The sole according to claim 1, wherein: The first portion includes a toe area of ​​the sole and the second portion includes a heel area of ​​the sole.

6. The shoe sole according to claim 1, wherein: The first portion includes an upper area of ​​the sole and the second portion includes a lower area of ​​the sole.

7. The shoe sole according to claim 1, wherein: The solid material comprises an expandable foam material.

8. The sole according to claim 1, wherein: The solid material does not contact the second subset of unit cells.

9. The shoe sole according to claim 1, wherein: The first subset of unit cells includes mesh parameters that are different from mesh parameters of the second subset of unit cells.

10. The shoe sole according to claim 9, wherein: The first subset of unit cells has a unit cell density greater than the unit cell density of the second subset of unit cells.

11. The shoe sole according to claim 9, wherein: The cell surface openings of the first subset of the unit cells are smaller than the cell surface openings of the second subset of the unit cells.

12. The shoe sole according to claim 9, wherein: Each of the plurality of unit cells includes a plurality of interconnected pillars, wherein a thickness of the pillars of a first subset of the unit cells is greater than a thickness of the pillars of a second subset of the unit cells.

13. A method of forming a sole for an article of footwear, the method comprising: providing a grid structure in a mold cavity defining a shape of a shoe sole, wherein the grid structure comprises a plurality of unit cells, wherein the plurality of unit cells comprises a first subset of unit cells and a second subset of unit cells different from the first subset of unit cells; as well as A solid material is flowed into the mold cavity such that the solid material at least partially encapsulates one or more unit cells of the first subset of unit cells.

14. The method of claim 13, further comprising controlling the flow of solid material into the first subset of unit cells by adjusting one or more of molding temperature or molding pressure.

15. The method according to claim 13, wherein: The grid structure is formed by an additive manufacturing method.

16. The method according to claim 13, wherein: The first subset of unit cells includes mesh parameters that are different from mesh parameters of the second subset of unit cells.

17. The method according to claim 16, wherein: The first subset of unit cells has a unit cell density greater than the unit cell density of the second subset of unit cells.

18. The method according to claim 16, wherein: The cell surface openings of the first subset of the unit cells are smaller than the cell surface openings of the second subset of the unit cells.

19. The method according to claim 16, wherein: Each of the plurality of unit cells includes a plurality of interconnected pillars, wherein a thickness of the pillars of a first subset of the unit cells is greater than a thickness of the pillars of a second subset of the unit cells.

20. A molded article comprising: comprising a first portion of a grid structure, the grid structure comprising a plurality of unit cells, wherein the plurality of unit cells comprises a first subset of unit cells and a second subset of unit cells different from the first subset of unit cells; as well as A second portion of foam material is included, wherein the foam material at least partially encapsulates one or more unit cells of the first subset of unit cells.

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