Detachable article of footwear
By using cables to connect the upper and soles in footwear products, the problems of material contamination and difficulty in disassembly are solved, achieving more efficient recycling and replacement convenience.
Patent Information
- Application Number
- CN202380085752.X
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Priority Date
- 2023-12-14
- Filing Date
- 2023-12-15
- Publication Date
- 2025-07-22
AI Technical Summary
When disassembly, existing footwear products are easily contaminated and difficult to effectively separate, limiting the convenience of recycling and replacement of components.
The upper and sole are connected through a series of orifices to reduce or eliminate non-cable connections such as chemical adhesives, and designed to be easily disassembled, ensuring that each part does not contaminate each other when disassembled.
It realizes the decomposition of footwear products, improves recycling efficiency and the purity of components, and facilitates replacement and reuse.
Smart Images

Figure CN120358962A_ABST
Abstract
Description
Background Art
[0001] A footwear article typically includes a sole attached to an upper, and in many cases, the various parts of the footwear article can include various different types of materials. For example, the upper can include one type of material (e.g., polyester (PET), nylon, natural fibers, etc.), while the sole can include other different types of materials (e.g., rubber, ethylene-vinyl acetate (EVA) foam, thermoplastic polyurethane (TPU), etc.). Additionally, various different mechanisms are typically used to attach one or more components together. For example, the footwear article can include a combination of adhesives (e.g., chemical bonding), mechanical fasteners, stitching, fusing (e.g., heat bonding), ultrasonic welding, etc.
[0002] In some cases, it may be desirable to disassemble a footwear article, such as when recycling the footwear article or replacing a component of the footwear article (e.g., replacing the sole or upper or a portion thereof). However, conventional construction methods (e.g., attaching parts using various mechanisms) typically make it challenging to disassemble the footwear article into its constituent parts such that one material or part is not contaminated by another material or part or remains at least partially attached to another material or part. For example, separating the upper from the sole such that at least a portion of the sole does not remain attached to the upper (and vice versa) can be challenging because the parts of the sole (including fragments or chunks of the sole that break off and remain attached to the upper) typically remain attached to the upper (e.g., based on adhesives or other attachment mechanisms). Similarly, separating one part of the sole (e.g., a midsole including foamed EVA) from another part of the sole (e.g., an outsole including rubber or some material other than foamed EVA) such that these parts do not contaminate each other (e.g., remain attached to each other) can be challenging. Brief Description of the Drawings
[0003] The present article, system, and method for a disassemblable footwear article are described in detail below with reference to these figures.
[0004] Figure 1A An exterior perspective view of a footwear article according to an example of the present disclosure is depicted.
[0005] Figure 1B Depicts an example of the present disclosure Figure 1A of an interior view of a footwear article.
[0006] Figure 2A A top view of a footwear article according to an example of the present disclosure is depicted.
[0007] Figure 2B Depicts an example of the present disclosure associated with Figure 2A a cross-sectional view.
[0008] Figure 2C depicts a cross-sectional view associated with an example in accordance with the present disclosure Figure 2A .
[0009] Figure 3A and Figure 3B depicts an upper of a footwear item in accordance with an example of the present disclosure.
[0010] Figure 4 depicts an exploded top perspective view of a sole structure of a footwear item in accordance with an example of the present disclosure.
[0011] Figure 5 depicts an exploded bottom perspective view of a sole structure of a footwear item in accordance with an example of the present disclosure.
[0012] Figure 6A depicts a bottom plan view of a sole structure of a footwear item in accordance with an example of the present disclosure.
[0013] Figure 6B depicts a cross-sectional view associated with an example in accordance with the present disclosure Figure 6A .
[0014] Figure 7 depicts, in a partially exploded view, a sole structure, a heel counter, and a toe cap for a footwear item in accordance with an example of the present disclosure.
[0015] Figure 8 depicts a heel counter attached to a footwear item in accordance with an example of the present disclosure.
[0016] Figure 9A and Figure 9B depicts steps associated with a method of assembling a footwear item in accordance with an example of the present disclosure.
[0017] Figure 10 depicts a diagram including various stages associated with a life cycle of a footwear item in accordance with an example of the present disclosure. DETAILED DESCRIPTION
[0018] This specific embodiment relates to a disassemblable footwear article that includes an upper and a sole, where the upper and the sole have multiple parts attached together by one or more cables. In at least some instances, the upper can be fixed to the sole via a cable around the perimeter or outer edge. For example, the cable can pass through a series of holes or apertures in the sole and through a series of apertures or channels in the upper to attach the parts together. In at least some instances, in addition to the cable, the upper and the sole can have no (or substantially no) other non-cable connections (such as chemical adhesives, stitching, fusion joints, ultrasonic welding, etc.). Thus, in at least some instances, at least a portion of the footwear article can be disassembled by untying (or otherwise removing) the cable. Additionally, due to the omission of non-cable connections, when the footwear article is disassembled, the parts can be free from cross-contamination (e.g., remnants of one part of the sole do not remain attached to another part of the sole). Thus, in some instances, the parts can be more suitable for recycling (e.g., regranulation) because the parts include a purer form of the constituent materials that are not contaminated by the materials of other parts. Additionally, one or more of the parts can be reused in subsequent footwear articles (e.g., by attaching with the cable or a new cable).
[0019] In contrast to the subject matter of the present disclosure, conventional methods associated with footwear construction typically include attaching footwear components to each other by using chemical adhesives, thermal bonding, stitching, ultrasonic welding, etc. For example, chemical adhesives are typically used to attach the upper to the sole, and similarly, chemical adhesives can be used to attach the outsole to the midsole. Thus, when these footwear articles are disassembled, fragments or remnants of one component typically remain attached to another component, which can limit the usefulness of the component in subsequent applications. In other instances, conventional solutions can couple components to thermally bonded structures that can include re-curing materials that (e.g., using heat) transition to a softened or molten state and can then capture or encapsulate surrounding structures and re-cure (e.g., by cooling) to bond with the surrounding structures.
[0020] Generally, one aspect of the present disclosure relates to a footwear article that includes components attached to each other via a cable. The disclosed footwear article includes various features that are designed to make the footwear article more recyclable (e.g., compared to conventional constructions), while maximizing, for example, the stability and wearer comfort of the footwear article.
[0021] For example, the footwear article can include an upper having a strobel or other portion configured to extend under a wearer's foot. In an example, the aperture can be positioned near a perimeter of the strobel and / or in a peripheral edge around the strobel. In at least some examples, an aperture in the upper can be aligned with an aperture formed in a sole of the footwear article (e.g., in a sidewall of the sole) such that the upper can be attached to the sole by passing a cable through the aligned apertures without using an adhesive or other connecting mechanism. Additionally, a groove (e.g., on a surface of the sole) can connect the aperture associated with the sole and can be configured to receive a cable (e.g., such that a portion of the cable exposed on an outer surface of the sole is less likely to be worn or abraded). In at least some examples, the sole can also include multiple components attached together by using a cable (e.g., another cable that can connect one or more midsole components and one or more outsole components).
[0022] As another example, the strobel can include a spacer knit that can cushion the wearer's foot and can reduce the likelihood of discomfort caused by the presence of the cable.
[0023] As yet another example, the footwear article can include a heel stabilizer and / or a toe that can also be attached to other elements of the footwear article using one or more cables. Additionally, the heel stabilizer and / or the toe can receive one or more cables that are also used to attach other elements of the footwear article to each other, thereby serving as an anchor point and enhancing the stability of the footwear article. For example, in some cases, the heel stabilizer and / or the toe can be composed of a material that is less likely to tear, such as when tension is applied via a threaded cable. Thus, the heel stabilizer and / or the toe can operate to reinforce the anchor point.
[0024] In examples of the present disclosure, various features can contribute to the disassemblability of a footwear article. For example, in at least some examples, a sole of a footwear article can include a midsole carrier component that is configured to support one or more other components of the footwear article. For example, the midsole carrier can include a cavity or recess in a top surface (e.g., similar to a cup sole in some aspects), and one or more components can be disposed within the cavity (e.g., an embedded component). For example, the sole can include an outsole component that can be embedded within the cavity of the midsole carrier (e.g., the outsole is disposed on top of the midsole carrier) and protrude through the midsole carrier (e.g., via a through-hole) to form a ground-contacting member. Additionally, the sole can include a midsole core that can be embedded within the cavity of the midsole carrier such that the outsole component is laminated between the midsole core and the midsole carrier. In an example, a cable can pass through at least the midsole carrier and the midsole core to secure the components together.
[0025] In at least some examples, portions of the sole can include various elements that contribute to a snug and stable connection between the portions. For example, the midsole carrier can include through-holes configured to receive traction lugs of the outsole component. In at least some examples, the through-holes and the traction lugs can include similar shapes (e.g., both the through-holes and the traction lugs can be rectangular). In some examples, the similar shape can include one or more straight portions and / or oval portions, which can reduce the likelihood of the traction lug rotating relative to the through-hole (e.g., when the similar shapes include similar dimensions and based on interference between corresponding straight portions). Additionally, the traction lugs and the through-holes can be similar in size such that when the traction lugs are inserted into the through-holes, the perimeter of the through-hole can frictionally engage the traction lugs. In some examples, the traction lugs can include one or more protrusions (e.g., annular ribs) that increase the width of the traction lugs at certain portions such that once the traction lugs have been inserted into the through-holes, these protrusions can prevent the traction lugs from disengaging from the through-holes.
[0026] In some examples, the through-holes in the midsole carrier can extend through layers of the midsole carrier from an upper surface of the midsole carrier (e.g., the upper surface facing the foot-receiving cavity) and extend to a lower surface of the midsole carrier (e.g., the lower surface facing away from the foot-receiving cavity). Additionally, the upper surface can include a recessed portion surrounding the through-holes. In at least some examples, the embedded outsole can include a protruding portion surrounding the traction lugs that has a profile corresponding to the recessed portion of the cup-shaped midsole upper surface. Thus, when the traction lugs mate with the through-holes, the protruding portion of the embedded outsole can nest into the recessed portion of the cup-shaped midsole upper surface.
[0027] As described above, in at least some instances, the midsole core may also be disposed or stacked within a cavity of the midsole carrier and on top of the outsole such that the outsole is laminated between the midsole carrier and the midsole core. In at least some instances, the upper surface of the midsole carrier may include a recess having an outer edge that defines the profile or shape of the recess. In some cases, the midsole core may include a perimeter, a terminal edge that also defines a shape corresponding to the shape of the recess. Thus, the midsole core may nest into the recess and on top of the outsole. In at least some instances, the various components having corresponding shapes and profiles may contribute to an improved fit between the components and a smooth transition from one component to another. In at least some instances, this may reduce the likelihood that the components may include protruding edges or other protruding surfaces in the underfoot portion of the shoe that may cause discomfort (e.g., poking, rubbing, hot spots, etc.).
[0028] In an example, portions of the sole may be attached to each other using a cable. For example, the portions may include various through-holes that receive the cable when the cable passes between the respective portions. In at least some instances, one or more of these portions may include a surface groove that connects a first through-hole to a second through-hole. Thus, when the cable passes or extends along the surface from the first through-hole to the second through-hole, the cable may be positioned within the groove, which may protect the cable, prevent the cable from moving side to side, and reduce the likelihood that the cable protrudes from the surface and may cause discomfort to the wearer. For example, the upper surface of the midsole core (e.g., facing the foot receiving cavity) may include a cable retaining surface groove that may accommodate the cable, with a depth sufficient to reduce the likelihood that the cable protrudes into the shoe bed of the footwear article and may prevent the cable from sliding around. In some instances, the lower surface of the midsole carrier (e.g., when the footwear article is worn, facing away from the foot receiving cavity and sometimes facing the ground surface) may include a cable retaining surface groove that may accommodate the cable, help protect the cable from the ground surface (e.g., reduce wear, tear, breakage, etc.), and may prevent the cable from sliding around.
[0029] In at least some instances, the footwear article can include various different types of materials. For example, the upper can include one type of material (e.g., polyester (PET), recycled polyester (rPET), nylon, recycled nylon, natural fibers, etc.), while the sole can include other different types of materials (e.g., rubber, ethylene vinyl acetate (EVA), thermoplastic polyurethane (TPU), etc.). Additionally, in some cases, it may be desirable to disassemble the footwear article, such as when recycling the footwear article or replacing components of the footwear article (e.g., replacing the sole or upper or a portion thereof). Examples of the present disclosure provide a footwear assembly that facilitates disassembly such that parts of a footwear article including one material are not contaminated by different materials of other parts (e.g., not contaminated to the extent that the part is not suitable for recycling into that material). That is, using cables to attach the various parts also allows the cables to be untied and removed when disassembly is needed. When the footwear assembly includes a minimum of non-cable connections and does not include various types of non-cable connections (e.g., chemical adhesives, thermally bonded structures, etc.), the likelihood that a part of one part does not remain attached or bonded to another part after disassembly increases.
[0030] As described, certain aspects of the present disclosure relate to a footwear article or aspects thereof formed at least in part from a knitted fabric. In illustrative examples, aspects relate to an upper formed at least in part from knitted components. As used herein, the term "upper" refers to a footwear component that extends over the dorsal region (e.g., the top) and toe region of the foot, along the medial and lateral sides of the foot, and around the heel region of the foot to form a void for receiving a wearer's foot. Illustrative, non-limiting examples of uppers can include uppers incorporated into basketball shoes, cycling shoes, cross-training shoes, association football (soccer) shoes, American football shoes, bowling shoes, golf shoes, hiking shoes, ski or snowboard boots, tennis shoes, running shoes, and walking shoes. Additionally, in other aspects, the upper can also be incorporated into non-sports shoes (such as dress shoes, loafers, and sandals). Thus, the concepts disclosed with respect to the footwear article apply to a variety of footwear types. Although the figures may illustrate a footwear article intended for use on only one foot of a wearer (e.g., the left foot), those skilled in the art will recognize that the corresponding footwear article for the other foot (e.g., the right foot) will be a mirror image of the left footwear article.
[0031] Position terms used in describing a footwear article or aspects thereof (such as top, bottom, front, side, back, upper, lower, outer, inner, right, left, interior, exterior, inward-facing, outward-facing, etc.) are used relative to the footwear article or the shoe upper as intended to be worn (where the wearer stands upright such that the wearer's foot is in the foot receiving void and the wearer's ankle or leg extends through the ankle opening). For example, the "uppermost surface" and / or "upper surface" of the shoe upper refers to the surface that is oriented in the "upward" anatomical direction (i.e., towards the wearer's head) when the footwear article is worn by the wearer. Similarly, the directional terms "downward" and / or "down" refer to the anatomical direction "down" (i.e., towards the ground and away from the wearer's head). "Front" or "forward" means "in front" (e.g., towards the toe), and "rear" means "in back" (e.g., towards the heel). "Inner" means "towards the midline of the body", and "outer" means "away from the midline of the body". The "longitudinal axis" refers to the centerline of the article that extends between the heel region and the forefoot region. Similarly, the "longitudinal length" refers to the length of the article along the longitudinal axis, and the "longitudinal direction" refers to the direction along the longitudinal axis. However, it should be understood that for purposes of explanation, the use of position terms does not depend on the actual presence of a person.
[0032] The term "knit component" refers to a fabric piece formed from at least one yarn that is manipulated (e.g., with a knitting machine) to form a plurality of interlooping loops that define courses and wales. As used herein, the term "course" refers to a primarily horizontal row of knitted loops produced by adjacent needles during the same knitting cycle (in an upright fabric knitted on a knitting machine). A course can include one or more stitch types, such as knit stitches, miss stitches, tuck stitches, transfer stitches, rib stitches, etc., which terms are known in the knitting art. As used herein, the term "wale" is a primarily vertical column of interlooping or interlacing knitted loops, typically produced by the same needle in consecutive (but not necessarily all) courses or knitting cycles.
[0033] As used herein, the term "integrally knit" can mean that the yarns from one or more courses of a knit component in a first region or zone are interlaced with one or more courses of another region or zone. The interlacing can be by way of a simple knit stitch, tuck stitch, holding stitch, float stitch, miss stitch, etc. In this way, the regions that are integrally knit together have a seamless transition.
[0034] As used herein, the term "periphery" refers to the region that forms the boundary of the object in question. For example, the periphery of a knitted component is the region that extends along the boundary of the structure. The "outer periphery" can refer to portions of the periphery of a knitted component that, once formed into a footwear article, are secured to the sole structure or form a seam between the two ends of the outer periphery (such that they can extend at least partially beneath the wearer's foot when the footwear article is worn). In contrast, the "inner periphery" can refer to portions of the periphery of a knitted component that, once formed into a footwear article, define an opening, such as an opening in the throat region and / or an ankle opening. The periphery (outer or inner) can refer to the edge of the knitted component or the peripheral region adjacent to the edge.
[0035] Aspects are described below with reference to the drawings, in which like elements are generally identified by like reference numerals. The relationship and function of the various elements of the aspects can be better understood by reference to the following detailed description. However, the aspects are not limited to those illustrated in the drawings or explicitly described below. It should also be understood that the drawings are not necessarily drawn to scale and that in some cases details unnecessary for understanding the aspects disclosed herein (such as conventional assemblies) may be omitted. Additionally, various measurements are provided herein. Unless otherwise indicated, the terms "about" or "substantially" with respect to a measurement mean within ±10% of the indicated value.
[0036] Example Footwear Article
[0037] Figure 1A and Figure 1B depict, respectively, an outer view and an inner view of a footwear article 100 and its components according to an example of the present disclosure. The footwear article 100 includes a sole structure 102 and a shoe upper 104. The shoe upper 104 is coupled to the sole structure 102 and extends from the sole structure 102, and in some examples, the shoe upper 104 can at least partially surround a foot receiving cavity 105 (e.g., Figure 2B ) or space. The region where the topline edge 106 of the sole 102 of the footwear article 100 aligns with the shoe upper 104 can be referred to as the biteline. In at least some examples of the present disclosure, the shoe upper 104 can be coupled to the sole structure 102 by a cable 107 (e.g., a peripheral cable that extends at least partially around the periphery of the footwear article 100), as discussed in more detail below. Additionally, portions of the sole 102 can be coupled together via a cable 101 (e.g., an underfoot cable that passes through various apertures in the midsole component and / or the outsole component). In addition to attaching the sole 102 to the shoe upper 104, in some examples, the cable 101 and / or the cable 107 can couple a heel stabilizer 118 and a toe 119.
[0038] The cables 101 and 107 can be at least partially nested into grooves or recesses and thus from Figure 1Ais partially obscured from view. The one or more cables can include various types of cables, such as braided cables, and can have various characteristics (e.g., diameter, constituent materials, filament count, etc.). For example, cables 101 and 107 can include a diameter in the range of from about 1.0 mm to about 1.4 mm. Additionally, cables 101 and 107 can include a filament count of about 96 filaments. Additionally, the one or more cables can include polyester, such as recycled polyester, or other high toughness materials. In at least some instances, components of footwear article 100 can be coupled together via cables 101 and 107 and without (or substantially without) at least some other forms of connection (e.g., chemical adhesives, thermal bonding, stitching, etc.).
[0039] Footwear article 100 (and / or its components) can be divided into one or more zones (which can also be referred to as “regions” or “portions”). For example, in the anterior-posterior direction, footwear article 100 (and / or its components) can be divided into (and / or include) a forefoot zone 108, a midfoot zone 110, and a heel zone 112. The forefoot zone 108 of footwear article 100 can correspond to the front portion of the foot, including the toes and the joints connecting the metatarsal and phalangeal bones of the foot. The midfoot zone 110 of footwear article 100 can correspond to the arch region of the foot. The heel zone 112 of footwear article 100 can correspond to the posterior portion of the foot including the calcaneus. In the medial-lateral direction, footwear article 100 (and / or its components) can be divided into a lateral side 114 (e.g., Figure 1A ) and a medial side 116 (e.g., Figure 1B ), both the lateral side 114 and the medial side 116 extending through the forefoot zone 108, the midfoot zone 110, and the heel zone 112. More specifically, when footwear article 100 is worn, the lateral side 114 corresponds to the outer region of the foot (i.e., the side facing away from the other foot), while when footwear article 100 is worn, the medial side 116 corresponds to the inner region of the foot (i.e., the side facing the other foot). Additionally, when footwear article 100 is worn, the insole of footwear article 100 can correspond to the region under the foot. These zones, sides, and regions (e.g., 108, 110, 112, 114, 116, etc.) are not intended to demarcate precise regions of footwear article 100, but rather are intended to represent approximate regions of footwear article 100 to aid in understanding the various descriptions provided herein.
[0040] When the footwear article 100 is worn, the sole structure 102 typically extends between the foot and the ground. The sole structure 102 can include multiple components, such as an outsole and a midsole. A variety of materials can be used to form the sole structure 102, such as rubber, ethylene-vinyl acetate (EVA) foam or phylon, thermoplastic polyurethane (TPU), thermoplastic elastomer (e.g., polyether block amide), and the like. The sole structure 102 can include various other features to attenuate forces, enhance stability, and / or provide traction, such as a sole pattern understood by those skilled in the art.
[0041] The upper 104 defines a foot receiving cavity 105 within the footwear article 100 for receiving and securing the foot relative to the sole structure 102 (e.g., Figure 2B ). An opening 125 to the foot receiving cavity 105 is provided through an ankle opening 125 located at least in the heel region 112 (e.g., Figure 1A and Figure 2B ). In at least some instances, the upper 104 can include a section 202 (e.g., Figure 2B ), such as a strobel, that extends from the inner side of the upper to the outer side of the upper and spans the top or upper side of the sole 102, and this section can form at least a part of a sole plate or insole beneath the foot receiving cavity 105. In some instances, this section can be referred to as a "underfoot portion" or "underfoot zone".
[0042] The footwear article 100 can also include a closure system to adjust the size or fit associated with the foot receiving cavity 105. In this way, the closure system can be used, for example, to secure the footwear article 100 to the wearer's foot and / or release it from the wearer's foot. In Figure 1A and Figure 1B , the closure system includes a cable 120 that passes between various tubular sheaths 122 and anchor points 124 and 126 (e.g., Figure 1A and Figure 2B the outer anchor point 124 in Figure 1B and Figure 2B the inner anchor point 126 in
[0043] Example uppers for footwear
[0044] As indicated, the footwear article 100 may include an upper 104. At least some portions of the upper 104 may be constructed from one or more different types of fabrics (such as knit, woven, non-woven, extruded film, braided, etc.). In an example, at least a portion of the upper 104 may include at least one knitted component formed by a knitting process (such as, for example, weft knitting on a flat knitting machine). In some aspects, the entire or substantially the entire upper 104 may be formed from knitted components. In some examples, multiple portions of the upper may be formed separately (e.g., knitted, woven, entangled, etc.) and then attached to each other to form the upper.
[0045] In an example, Figure 3A a first upper component 300a is depicted, and Figure 3B a second upper component 300b is depicted. According to some examples, the first upper component 300a and the second upper component 300b may be assembled (e.g., joined together along a seam) to form Figure 1A and Figure 1B the upper 104. For example, the first upper component 300a and the second upper component 300b (e.g., the edges of components 300a and 300b) may be connected to each other along a seam 142 (e.g., as Figure 1A and Figure 1B shown) such as by stitching, stitching tape, etc. Figure 3A A top plan view of the upper component 300a is illustrated, and Figure 3B a top plan view of the upper component 300b in a deployed configuration is illustrated. The upper components 300a and 300b may be assembled to include the same or similar features as the upper 104. For example, the upper component 300a (e.g., the front panel portion of the upper) may include a portion configured to surround at least a portion of the dorsal portion of the wearer's foot, and the upper component 300b may be configured to extend beneath the plantar region of the wearer's foot. In various examples, the upper components 300a and 300b form the entire or substantially the entire upper and may incorporate various types of yarns to impart different properties to separate regions of the upper.
[0046] In at least some examples, the upper component 300a may include a free edge 303a that is attached (e.g., via stitching, stitching tape, etc.) to the free edge 303b of the upper component 300b (e.g., along Figure 1A and Figure 1Bseam 142) in it. Additionally, the upper member 300b may include free edges 305a and 305b in the heel region, which are attached together along the seam (e.g., via stitching, stitching tape, etc.) to at least partially surround the heel end of the upper 104. That is, the heel flap 307 can be folded upward, the two edges 305a can be stitched together, and the two edges 305b can be stitched together.
[0047] The first upper member 300a and the second upper member 300b can incorporate various types of yarns that impart different properties to the separated regions of the upper 104. That is, one region of the first upper member 300a and / or the second upper member 300b can be formed of a first type of yarn that imparts a first set of properties, while another region can be formed of a second type of yarn that imparts a second set of properties. In this configuration, by selecting specific yarns for different regions of the first upper member 300a and the second upper member 300b, the properties can vary throughout the upper 104. The properties that a particular type of yarn will impart to a region of the first upper member 300a and / or the second upper member 300b depend in part on the materials of the various filaments and fibers that form the yarn. For example, cotton provides a soft handfeel, natural aesthetic, and biodegradability. Elastane and stretch polyester each provide significant stretch and recovery, and stretch polyester also provides recyclability. Rayon provides high luster and moisture absorbency. In addition to insulating properties and biodegradability, wool also provides high moisture absorbency. Nylon is a durable and abrasion-resistant material with relatively high strength. Polyester is a hydrophobic material that also provides relatively high durability. In addition to the material, other aspects of the yarn selected for the knitted member 140 may also affect the properties of the upper 104. For example, the yarn forming the first upper member 300a and / or the second upper member 300b can be a monofilament yarn or a multifilament yarn. Thus, unless otherwise stated, the term "yarn" as used herein does not require multiple filaments or fibers. The yarn can also include individual filaments each formed of a different material. Additionally, the yarn can include filaments each formed of two or more different materials, such as a multicomponent yarn (e.g., a bicomponent yarn) having filaments with a sheath-core configuration or two halves formed of different materials. Different degrees of twist and crimp and different deniers can also affect the properties of the upper 104. Thus, the materials of the yarn and other aspects of the yarn can be selected to impart various properties to the separated regions of the upper 104.
[0048] The first shoe upper component 300a and the second shoe upper component 300b are illustrated as discrete components that may be knitted as separate pieces and then attached to each other to form the shoe upper 104. In some instances, the first shoe upper component 300a and the second shoe upper component 300b may be integrally knitted as a single knitted component during a knitting process such as weft knitting, warp knitting, or any other suitable knitting process. Forming the shoe upper 104 with the knitted component may provide advantageous properties for the shoe upper 104, including but not limited to a particular degree of elasticity, breathability, bendability, strength, moisture absorbency, weight, abrasion resistance, and / or combinations thereof. Additionally, forming the shoe upper 104 from an integrally knitted component may form various features and structures of the shoe upper 104 without the need for a large number of additional manufacturing steps or processes, thereby increasing production efficiency.
[0049] In at least some instances, the shoe upper component 300b may include respective apertures 302a through 302d that extend completely through the thickness of the shoe upper component 300b. For example, the apertures 302 may include one or more heel apertures 302a in the heel region 310 of the shoe upper component, one or more medial apertures 302b positioned along the medial side of the shoe upper component 300b, one or more lateral apertures 302c positioned along the lateral side of the shoe upper component, and one or more forefoot apertures 302d positioned in the forefoot region 308 of the shoe upper component 300b. Additionally, the shoe upper component 300a may also include an aperture 302e in the forefoot region (e.g., the top of the toe box). In an instance, the apertures 302a through 302e may threadably receive one or more cables (e.g., Figure 1A cable 107 in ) for attaching the shoe upper components 300a and 300b to one or more components associated with a sole (e.g., sole 102). In cases where the shoe upper includes or is formed from a knitted component, the shoe apertures 302a through 302e may be integrally knitted with the shoe upper. That is, the shoe apertures 302a through 302e may be formed during the knitting process.
[0050] As Figure 3B shown, a plurality of shoe apertures 302a through 302d may be positioned around the perimeter of the underfoot portion 306 (e.g., the strobel) of the shoe upper component 300b. That is, the apertures among the plurality of shoe apertures 302a through 302d may be positioned in the underfoot portion 306 and near the transition from the underfoot portion 306 to the sides of the shoe upper (e.g., the medial and lateral sides). In at least some instances, for example, the aperture 302d in the forefoot region 308 (or positioned closer to the forefoot region 308 than the heel region 310) may include a higher density (e.g., linear density) of apertures compared to the apertures 302a, 302b, and 302c in other regions, in order to provide enhanced stability (e.g., a higher density of cable penetration) in or near the forefoot region 308.
[0051] In some cases, multiple shoe apertures 302a-302d may be positioned within a peripheral edge 316 that extends around the underfoot portion 306. In some instances, the peripheral edge 316 may form a boundary around (or enclose) an open-knit fabric associated with the underfoot portion 306. In some instances, the peripheral edge 316 associated with the underfoot portion 306 may overlap the open-knit fabric such that the apertures 302a-302d extend through at least a portion of the open-knit fabric. Additionally, the peripheral edge 316 may be integrally knitted with the upper component 300b. Because the multiple shoe apertures 302a-302d are positioned within the peripheral edge 316, and / or because the open-knit fabric is located within the boundary formed by the underfoot peripheral edge 316, the foot may be cushioned or separated from a cable passing through the multiple shoe apertures 302a-302d when the foot is placed within the footwear article. Additionally, in some embodiments, the multiple shoe apertures 302a-302d may be positioned within a second (e.g., bottom) layer 210 but not within a first (e.g., top) layer 208 such that when a cable (e.g., cable 107) passes through the first multiple shoe apertures, the cable passes through the second layer 210 and into a gap space between the first layer 208 and the second layer 210 without passing through the first layer 208 - minimizing or eliminating contact between the cable and the wearer's foot when the footwear article is in a worn configuration.
[0052] In at least some instances, the upper component 300b may include one or more outer cable anchors 318 and one or more inner cable anchors 320, which may include a portion of a closure system for adjusting the size or fit associated with the upper 104. For example, once the upper component 300a has been attached to the upper component 300b, the outer cable anchors 318 and the inner cable anchors 320 may threadably receive the cable 120 of the closure system. In at least some instances, the upper component 300b includes an outer panel 312 (e.g., panel, wing, extension, quarter, etc.) and an inner panel 314 (e.g., panel, wing, extension, quarter, etc.) that extend from respective sides of the underfoot portion (e.g., integrally knitted with the underfoot portion in some instances). In an instance, the outer panel 312 and the inner panel 314 may be folded upward to attach to the upper component 300a when forming the upper (e.g., upper 104). In some instances, the outer panel 312, the inner panel 314, and / or the edge 316 may include a lower peripheral edge associated with the upper (e.g., upper 104). In Figure 3BIn [the figure], cable anchors (e.g., 318 and 320) are depicted as being associated with the upper component 300b. In some instances, one or more cable anchors (e.g., similar to cable anchors 318 and 320) can be integrally formed with the upper component 300a (e.g., also formed on the upper component 300a or alternatively formed on the upper component 300b).
[0053] Return reference Figure 1A and Figure 1B and Figure 2A , the upper 104 can include one or more outer anchor points 124 (e.g., the same as or similar to the outer anchor point 318) positioned on the outer side 114 and one or more inner anchor points 126 (e.g., the same as or similar to the inner anchor point 320) located on the inner side 116. The outer anchor points 124 and the inner anchor points 126 can include loops, hooks, or other structures having openings for threadably and slidably receiving the cable 120. For example, the outer anchor points 124 and the inner anchor points 126 can include openings that are configured to frictionally engage the cable when the cable passes through and restrict the left - right movement of the cable. In some instances, the outer anchor points 124 and the inner anchor points 126 can be integrally knitted with the knitted component. For example, briefly returning to the reference Figure 3B , the anchor points 318 and 320 can be knitted together with the upper component 300b, and then when assembled with the upper component 300a (e.g., along the seam 142), the anchor points 318 and 320 can form the outer anchor points 124 and the inner anchor points 126. Although the upper 104 is depicted as including three outer anchor points 124 and three inner anchor points 126, it is contemplated that the upper 104 can include more or fewer outer anchor points 124 and / or inner anchor points 126. It is also contemplated that the upper 104 can include one or more additional anchor points on the upper surface of the upper 104, e.g., at the location where the first portion of the cable 120 (which can be the same cable as the cable 107) intersects the second portion of the cable 120.
[0054] The upper 104 can also include one or more tubular sheaths 122 (e.g., the tubular sheath 322 depicted as being associated with the upper component 300a) positioned on the outward - facing surface of the upper 104. The tubular sheaths 122 can be configured to receive a cable, such as the cable 120. For example, the tubular sheath 122 can include a tubular wall having an inner diameter (or other inner width) large enough to receive the cable 120 and small enough to restrict the lateral or left - right movement of the cable within the tubular sheath 122. The tubular sheaths 122 can be positioned such that they guide the cable 120 in a desired path or pattern.
[0055] In some instances, reference Figure 2A and Figure 3A, the arrangement or array of tubular sheaths 322 can include various characteristics. In at least some instances, the tubular sheath 322 can include a first tubular sheath that is more outwardly oriented (e.g., 122a or 322a) and a second tubular sheath that is more inwardly oriented (e.g., relative to the first tubular sheath) (e.g., 122b or 322b). In some instances, the first tubular sheath and the second tubular sheath can be aligned (e.g., axially aligned) between the outer anchor 124 and the inner anchor 126 such that when the cable passes through the first tubular sheath 122a / 322a and the second tubular sheath 122b / 322b, the tubular sheath provides a conduit for guiding the cable between the anchors. In some instances, the ends of the tubular sheaths are spaced apart from each other (e.g., see space or gap 123), which can improve the threadability associated with the tubular sheath. That is, when using a needle to thread the cable through the tubular sheath, the gap 123 between the ends of the tubular sheath can improve the threading operation by enhancing the ability of the tip of the needle to be guided through the tubular sheath. Additionally, the gap 123 can reduce the likelihood of cable damage during threading (such as when the cables cross) by reducing the likelihood that the tip of the needle may pierce or damage another crossing cable. The gap 123 can also reduce the likelihood that the needle is blocked or impeded from threading by a crossing cable during the threading operation. In at least some instances, the first tubular sheath 122a / 322a and the second tubular sheath 122b / 322b can be generally aligned along a first orientation (e.g., generally aligned along corresponding axes), and a second pair of tubular sheaths (e.g., 122c and 122d) can be generally aligned along a second orientation that includes a crossing or "X-shaped" pattern. In some instances, this pattern that crosses on the dorsal portion of the upper can help distribute tension relatively evenly between the lacing systems. In some embodiments, the tubular sheath 122 can be integrally knitted with the knitted component. In some instances, the tubular sheath 122 can be a discrete tubular cable guide attached to the upper.
[0056] Reference Figure 2B and Figure 2C , a cross-sectional view of a footwear article 100 is shown based on a cross-sectional reference associated with Figure 2A . As depicted in Figure 2B and Figure 2C , the upper 104 (e.g., 300a and 300b) can include a spacer knitted fabric 204 (e.g., associated with the underfoot portion 306, which can also be referred to as the strobel). The spacer knitted fabric 204 can be defined by a first layer 208 (e.g., a first knitted layer) and a second layer 210 (e.g., a second knitted layer 210) and a plurality of tying yarns 206 that extend between the first layer 208 and the second layer 210 (e.g., across the gap space between the first layer 208 and the second layer 210).
[0057] These tying yarns 206 can be made of monofilaments or other suitable materials. For example, the tying yarns 206 (as well as the yarns including the first layer 208 and the second layer 210) can be made of polyester (such as PET) or recycled polyester (such as rPET). In some instances, these yarns can include one end, two ends, three ends, or more than three ends. In some cases including three ends, each end can include a diameter between about 0.15 mm and 0.30 mm. In at least one instance, the three ends of the tying yarn include one end with a diameter of 0.20 mm and two ends with a diameter of 0.25 mm. In at least some instances, this diameter and the associated fineness (which can be greater than the fineness in at least some other spacer knitted fabrics) can contribute to the operability of the spacer knitted fabric 204 in the underfoot area. For example, this fineness can contribute to the cushioning provided by the spacer knitted fabric 204 and the ability of the spacer knitted fabric 204 to rebound. However, this is merely an example, and it is contemplated that the yarn can include any number of yarns and any combination of their diameters.
[0058] The tying yarns 206 can extend substantially perpendicular to the first knitted layer 208 and / or the second knitted layer 210, extend at an angle other than 90 degrees, and / or can travel in a zigzag manner between the first layer 208 and the second layer 210. For example, the tying yarns 206 (or a subset of the tying yarns) can extend at an angle of about 45 degrees (e.g., between 30 degrees and 60 degrees) relative to the first knitted layer 208 and / or the second knitted layer 210. That is, if the bottom layer 210 is disposed on a horizontal surface (such as a table), then in some instances, at least some of the tying yarns 206 can extend from the bottom layer 210 at an angle and toward the top layer 208, and this angle can be in the range of about 30 degrees to about 60 degrees. In at least some instances, the angled orientation of the tying yarns 206 can contribute to the operability of the spacer knitted fabric 204 in the underfoot area. For example, in some cases, as opposed to a more vertical orientation, a more inclined orientation can enhance the operation of the spacer knitted fabric 204 being compressed along a greater up-down orientation (such as like an accordion). On the other hand, in a spacer knitted fabric with tying yarns having a more vertical orientation, the top layer is more likely to shift along an inner-outer orientation and / or a front-back orientation (e.g., relative to the bottom layer), which may be undesirable and create a sliding feeling in the insole (e.g., for the wearer). Thus, such a configuration (i.e., where the tying yarns 206 are not perpendicular to the first knitted layer or the second knitted layer) can enhance the stability of the underfoot portion. The tying yarns 206 can also couple the first layer 208 and the second layer 210 and / or provide spacing between the first layer 208 and the second layer 210. These tying yarns can also fill the underfoot portion with a rebounding effect.
[0059] As described, the spacer knitted fabric 204 can be positioned in the underfoot portion of the shoe upper 104 (e.g., the underfoot portion 306 of the shoe upper component 300b) and can be surrounded by the underfoot peripheral edge (e.g., the underfoot peripheral edge 316) and / or by a plurality of shoe apertures (e.g., the plurality of shoe apertures 302a to 300d). In some instances, the spacer knitted fabric 204 can span the entire length and / or the entire width of the underfoot portion. In some instances, the spacer knitted fabric 204 can extend only partially across the width of the underfoot portion and / or only partially through the length of the underfoot portion. In at least some instances, the spacer knitted fabric 204 can include one or more thicknesses (e.g., between the upper surface of the top layer 208 and the lower surface of the bottom layer 210) at one or more locations. For example, the spacer knitted fabric 204 can include a first thickness 212 in a more central region (e.g., near or at least partially along the longitudinal midline) and a second thickness 214 in a more peripheral region (e.g., near the peripheral edge of the spacer knitted fabric). Alternatively or additionally, the second thickness can be closer to the toe portion, the outer side, the inner side, and / or the heel portion of the shoe upper 104, the spacer knitted fabric 204, and / or the footwear. In an instance, the first thickness is measured at the intersection of the longitudinal midline and the transverse midline (e.g., the center point of the shoe upper 104, the spacer knitted fabric 204, and / or the footwear). In some instances, the first thickness 212 is greater than the second thickness 214 such that the thickness of the spacer knitted fabric tapers gradually from the more central region to the more peripheral region. The thickness can taper while moving away from the first thickness in the transverse direction, the longitudinal direction, or any other direction. In at least some instances, the first thickness 212 can be at least about 10 mm. In some cases, the first thickness 212 of at least about 10 mm can contribute to the cushioning associated with the spacer knitted fabric 204 and can contribute to the resilience associated with the spacer knitted fabric 204. In some instances, the first thickness 212 can reduce the likelihood that a wearer may feel or experience irritation from the cable 101 and / or the cable 107. In at least some instances, the angle of the tying yarn 206 can vary from one region of the spacer knitted fabric 204 to another region. For example, the tying yarn in the more central region can include a first angular orientation, and the more peripheral tying yarn can include a second angular orientation that is smaller (e.g., flatter or more horizontal) than the first angular orientation. In an instance, the transition in angular orientation can contribute to the tapered thickness of the spacer knitted fabric.
[0060] Reference Figure 2C, in some instances, multiple shoe apertures (e.g., 302a to 302d) may be positioned in the second (e.g., bottom) layer 210 such that when the cable 107 passes through the multiple shoe apertures, the cable 107 passes through the second layer 210 and into the gap space between the first layer 208 and the second layer 210 without passing through the first layer 208. In at least some instances, when the footwear is in a worn configuration, this structure and arrangement may minimize or eliminate contact between the cable 107 and the wearer's foot, which may reduce the likelihood that the cable 107 causes irritation and / or discomfort.
[0061] In some instances, the spacer knitted fabric 204 may be knitted integrally with the shoe upper. For example, the spacer knitted fabric 204 may be knitted integrally with the outer panel 312 and / or with the inner panel 314. In some cases, knitting the spacer knitted fabric 204 integrally with the shoe upper (e.g., with the outer panel and / or the inner panel) may contribute to the sustainability of the footwear 100 in one or more different aspects. For example, knitting the spacer knitted fabric 204 integrally may reduce (e.g., eliminate) the need for an insole or sockliner, which may reduce the total number of parts to be manufactured, assembled, used for installing the insole, etc. Additionally, the spacer knitted fabric 204 may be composed of yarns having the same material (e.g., PET or rPET) as other parts of the shoe upper, which may allow the shoe upper and the spacer knitted fabric 204 to be recycled together in the same process (e.g., shredding or regranulating).
[0062] Example sole components for a footwear
[0063] Reference Figure 4 , depicts an example associated with the sole 102. In at least some instances, the sole 102 may include multiple layers, such as one or more midsole components and one or more outsole components, which are stacked on top of each other and via a cable (e.g., illustrated in FIG. 1 but from Figure 4is attached to the cable 101 omitted in the depiction in []. In some examples, the one or more layers or components may include a midsole carrier component 410, a midsole core component 412, and one or more outsole components 414 (e.g., having one or more outsole portions 414a, 414b, and 414c). In some cases, the one or more layers or components 410, 412, and 414 may include different constituent materials. For example, at least one of the midsole carrier 410 and the midsole core 412 may include a compressible polymer foam element (e.g., polyurethane foam, ethylene-vinyl acetate (EVA) foam, phylon, etc.). In some configurations, these materials may be configured to help attenuate ground reaction forces (e.g., provide cushioning) when compressed between the foot and the ground during walking, running, or other locomotive activities. In some examples, at least one of the midsole carrier 410 and the midsole core 412 may include a fluid-filled chamber, plate, reducer, or other element configured to attenuate forces, enhance stability, or affect foot motion, and these elements may be made of polymers (e.g., polyurethane, thermoplastic polyurethane, carbon fiber, etc.), foam materials, or other materials. In at least some examples, the outsole component 414 may include a wear-resistant rubber material configured to impart traction friction to the ground-facing surface of the sole 102 and provide wear resistance (e.g., form a "ground contact element").
[0064] In at least some examples, the cable may pass through a series of holes or apertures (e.g., 416 and 418) in the plurality of layers or components 410, 412, and / or 414 and may be fixed thereto (e.g., by tying, hardware, etc.). In at least some examples, the plurality of layers or components 410, 412, and 414 may have no (or substantially no) other non-cable connections (e.g., chemical adhesives, fusion connections (e.g., thermally bonded structures), ultrasonic welding, etc.) for attaching one layer to another. Thus, in at least some examples, the sole 102 may be disassembled by untying the cable (e.g., 101) to separate one portion of the sole 102 from another portion of the sole 102. Additionally, due to the omission of non-cable connections, when the sole 102 is disassembled, the parts may be free from cross-contamination (e.g., chunks of one portion of the sole do not remain bonded to another portion of the sole). Thus, in some examples, the parts may be more suitable for recycling (e.g., pelletizing) because the parts include a purer form of the constituent materials that are not contaminated by the materials of other parts. Additionally, one or more of the parts may be reused in subsequent footwear articles (e.g., by attaching with the cable or a new cable).
[0065] Various features can contribute to the operations and functions associated with the sole 102, such as disassemblability, shock attenuation, comfort, support, stability, motion control, and the like. For example, in at least some instances, the midsole carrier 410 can be configured to support one or more layers of the sole 102 or provide a base or mounting structure for one or more layers of the sole 102. For example, the midsole carrier 410 supports the midsole core 412 and the outsole component 414 sandwiched between the midsole carrier 410 and the midsole core 412. In at least some instances, the midsole carrier 410 can include an upper surface 420 and a lower surface 422 (as Figure 5 shown), the upper surface 420 facing the foot receiving cavity when the sole 102 is assembled with the upper, and the lower surface 422 generally facing away from the foot receiving cavity and toward the ground surface (e.g., the surface facing the ground) in a direction opposite to the upper surface. Additionally, the midsole carrier 410 can include one or more sidewalls 424 and 426 that extend upward and form a peripheral wall around at least a portion of the upper surface 420. Thus, in at least some instances, the upper surface 420 can be associated with a recessed portion (e.g., 446). In at least some instances, the upper surface 420 transitions or curves smoothly when transitioning from a more interior portion of the midsole carrier 410 to the sidewalls 424 and 426. Thus, the top or upper portion of the midsole carrier 410 can include a cavity for receiving at least a portion of the midsole core 412 and the outsole component 414. Additionally, in some cases, the sidewalls 424 and 426 can operate to connect to the upper 104, such as connecting to the upper 104 via a cable 107. That is, in some instances, the midsole carrier 410 can include an aperture 428 (e.g., a sidewall aperture) for receiving a cable 107 to attach the upper 104 (e.g., via apertures 302a to 302d) to the sole 102.
[0066] In some instances, the midsole carrier 410 includes one or more through-holes 430 that extend from the upper surface 420 through the layer 432 of the midsole carrier 410 (e.g., as Figure 6B shown) and reach the lower surface 422. In at least some instances, the through-holes 430 are configured to receive attachment friction lugs 434 of the outsole component 414 (e.g., obscured in the view in Figure 4 and shown in Figure 5 ). For example, Figure 4 and Figure 5 depict an outsole component 414 in which the attachment friction lugs 434 are disengaged from the midsole carrier 410, and Figure 6A and Figure 6BDepicts an example in which the attachment friction lug 434 is received in the through-hole 430. In at least some examples, the attachment friction lug 434 may include a body or base (e.g., 436) that protrudes from the lower surface of the outer sole layer 414 (e.g., 438). That is, the outer sole member 414 may include a relatively thin and wide plate body that forms a base or pedestal from which the body 436 of the lug 434 may extend. Additionally, the attachment friction lug 434 may include a protrusion 440 (e.g., a protruding rib) that extends outwardly from the body 436 (e.g., forming an overhang). Although various portions of this specification may generally refer to a single attachment friction lug 434 when describing examples associated with attachment friction lugs, in some examples, the outer sole member 414 may include a plurality of attachment friction lugs (e.g., as illustrated in the figures).
[0067] In at least some examples, the through-hole 430 and the attachment friction lug 434 may include similar shapes (e.g., both the through-hole 430 and the attachment friction lug 434 may be rectangular, oval, circular, or various other n-sided shapes). For example, the through-hole 430 may include a hole profile shape, and the body 436 of the attachment friction lug 434 may include a cross-sectional profile shape in a cross-section associated with a reference line 437 that corresponds to (e.g., is adapted to) the hole profile shape. In some examples, the similar shapes may include one or more oval portions or straight portions (e.g., non-circular portions), which may reduce the likelihood of the attachment friction lug rotating relative to the through-hole (e.g., when the similar shapes include similar dimensions and based on interference between corresponding portions). For example, the through-hole 430 may include at least one straight edge or wall, and the attachment friction lug 434 may also include at least one straight wall that abuts the straight edge or wall of the through-hole 430. Additionally (or alternatively), the similar shapes may include one or more curves or arcs (e.g., not a circle) having different radii. Further, the dimensions of the attachment friction lug and the through-hole may be similar such that when the attachment friction lug is inserted into the through-hole, the perimeter of the through-hole 430 may frictionally engage the body 436 of the attachment friction lug 434. In some cases, the protrusion 440 may be associated with a width that is greater than the through-hole 430 such that once the attachment friction lug 434 has been inserted into the through-hole 430, the protrusion 440 may prevent the attachment friction lug 434 from disengaging from the through-hole 430. This configuration may also prevent foreign objects from entering the footwear via the through-hole 430. In at least some examples, the attachment friction lug 434 may snap into place when engaged in the through-hole 430, which may interlock the attachment friction lug 434 (and the outer sole member) with the midsole carrier 410.
[0068] In some examples, the through hole 430 in the midsole carrier 410 may extend from the upper surface 420 of the midsole carrier 410 (e.g., the upper surface facing the foot receiving cavity) through the layer 432 of the midsole carrier 410 and to the lower surface 422 of the midsole carrier 410 (e.g., the lower surface facing away from the foot receiving cavity). Additionally, the upper surface 420 may include a recessed portion 442 or depression (e.g., Figure 4 and Figure 6B ) that curves into the layer 432 on a portion of the upper surface surrounding the through hole 430. In at least some examples, the outsole member 414 may include a protruding portion 444 around the attachment friction lug 434 and on the lower surface 438 of the outsole layer 414 (e.g., as part of a relatively thin and wide portion of the outsole layer), the protruding portion 444 having a profile corresponding to the recessed portion 442 of the upper surface 420 of the midsole carrier 410. For example, the recessed portion 442 and the protruding portion 444 may include similar curvatures and be associated with similar radii. In an example, the protruding portion may be protruding along a mid-lateral orientation and / or along an anterior-posterior orientation. Thus, when the attachment friction lug 434 mates with the through hole 430, the protruding portion 444 of the outsole layer 414 may nest into the recessed portion 442 of the upper surface 420 of the midsole carrier 410.
[0069] In an example, the outsole member 414 may include one or more embedded units, each embedded unit having a corresponding set of attachment friction lugs for insertion into a corresponding through hole. For example, in the figures, the outsole layer 414 includes three outsole members 414a, 414b, and 414c. In some examples, the outsole member 414 may include a single embedded outsole, two embedded outsoles, or more than three embedded outsoles. In at least some examples, when assembled with the midsole carrier 410, the inserts may be spaced apart to provide an opening through which a cable (e.g., 101) may pass.
[0070] As described above, in at least some examples, the midsole core 412 may also be disposed or stacked in the cavity of the midsole carrier 410 and on top of the outsole member 414 such that the outsole member 414 is stratified between the midsole carrier 410 and the midsole core 412. In at least some examples, the upper surface 420 of the midsole carrier 410 may include a recess 446 (e.g., Figure 4), the recess 446 has an outer edge that defines the contour or shape of the recess, such as outer edge segments 448 (e.g., some of which may also be associated with one or more of the sidewalls 424 and 426). In some cases, the midsole core 412 may include a perimeter, terminal edge 450 that also defines the contour shape of the midsole core 412 and corresponds to the recess shape. Thus, the midsole core (e.g., an embedded midsole core) can be nested into the recess 446 and over the outsole component 414.
[0071] In at least some instances, the upper surface 439 of the outsole layer 414 may include a recessed portion 452 that curves toward the attachment friction lug 434 (e.g., Figure 4 and Figure 6B ). In an instance, the midsole core 412 may include a protruding portion 454 at a portion aligned with the recessed portion 452 of the outsole layer 414, the protruding portion 454 having a contour corresponding to the recessed portion 452 of the upper surface 439 of the outsole layer 414. For example, the recessed portion 452 and the protruding portion 454 may include similar curvatures and be associated with similar radii. In an instance, these portions may curve along a mid-lateral orientation and / or along an anterior-posterior orientation. Thus, when the midsole core 412 is nested within the midsole carrier 410 with the outsole component 414 therebetween, various face-to-face surfaces (e.g., associated with 442, 444, 452, and / or 454) may be flush with each other, which can reduce the likelihood of corners or edges digging into other layers or causing discomfort to the wearer.
[0072] In at least some instances, one or more of the layers may include surface grooves that connect a first through-hole to a second through-hole. Thus, when a cable passes or extends along the surface from the first through-hole to the second through-hole, the cable can be positioned within the groove, which can protect the cable, prevent the cable from moving laterally, and reduce the likelihood of the cable protruding from the surface and potentially causing discomfort to the wearer. For example, the upper surface 456 of the midsole core 412 (e.g., facing the foot receiving cavity) may include apertures 418, such as a first aperture 418a and a second aperture 418b. The upper surface 456 may also include a cable retaining surface groove (e.g., 458) that connects the apertures (along the upper surface 456) to each other (e.g., connects the first aperture 418a to the second aperture 418b). The surface groove 458 may accommodate the cable 101 (e.g., FIGS. 1 and Figure 6B ), may be deep enough to reduce the likelihood of the cable 101 protruding into the insole of the footwear article, and may prevent the cable 101 from slipping out of position. Additionally, in some instances, the lower surface 422 of the midsole carrier 410 (e.g., when the footwear article is being worn, facing away from the foot receiving cavity and sometimes facing the ground surface) may include a portion of the aperture 416 associated with the recessed portion 446, such as a first aperture 416a (e.g.,Figure 5 and Figure 6A ) and a second aperture 416b. The lower surface 422 may also include a cable retention surface groove that connects the apertures (along the lower surface 422) to each other (e.g., connects the first aperture 418a to the second aperture 418b), such as, for example, Figure 5 and Figure 6B 460 shown in. In an example, the cable retention surface groove may help protect the cable 101 from the ground surface (e.g., reduce abrasion, tearing, breakage, etc.) and may prevent the cable from slipping out of position.
[0073] In at least some examples, the apertures 418 (e.g., the apertures in the midsole core 412) may be positioned such that they are vertically (or substantially vertically) aligned (e.g., in the up-down direction) with the apertures 416 in the midsole carrier 410. In some examples, the apertures in the sole component may be offset such that they are angled (e.g., the cable is angled as it extends from one aperture to the next). Thus, in some cases, a cable (e.g., 101) may pass through the apertures 418 and corresponding apertures to couple the midsole core 412 to other portions of the sole 102, such as the midsole carrier 410. In some cases, offsetting the apertures such that the cable is angled may improve the threading operation. In some examples, offsetting the apertures such that the cable is angled may reduce the likelihood that the wearer feels the cable while walking, jumping, etc. (e.g., compared to vertically aligned apertures or cable segments), because the downward force applied by the wearer is more like an axial force (e.g., angled relative to the cable axis) and less like a compressive force (e.g., more parallel to the cable axis). In some examples, the spacer knit 204 may help provide cushioning on the cable 101 and may reduce the likelihood that the cable 101 may cause discomfort (e.g., at the bottom of the wearer's foot).
[0074] In an example, the apertures in the lower surface 422 may be arranged in one or more rows (e.g., four rows, as Figure 6A shown). The multiple rows of apertures may extend in the longitudinal direction. Additionally, the arrangement of the apertures in the upper surface 456 may also be arranged in one or more rows (e.g., four rows, as Figure 4 shown), which may extend in the longitudinal direction. In some examples, the arrangement of the apertures 416 and 418 may also be associated with a threading pattern (e.g., the order in which the cable 101 passes through the apertures), as described in other parts of this disclosure. Although the lower surface 422 and the upper surface 456 are depicted as including four rows of apertures, it is contemplated that the surfaces may contain any number of rows of apertures (e.g., two rows of apertures: one row of apertures on the outside and one row of apertures on the inside). In other embodiments, the apertures may not be organized into rows.
[0075] In at least some examples of the present disclosure, the sole 102 can be attached to the upper 104 via one or more cables and without (or substantially without) other non-cable couplings (e.g., chemical adhesives, thermally bonded structures, etc.). For example, referring to Figure 4 , Figure 6A and Figure 6B , the midsole carrier 410 can include sidewall apertures (e.g., sidewall aperture 428), which can extend around the perimeter of the midsole carrier member 410 (e.g., can also be referred to as a "perimeter aperture"). In an example, the sidewall aperture 428 can extend along the medial side and along the lateral side. Additionally, a cable (e.g., 107) can pass through and out of the sidewall aperture 428 and the apertures 302a to 302d to couple the upper 104 to the sole 102.
[0076] In some examples, positioning the perimeter aperture in the sidewall can reduce or eliminate contact between the cable and the ground (or another outer surface), thereby improving wearer comfort and reducing cable wear - e.g., compared to embodiments where the perimeter aperture is more directly located beneath the wearer's foot. In other examples, the aperture can be located in other regions of the midsole carrier 410 (e.g., not in the sidewall of the midsole carrier 410 and / or around the perimeter of the midsole carrier 410). The sidewall aperture (e.g., 428) can be connected by surface grooves (e.g., 618) in the same or substantially the same manner as previously described with respect to the surface groove 460.
[0077] Although the sole 102 is described in some respects as including two or more components (e.g., a midsole carrier 410, an outsole component 414, and a midsole core 412), it is contemplated that the sole 102 may include fewer components (e.g., a one-piece sole) or more components. For example, in some embodiments, the sole 102 does not include components connected to each other using one or more cables. However, in such cases, the sole 102 can still be attached to the upper 104 by one or more cables (e.g., 107). In at least some instances, one or more components of the sole may be combined or omitted. For example, the midsole carrier 410 may be coupled to the outsole component 414, and the midsole core 412 may be omitted, in which case the midsole carrier 410 can still interlock with the outsole component 414. In some cases, the midsole core 414 may be combined with the outsole component 412 into a single component. In some instances, the outsole component 414 may be omitted, and the midsole carrier 410 can still be coupled (e.g., via cable 101) to the midsole core 412. In some instances, one or more additional components may be included with the sole 102 or the upper 104 to form at least a portion of the shoe bed. For example, one or more additional layers or components may be included within the stack of the midsole carrier 410, the midsole core 412, and / or the outsole component 414. In some instances, an insole or other component may be positioned between the midsole core 410 and the foot receiving cavity (e.g., above the midsole core 412).
[0078] Example heel stabilizers and toe regions of footwear
[0079] Reference Figure 7 , in some instances, the sole 102 can be connected to a heel stabilizer 710 (e.g., Figure 1A and Figure 1B the heel stabilizer 118 in Figure 7 ). In some cases, the heel stabilizer 710 can help reinforce the heel region (e.g., 112) of the midsole carrier 410. For example, the midsole carrier 410 may include a heel portion 714 of the midsole carrier sidewall that wraps around the rear end of the sole 102 from the medial side to the lateral side. The heel portion 714 may include an inward-facing surface 716 and an outward-facing surface ( Figure 7 not shown in
[0080] The heel stabilizer 710 may include a series of apertures (e.g., 718a through 718f) that may be aligned with apertures (e.g., 720a through 720f) in the heel portion 714 of the midsole carrier 410. In Figure 7 it, example reference lines 722a and 722b are depicted to illustrate example aperture alignment, where the heel stabilizer 710 is arranged adjacent to the inward-facing surface 716. In at least some instances, one or more cables may pass through the access apertures (e.g., 718a through 718f and 720a through 720f) to attach the heel stabilizer 710 to the midsole carrier 410 and, in some instances, also to the upper 104. For example, the cable 101 that attaches the midsole carrier 410 to the midsole core 412 may also pass through at least some of the apertures (e.g., 718a through 718d and 720a through 720d) of the heel stabilizer 710 and the heel portion 714 of the midsole carrier 410. Additionally, the cable 107 may pass through the apertures 718e and 718f, through the apertures 720e and 720f, and through an aperture in the upper (e.g., 302a) to attach the upper 104 to the sole 102.
[0081] The heel stabilizer 710 may also include various other apertures. For example, the heel stabilizer 710 may include an aperture 719 that may be positioned to align with a sidewall aperture in the midsole carrier 410 (e.g., the sidewall aperture is Figure 7 occluded in the view in). In some instances, the heel stabilizer 710 may be attached to the midsole carrier 410 before the midsole core 412 is placed in position (e.g., within the recess 446) to allow the aperture 719 to align with the sidewall aperture of the midsole carrier 410. For example, according to an example, Figure 8 a heel stabilizer attached in place and aligned with sidewall apertures (e.g., 428) that are occluded by the heel stabilizer 710 is depicted.
[0082] In an example, the heel stabilizer 710 may be composed of a first material, and the midsole carrier 410 may be composed of a second material that is different from the first material. For example, in some cases, the first material may include thermoplastic polyurethane or thermoplastic polyethylene. In some instances, the midsole carrier 410 may include a foamed material (e.g., EVA foam). In some instances, the first material includes a first tear strength, and the second material includes a second tear strength that is lower than the first tear strength. Thus, in some instances, the heel stabilizer 710 may reinforce the midsole carrier 410 (e.g., reinforce in association with the portion 714) and reduce the likelihood of the midsole carrier 410 tearing, such as when a cable is fixed to the midsole carrier 410 under tension (e.g., when assembling and connecting the various parts of the sole 102). For example, referring to Figure 8, shows another view depicting a heel stabilizer 710 attached to the midsole carrier 410 via a cable 701. In some instances, cable 701 is the same as cable 101 and also passes through other apertures in midsole carrier 410 and midsole core 412. In at least some cases, cable 701 may first pass through apertures 718a - 718d of heel stabilizer 710 and apertures 720a - 720d of section 714 and be anchored in place (e.g., via multi - stranded cable structure 724), then through an aperture in the recessed portion of midsole carrier 410 and through aperture 418 of midsole core 412. In an example, a heel stabilizer 710 with a higher tear strength allows the combined structure of heel stabilizer 710 and section 714 to provide a secure mounting location to first secure cable 701 before continuing to pass through other apertures (e.g., apertures in the recessed portion) of midsole carrier 410 and midsole core 412. In at least some instances, once heel stabilizer 710 is attached to midsole carrier 410, apertures 718e and 718f are configured to receive a cable (e.g., 107) for attaching sole 102 to upper 104.
[0083] In at least some instances, midsole carrier 410 may be connected to toe 712 (e.g., in Figure 7 and similar to Figure 1A and Figure 1B toe 119 in). In some cases, toe 712 may help reinforce the forefoot region (e.g., 108) of midsole carrier 410. For example, midsole carrier 410 may include a toe portion 726 of the midsole carrier sidewall that forms the front end wall of the sole and at least partially wraps around the front end of sole 102. The toe portion 726 may include an inward - facing surface and an outward - facing surface. In some instances, toe 712 may be positioned adjacent to the inward - facing surface of toe portion 726. In some instances, toe 712 may be positioned adjacent to the outward - facing surface of toe portion 726.
[0084] Toe 712 may include a series of apertures (e.g., 728a and 728b) that may be aligned with apertures (e.g., 730a and 730b) in toe portion 726 of midsole carrier 410. In Figure 7In [the figure], exemplary reference lines 732a and 732b are depicted to illustrate an exemplary hole alignment between the toe box 712 and the toe portion 726. In at least some instances, one or more cables may pass through the apertures (e.g., 728a, 728b, 730a, and 730b) to attach the toe box 712 to the midsole carrier 410. For example, the cable 101 or 701 that attaches the midsole carrier 410 to the midsole core 412 may also pass through at least some of the apertures of the toe box 712 and the toe portion 726. The toe box 712 may also include various other apertures. For example, the toe box 712 may include an aperture 729 and an aperture 731. The apertures 729 and 731 may be configured to align with other portions of the footwear (e.g., other portions of the sole 102 and / or other portions of the upper 104) for receiving one or more other cables for attaching the respective components together. For example, an aperture (e.g., 729) in the toe box 712 may be positioned to align with an aperture in the forefoot region of the upper 104. These apertures may receive a tension cable associated with a closure system (e.g., a lacing system). In some instances, the tension cable associated with the closure system is a portion of the cable 107 for attaching the sole 102 to the upper 104.
[0085] In an instance, the toe box 712 may compositionally include a first material, and the midsole carrier 410 may compositionally include a second material that is different from the first material. For example, in some cases, the first material may include thermoplastic polyurethane or thermoplastic polyethylene. In some instances, the midsole carrier 410 may include a foamed material (e.g., EVA foam). In some instances, the first material includes a first tear strength, and the second material includes a second tear strength that is lower than the first tear strength. Thus, in some instances, the toe box 712 may reinforce the midsole carrier 410 (e.g., reinforce in association with the toe portion 712) and reduce the likelihood of the midsole carrier 410 tearing, such as when the cable is fixed to the midsole carrier 410 under tension (e.g., when assembling and connecting the respective parts of the sole 102).
[0086] In at least some instances, the toe box 712 provides an anchor point for the cable 101 or 701 at a direction transition of the cable path. For example, refer to Figure 7, the cable path can generally extend upward along the outer side of the sole assembly in the direction indicated by the direction arrow 734 (e.g., when the cable passes through the apertures in the midsole carrier 410 and the midsole core 412), or vice versa. Once the cable reaches the forefoot portion of the sole (e.g., near the toe portion 726), it may be desirable for the cable to then transition to the inner side of the sole. In at least some instances, the toe 712 provides a robust structure for anchoring the cable while also allowing the cable to be threaded from the outer side to the inner side. For example, the cable can exit the aperture 736, enter the apertures 730a and 728a, and be threaded through a series of apertures depicted in association with the toe 712 and the toe portion 726, and then extend to the inner side and then cross toward the heel region of the sole. In an instance, the toe 712 with a relatively high tear strength allows the combined structure of the toe 712 and the toe portion 726 to provide a robust mounting location for securing the cable.
[0087] In at least some instances, once the components of the sole assembly (e.g., including the heel stabilizer 710 and the toe 712) have been attached via one or more cables, the assembly can be attached to the upper (e.g., the upper 104). For example, a cable (e.g., the cable 107) can pass through a series of apertures in the upper and respective apertures associated with the midsole carrier 410, the heel stabilizer 710, and the toe 712.
[0088] Example cables and cable threading for a footwear article
[0089] Respective apertures are described in association with the sole 102 and the upper 104, and as mentioned, in the instances of the present disclosure, at least some of the apertures can threadedly receive one or more cables for joining the various parts of the footwear article 100 together. These apertures can be configured to facilitate relatively simple cable threading, for example, when assembling the footwear article 100. For example, these apertures can be located in positions that are conducive to aperture alignment and needle reception. In at least some instances, based on the assembly and partial connection facilitated by the cables, the footwear article can be more easily disassembled compared to conventional footwear articles, which can improve recyclability. That is, the process of disassembling a conventional footwear article can include several steps, such as separating elements glued together (e.g., the upper and the sole), tearing out stitches, and / or removing parts contaminated with adhesive. In contrast, the components of the footwear article 100 can be separated from each other simply by cutting and / or removing one or more cables.
[0090] In some instances, because components of the footwear article can be attached to each other using cables, the footwear article can be formed without using (or substantially without using) adhesives or other joining methods (e.g., heat bonding or fusing, ultrasonic welding, etc.). The adhesive-free construction can provide several benefits, including improved recyclability (since recyclable components will not be contaminated by adhesives), reduced manufacturing time, reduced energy consumption during manufacturing (e.g., because some adhesives must be heated to increase bond strength), and environmental friendliness (e.g., due to the lack of potentially toxic adhesives).
[0091] In some cases, the one or more cables can be formed from one or more recycled and / or recyclable materials (e.g., recycled polyester), while effectively replacing non-recyclable and / or environmentally unfriendly materials (e.g., adhesives and / or stitches).
[0092] In at least some instances, the one or more cables can include greater toughness, greater thickness, and / or greater durability than materials typically used to form stitches in conventional footwear articles. Thus, compared to stitches, the cables can have a lower likelihood of tearing, breaking, or otherwise failing.
[0093] In one embodiment, the footwear article can include three cables; in other embodiments, the footwear article can include only one or two cables. In other embodiments, the footwear article can include more than three cables. The cables among the one or more cables can have the same or different characteristics compared to any other cable among the one or more cables. The one or more cables can include various types of cables, such as braided cables, and can have various characteristics (e.g., diameter, constituent material, filament count, etc.). For example, cables 101 and 107 can include a diameter in the range of about 1.0 mm to about 1.4 mm. Additionally, cables 101 and 107 can include a filament count of about 96 filaments. Additionally, the one or more cables can include polyester, such as recycled polyester, or other high-toughness materials.
[0094] Various apertures are described in connection with the sole 102 and the upper 104, and these apertures can be arranged to facilitate various threading steps or operations. For example, as described in connection with the midsole carrier member 410, these apertures can include apertures 416 associated with the recessed portion 446, and apertures 428 associated with the sidewall (e.g., sidewall apertures). Additionally, the heel portion 714 of the midsole carrier member 410 can include apertures 720a to 720d, and the toe portion 726 of the midsole carrier member 410 can include apertures 730a, 730b, and 736. In some instances, the apertures 720a to 720d, 730a, 730b, and 736 can be a type of sidewall aperture characterized by their relative positions. Additionally, the apertures of the midsole carrier member 410 can be characterized based on their positions on the inner or outer side or along the inner or outer side or more centrally located between the inner and outer sides. Additionally, as described, the midsole core member 412 can include an aperture 418, and this aperture 418 can also be characterized based on its position on the inner or outer side or along the inner or outer side or more centrally located between the inner and outer sides. Additionally, as described with respect to Figure 3B the upper 104 can include apertures 302a to 302e, and the apertures 302a to 302e can be characterized based on their positions along the inner or outer side in the heel region or the forefoot region, or more centrally located between the inner and outer sides.
[0095] In an example, the operation of threading various components together via one or more cables to assemble the footwear article can include various steps. Referring to Figure 9A and Figure 9B , a flowchart is associated with the operations of method 900. Additionally, Figure 9A and Figure 9B include illustrations that illustratively depict at least some of the operations associated with method 900 according to at least some examples. These illustrations are examples, and method 900 is not limited to the example illustrations.
[0096] In an example, method 900 includes positioning the midsole core member in the recessed portion of the midsole carrier member at 902. Additionally, the midsole carrier member can include a sidewall that forms a perimeter around the recessed portion. For example, Figure 9A illustrates a midsole core member 904 positioned in a recessed portion 906 of a midsole carrier member 908 that includes a sidewall 910.
[0097] Method 900 can also include passing a first cable through an aperture in the recessed portion of the midsole carrier member and through an aperture in the midsole core member at 912. For example, Figure 9ADepicts a cable 914 passing through an orifice (e.g., 916) in the recessed portion 906 of the midsole load-bearing member 908 and through an orifice (e.g., 918) in the midsole core member 904. In some instances, prior to positioning the midsole core member 904 within the recessed portion 906 (e.g., as part of operation 912), the heel stabilizer 920 may be attached to the heel portion 922 of the midsole load-bearing member 908. For example, prior to passing the cable 914 through the orifice in the recessed portion 906 and through the orifice in the midsole core member 904, the cable 914 may pass through an orifice (e.g., 924) in the heel stabilizer 920 and through a corresponding (e.g., aligned) orifice (e.g., 926) in the heel portion 922 of the midsole load-bearing member 908.
[0098] In an example, the orifice in the recessed portion and the orifice in the midsole core member may threadably receive the cable 914 in various sequences or orders. For example, in some cases, after initially being anchored to the heel stabilizer 920 and the heel portion 922, the cable 914 may be threaded in a direction generally from the rear or heel region of the sole (e.g., 928) to the front or forefoot region of the sole (e.g., 930) (e.g., as indicated by direction arrows 932 and 934). Additionally, in the front or forefoot region 930, the general direction of the threading operation may be switched such that the cable 914 is generally threaded in a direction from the front or forefoot region 930 back to the rear or heel region 928 (e.g., as indicated by direction arrows 936 and 938). In some instances, the cable 914 may be threaded in a relatively linear path in a posterior-anterior orientation. In some instances, the cable 914 may include a lateral segment that extends in a mid-lateral orientation (e.g., as shown in the bottom view of Figure 6A ). For example, when a series of posterior-anterior segments are combined with a series of mid-lateral segments, the segments of the cable 101 may form a shape (e.g., a square, rectangle, or any other n-sided polygon). In some instances, the combination of the posterior-anterior segments and the mid-lateral segments helps to create friction points (e.g., based on the cable changing direction), which may help to lock the cable in a stable configuration to securely couple the midsole load-bearing member to the midsole core. In at least some instances, when being threaded as indicated by arrows 932, 934, 936, and 938, the cable 914 may pass primarily through orifices that are more centrally located and less oriented towards the medial or lateral sides.
[0099] In at least some instances, after threading in the direction indicated by arrow 938, the general direction of the threading operation can be switched such that the cable 914 is generally threaded along a direction generally from the rear or forefoot region 928 back to the front or forefoot region 930 and along the medial or lateral side (e.g., as indicated by direction arrows 940 and 942). Additionally, in the forefoot region 930, the cable 914 can be threaded from one side (e.g., the lateral side) of the forefoot region 930 to the other side (e.g., the medial side) of the forefoot region 930, as indicated by direction arrow 944. In at least some instances, when transitioning the cable 914 from one side of the forefoot 930 to the other side of the forefoot 930, the cable 914 can pass through an aperture (e.g., Figure 7 736 in
[0100] the midsole carrier member 908 and through apertures in the toe 948 (e.g., 730a and 730b). On the other side, the cable 914 can be threaded from the forefoot region 930 back to the heel region 928, as indicated by direction arrows 950 and 952.
[0101] Method 900 can also include securing a first cable at 954 to couple the midsole carrier member to the midsole core member without an adhesive. In some instances, the cable 914 can be tied or otherwise secured (e.g., after completing the operations associated with arrow 952) to maintain a secure connection between the midsole carrier member 908, the midsole core member 904, the heel stabilizer 920, and the toe 948. For example, the cable 914 can be threaded around one or more other segments of the cable (e.g., where they have passed through apertures) to form a knot in the cable 914. Figure 1A 、 Figure 1B 、 Figure 4 、 Figure 5 、 Figure 6A 、 Figure 6B and Figure 7 In some instances, at least some portions of the footwear article and / or sole can be constructed based on method 900, in which case the cable 914 can be the same or similar to cable 101.
[0102] Reference Figure 9B depicts additional operations associated with method 900, according to some instances. For example, at 954, method 900 can include passing a second cable through a first sidewall aperture in the sidewall of the midsole carrier member and through a first aperture in the upper of the footwear article. For example, as associated with Figure 9BAs depicted in the associated figures, the heel stabilizer 920 can include apertures 956 and 958 that can be aligned with apertures (e.g., Figure 7 apertures 720e and 720f in Figure 9B FIG. Figure 9B depicts a rear elevation view of a footwear article 960 after a second cable 962 has been threaded through apertures 956 and 958 and apertures 964 and 966 of the midsole carrier member and the upper 968 has been secured to the midsole carrier member 908.
[0103] In at least some instances, after passing through a series of apertures associated with the upper 968, heel stabilizer 920, and midsole carrier member 908, the second cable 962 can be threaded from the heel region and along the medial and lateral sides of the footwear article 960 and toward the forefoot. For example, as indicated by direction arrows 970 (e.g., lateral) and 972 (e.g., medial), opposite ends or segments of the second cable 962 can pass into and out of apertures associated with the upper 968 (e.g., Figure 9B obscured in
[0104] Figure 9B FIG. Figure 9B and similar to apertures 302b and 302c) and sidewall apertures associated with the midsole core member (e.g., 974 and 976). Figure 9A FIG. Figure 9A also depicts a front elevation view of the footwear article 960 and a partial perspective view of the forefoot. In at least some instances, after the second cable 962 has been threaded along the lateral and medial sides (passing into and out of apertures associated with the upper 968 and sidewall apertures), the cable 962 can also pass through an aperture associated with the toe 948. For example, returning to the forefoot illustration associated with Figure 9B FIG. Figure 9B , when the cable 962 is threaded along the medial and lateral sides, the second cable 962 can also pass through an aperture 978 (e.g., 731) associated with the toe 948. In some instances, these apertures 978 can be aligned with at least some of the apertures (e.g., 302d) associated with the forefoot of the upper. Additionally, referring toFigure 3A and tubular sheaths 323), which are protected under the toe 948. Additionally, after passing through the tubular sheaths, the cable 962 can transition from passing through apertures 984 and 986 associated with the toe 948 to passing through a tubular sheath 988 associated with the upper. In this way, the cable 962 can transition from operating to couple the upper to the sole to operating as part of a closure mechanism associated with the upper (e.g., to adjust the fit of the upper).
[0105] Referring to method 900, at 990, after the second cable 962 has passed through a sidewall aperture associated with the midsole carrier member and through an aperture associated with the upper, the second cable 962 can be secured to couple the midsole carrier member to the upper without an adhesive. For example, the second cable can be secured by tying the second cable, attaching hardware to the second cable (e.g., a clip, a spring-loaded buckle, a lasso buckle, etc.), or a combination thereof.
[0106] Once the second cable has passed through between the various components, the resulting footwear article can have various features. For example, in some cases, based on the second cable 962 extending around the perimeter of the footwear article, the second cable 962 can be considered a "perimeter" cable. Returning to the reference Figure 1A and Figure 1B , in some instances, at least some portions of the footwear article 100 can be constructed based on method 900. Thus, a perimeter cable 962 that can be similar (or identical) to the cable 107 can extend through different zones of the footwear article 100. For example, the cable 107 can be present in the heel zone of the footwear article 100 (e.g., the heel zone 112), and can attach the upper 104, the sole 102, and / or the heel stabilizer to each other in the heel zone 112. In the heel zone 112, the shoe apertures (e.g., aperture 302a), the sidewall apertures (e.g., 720e and 720f), and the apertures in the heel stabilizer (e.g., apertures 718e and 718f) can correspond to each other (e.g., can be aligned with each other), and the perimeter cable 107 can extend through the aligned apertures.
[0107] In addition to extending through various portions of the heel region 112, the cable 107 can extend along both the lateral side 114 and the medial side 116 and extend through various sidewall apertures (e.g., 428) and apertures (e.g., 302b and 302c) associated with the respective sides of the shoe upper. That is, in some instances, the cable 107 can (e.g., for coupling the shoe upper 104 to the midsole carrier 410) extend from the heel region 112 along both the lateral side 114 and the medial side 116 through the midfoot region 110 and into the forefoot region 108. In the forefoot region 108, the cable 107 can attach the shoe upper 104, the sole 102, and / or the toe cap 712 to each other. For example, in the forefoot region 108, an aperture (e.g., 302d) associated with the shoe upper 104 can be aligned with an aperture (e.g., 731) associated with the toe cap 712 and an aperture associated with the midsole carrier, and the peripheral cable 107 can extend through the aligned apertures. Additionally, in some instances, the cable 107 can exit an aperture in the toe cap and extend between various tubular sheaths (e.g., 120) and cable anchors (e.g., 124 and 126) to form at least a portion of a closure system.
[0108] Examples of the present disclosure are associated with improved recyclability. For example, as explained, using cables to assemble portions of a footwear article can improve the ability to disassemble the footwear article into components that are free from contamination (e.g., free from adhesives or residual chemicals or other materials from other parts). Accordingly, some examples of the present disclosure relate to systems and methods for recycling footwear articles. Refer Figure 10 , the figure depicts various stages associated with the life cycle of a footwear article.
[0109] In at least some instances, a footwear article can be associated with component formation and assembly 1010. For example, the upper 1012a (and the formation of the upper) can be associated with various operations. In at least some instances, materials for the upper can be prepared. In some cases, these materials can include raw materials. In at least some instances, these materials can include recycled materials 1014 derived from other footwear articles. For example, fibers can be formed or harvested, and in some cases, yarns for the upper 1012a can be formed (e.g., spun from the fibers, extruded, etc.). Using the fibers, yarns, etc., the upper 1012a (e.g., or portions of the upper 1012a) can be formed by knitting, weaving, braiding, fiber entanglement (e.g., needle punching, hydroentanglement, etc.), and the like. In at least some instances, portions of the sole (e.g., the midsole carrier 1016a, the midsole core 1018a, the outsole member 1020a, etc.), the heel stabilizer 1022a, and the toe 1024a are formed, such as by molding from particulate or other forms of raw materials (e.g., virgin and / or recycled) using known methods. In at least some instances, the various components are assembled into the footwear article 1026, such as by using one or more cables (e.g., 101 and 107) described in other parts of the present disclosure. Additionally, the footwear article 1026 can be free (or substantially free) of at least some other types of component bonding structures, such as chemical adhesives, thermal bonding structures, and the like.
[0110] In at least some instances, the footwear articles of the present disclosure can be associated with being disassembled into non - contaminated components 1028. That is, by simply removing (e.g., untying and / or cutting) the cables 101 and 107, the various components 1012a, 1016a, 1018a, 1020a, 1022a, and 1024a that are assembled into the footwear article 1026 can be disassembled into constituent components 1012b, 1016b, 1018b, 1020b, 1022b, and 1024b that are not contaminated with residual materials (including chemical adhesives and / or remnants from other components that have come off). In contrast, conventional solutions typically include bonding methods that result in some contamination. For example, the upper and the sole can sometimes be detached, but under conventional methods, these components typically include residual adhesives and / or remnants of another component that has broken off.
[0111] In at least some instances, the footwear article 1026 (and / or the footwear article 100) can include some bonding structures other than the cables (e.g., chemical adhesives, thermal bonding structures, etc.) and can still be disassembled into parts in a manner that is conducive to recycling. For example, the footwear article 1026 can include a relatively small amount of chemical adhesive between two or more parts and still be substantially free (or substantially without) chemical adhesive such that the footwear article 1026 can still be disassembled into constituent parts that can be recycled. In some cases, the footwear article 1026 can be disassembled (e.g., by removing the cables), and two or more parts can still be bonded (e.g., via chemical adhesives, thermal bonding structures, etc.). In at least some instances, the bonded portions of the parts can be removed or extracted (e.g., by excision) to separate the bonded portions into particulate / remaining portions that are free of adhesives and other bonded portions and now recyclable constituent parts. In some instances, the footwear article 1026 can be substantially free of non-cable connections (e.g., chemical adhesives, thermal bonding structures, etc.), where the removed portion (e.g., the excised portion) is 5% or less of the weight of the footwear article 1026 (e.g., before removal). In other instances, the footwear article can be substantially free of bonding structures (e.g., chemical adhesives, thermal bonding structures, etc.), where the removed portion is less than 1% or less than 0.1% of the weight of the footwear article. In some instances, the constituent parts can be substantially free of bonding structures (e.g., chemical adhesives, thermal bonding structures, etc.), where the removed portion is less than 5%, less than 1%, or less than 0.1% of the overall weight of the component (e.g., upper, sole, toe, or heel stabilizer) from which the removed portion is extracted. The removed or extracted portion can be a part of any component (or combination of components) of the footwear article; likewise, the footwear article can include more than one removed or extracted portion.
[0112] In some instances, once a footwear article has been disassembled into parts 1012b, 1016b, 1018b, 1020b, 1022b, and 1024b, these parts can be sorted 1030 by material type. For example, the upper 1012b can be sorted into a category associated with the material of the fibers that form the upper 1012b. That is, if the fibers of the upper 1012b compositionally include polyester (PET) or recycled PET (rPET), the upper 1012b can be sorted as a group of parts that are all PET or rPET (e.g., PET parts 1032). In some instances, the heel stabilizer 1022b and the toe 1024b can compositionally include TPU, and these parts can be sorted as a group of parts that are all TPU (e.g., TPU parts 1034). In some instances, the midsole carrier 1016b and the midsole core 1018b compositionally include a foamed material (e.g., foamed EVA), and these parts can be sorted as a group of parts that are all foamed EVA or a similar material (e.g., foamed material parts 1036). In some instances, the outsole member 1020b compositionally includes rubber, and these parts can be sorted as a group of parts that are all rubber or a similar material (e.g., rubber parts 1038).
[0113] In instances, sorting 1030 by material type can include grouping or compiling various parts and products 1040. For example, sorting 1030 can include grouping other wearable 1042 parts and products such as other footwear uppers, footwear cables or laces, upper body clothing, lower body clothing, headgear, gloves, etc. Additionally, sorting 1030 can include grouping non-wearable 1044 parts and products such as bags (e.g., backpacks, duffel bags, etc.), rolls (e.g., rolled fabric), fabric remnants (e.g., remnants left after cutting a pattern piece), or other industrial waste and goods from other industries (e.g., PET containers, carpets, furniture, etc.).
[0114] In an example of the present disclosure, at least in part based on the cable-based construction of the footwear article 1026, at least some of the portions 1032, 1034, 1036, and 1038 include relatively low contamination from other materials and can be converted into the material 1014 for manufacturing additional articles, including the recycled material article 1046. For example, the portions 1032, 1034, 1036, and 1038 can be remelted and pelletized. Then, the pelletized material can be used to form recycled fibers, recycled polymer molded parts, recycled foamed material foamed parts, and the like. In at least some examples, at least some of the portions 1032, 1034, 1036, and 1038 can be shredded for use in fill materials, composite materials, and the like. In at least some examples, fibers can be formed, such as by extruding filaments or spinning fibers. Also, at least in part based on the cable assembly and the ability to disassemble the footwear article 1026 with relatively low part contamination, these various materials, including fibers, particles, fragments, yarns, and the like, can be relatively free of contaminants.
[0115] The following clauses represent example aspects of the concepts contemplated herein. Any of the following clauses can be combined in a multiple dependent manner to be subordinate to one or more other clauses. Additionally, any combination of dependent clauses (clauses that explicitly depend on a previous clause) can be combined while remaining within the scope of the aspects contemplated herein. The following clauses are examples and are not restrictive.
[0116] Clause 1. A footwear article, comprising: a sole; an upper that includes an underfoot portion that at least partially surrounds a foot receiving cavity; and the underfoot portion includes a spacer knitted fabric positioned between the foot receiving cavity and one or more cables that couple components of the footwear article together.
[0117] Clause 2. The footwear article according to clause 1, wherein: the sole includes one or more components coupled together via a first cable of the one or more cables; and the spacer knitted fabric is positioned between the foot receiving cavity and the first cable.
[0118] Clause 3. The footwear article according to any one of clauses 1 to 2, further comprising a second cable of the one or more cables that couples the upper to the sole around a perimeter of the underfoot portion.
[0119] Clause 4. The footwear article according to any one of clauses 1 to 3, further comprising: a heel stabilizer; a toe; and the first cable and the second cable that pass through the heel stabilizer and the toe.
[0120] Clause 5. The footwear article according to any one of Clauses 1 to 4, wherein the second cable comprises a part of a closure mechanism associated with the footwear article.
[0121] Clause 6. The footwear article according to any one of Clauses 1 to 5, further comprising a tubular sheath associated with the front panel of the shoe upper, wherein the second cable extends through the tubular sheath.
[0122] Clause 7. The footwear article according to any one of Clauses 1 to 6, wherein: the one or more components of the sole are joined together via the first cable and without a chemical adhesive; and the shoe upper is joined to the sole via the second cable and without a chemical adhesive.
[0123] Clause 8. The footwear article according to any one of Clauses 1 to 7, wherein: the sole includes an outward-facing surface, the outward-facing surface includes a groove; and at least a portion of the second cable is positioned in the groove.
[0124] Clause 9. The footwear article according to any one of Clauses 1 to 8, wherein: the spacer knitted fabric includes a first knitted layer, a second knitted layer, and a plurality of tying yarns in a gap space between the first knitted layer and the second knitted layer; the first knitted layer is positioned closer to the sole than the second knitted layer; and the cable in the one or more cables extends through the first knitted layer and into the gap space.
[0125] Clause 10. The footwear article according to any one of Clauses 1 to 9, wherein the diameter of the cable in the one or more cables is about 1.2 mm.
[0126] Clause 11. The footwear article according to any one of Clauses 1 to 10, wherein the shoe upper further comprises: an inner part and an outer part knitted integrally with the underfoot part; a plurality of apertures, the plurality of apertures being knitted integrally with the shoe upper and threadedly receiving the cable in the one or more cables; and a front panel part of the shoe upper, the front panel part of the shoe upper including a plurality of tubular sheaths, the plurality of tubular sheaths being knitted integrally with the front panel part of the shoe upper and threadedly receiving the cable in the one or more cables.
[0127] Clause 12. A footwear article, comprising: a sole; a shoe upper, the shoe upper including a lower peripheral edge, wherein the lower peripheral edge overlaps the sole; and a cable, the cable passing through the lower peripheral edge and through the sole to join the shoe upper to the sole, wherein the cable comprises at least a part of a lacing system associated with the footwear article.
[0128] Clause 13. The footwear article according to Clause 12 further includes a heel stabilizer, wherein the cable passes through the heel stabilizer and couples the heel stabilizer to the upper.
[0129] Clause 14. The footwear article according to any one of Clauses 12 to 13 further includes a toe cap, wherein the cable passes through the toe cap and couples the toe cap to the upper.
[0130] Clause 15. The footwear article according to any one of Clauses 12 to 14 further includes a spacer knitted fabric, which is integrally knitted with the lower peripheral edge and includes the underfoot portion of the footwear article.
[0131] Clause 16. The footwear article according to any one of Clauses 12 to 15, wherein: the spacer knitted fabric includes a first knitted layer, a second knitted layer, and a plurality of tying yarns in the gap space between the first knitted layer and the second knitted layer; the first knitted layer is positioned closer to the sole than the second knitted layer; and the cable extends through the first knitted layer and into the gap space.
[0132] Clause 17. The footwear article according to any one of Clauses 12 to 16, wherein the upper is coupled to the sole via the cable without chemical adhesives or thermally bonded structures.
[0133] Clause 18. The footwear article according to any one of Clauses 12 to 17, wherein the cable passes through a plurality of tubular sheaths positioned on the outward-facing surface of the upper.
[0134] Clause 19. A footwear article includes: a sole; an upper including a portion overlapping the sole; a heel stabilizer positioned between the portion of the upper and the sole; a toe cap positioned between the portion of the upper and the sole; and a cable passing through the portion of the upper, the heel stabilizer, the sole, and the toe cap.
[0135] Clause 20. The footwear article according to Clause 19, wherein the sole includes a sidewall, wherein the portion of the upper overlaps the sidewall, wherein the heel stabilizer is positioned between the portion of the upper and the sidewall, and wherein the toe cap is positioned between the portion of the upper and the sidewall.
[0136] Clause 21. The footwear article according to any one of Clauses 19 to 20, wherein the heel stabilizer includes a higher tear strength than the sole, and wherein the toe cap includes a higher tear strength than the sole.
[0137] Clause 22. The footwear article according to any one of Clauses 19 to 21, wherein the sole comprises ethylene vinyl acetate (EVA) foam, and the heel stabilizer and the toe comprise thermoplastic polyurethane (TPU).
[0138] Clause 23. The footwear article according to any one of Clauses 19 to 22, wherein: the sole comprises a plurality of components; the plurality of components of the sole are coupled via a second cable; and the second cable passes through the heel stabilizer and the toe.
[0139] Clause 24. The footwear article according to any one of Clauses 19 to 23, wherein: the upper at least partially encloses a foot receiving cavity; and the upper comprises a spacer knitted fabric that is integrally knitted with the portion of the upper that overlaps the sidewall, and the spacer knitted fabric is positioned between the second cable and the foot receiving cavity.
[0140] Clause 25. The footwear article according to any one of Clauses 19 to 24, wherein: the upper further comprises a front panel, the front panel comprising a plurality of tubular sheaths; and the cable passes through the plurality of tubular sheaths and comprises at least a portion of a lacing system configured to adjust the fit of the upper.
[0141] Clause 26. The footwear article according to any one of Clauses 19 to 25, wherein the upper is coupled to the sole, the heel stabilizer, and the toe via the cable and without chemical adhesives or heat bonding structures.
[0142] Clause 27. A footwear article comprising: a sole comprising one or more components coupled together via a first cable; an upper comprising a front panel and an underfoot portion that at least partially encloses a foot receiving cavity, wherein: the front panel comprises a plurality of tubular sheaths; and the underfoot portion comprises: a spacer knitted fabric positioned between the foot receiving cavity and the first cable; a heel stabilizer positioned between the upper and the sole; a toe positioned between the upper and the sole; and a second cable extending through and coupling the upper, the heel stabilizer, the sole, and the toe, wherein the second cable extends through the tubular sheaths and comprises at least a portion of a lacing system associated with the footwear article.
[0143] Clause 28. The footwear article according to Clause 27, wherein: the spacer knitted fabric includes a first knitted layer, a second knitted layer, and a plurality of tying yarns in the gap space between the first knitted layer and the second knitted layer; the first knitted layer is positioned closer to the sole than the second knitted layer; and the second cable extends through the first knitted layer and into the gap space.
[0144] Clause 29. The footwear article according to any one of Clauses 27 to 28, wherein the sole includes ethylene vinyl acetate (EVA) foam, and the heel stabilizer and the toe cap include thermoplastic polyurethane (TPU).
[0145] Clause 30. The footwear article according to any one of Clauses 27 to 29, wherein the upper is coupled to the sole, the heel stabilizer, and the toe cap via the second cable and without a chemical adhesive or a thermally bonded structure.
[0146] Clause 31. A footwear article, comprising: an upper including an inner portion, an outer portion, and an underfoot portion; a sole including a midsole carrier member, a midsole core member, and one or more outsole members positioned between the midsole carrier member and the midsole core member and extending through the midsole carrier member to form a ground contact element; a first cable passing through the upper and the midsole carrier member and coupling the upper to the sole; and a second cable passing through the midsole carrier member and the midsole core member and coupling the midsole carrier member to the midsole core member.
[0147] Clause 32. The footwear article according to Clause 31, further comprising a heel stabilizer disposed between a heel portion of the midsole carrier member and a heel portion of the upper, wherein the first cable and the second cable pass through the heel stabilizer and couple the heel stabilizer to the upper and the midsole carrier member without a chemical adhesive or a thermally bonded structure.
[0148] Clause 33. The footwear article according to any one of Clauses 31 to 32, further comprising a toe cap disposed between a forefoot portion of the midsole carrier member and a forefoot portion of the upper, wherein the first cable and the second cable couple the toe cap to the upper and the midsole carrier member without a chemical adhesive or a thermally bonded structure.
[0149] Clause 34. A footwear article according to any one of Clauses 31 to 33, wherein: the upper includes a tubular sheath disposed on a dorsal portion of the upper and integrally knitted with the upper; and the first cable passes through the tubular sheath and includes at least a portion of a closure mechanism associated with the footwear article.
[0150] Clause 35. A footwear article according to any one of Clauses 31 to 34, wherein: the one or more outsole components include attachment friction lugs positioned in through-holes of the midsole carrier component; and the one or more outsole components are secured between the midsole carrier component and the midsole core component via the second cable and without chemical adhesives or thermally bonded structures.
[0151] Clause 36. A footwear article according to any one of Clauses 31 to 35, wherein: the upper at least partially surrounds a foot receiving cavity; the midsole core component includes an upper surface facing the foot receiving cavity, and at least a portion of the second cable extends along the upper surface; and the underfoot portion includes a spacer knitted fabric that covers the upper surface and the second cable and is secured in place via the first cable.
[0152] Clause 37. A footwear article according to any one of Clauses 31 to 36, wherein the upper is coupled to the sole without chemical adhesives or thermally bonded structures, and wherein the midsole carrier component is coupled to the midsole core component without chemical adhesives or thermally bonded structures.
[0153] Clause 38. A method of manufacturing a footwear article, the method comprising: positioning a midsole core component in a recessed portion of a midsole carrier component, wherein the midsole carrier component includes sidewalls forming a perimeter around the recessed portion; passing a first cable through an orifice in the recessed portion of the midsole carrier component and through an orifice in the midsole core component; and securing the first cable to couple the midsole carrier component to the midsole core component.
[0154] Clause 39. The method according to Clause 38, wherein the method further comprises: passing a second cable through a first sidewall orifice in the sidewalls of the midsole carrier component and through a first orifice in the upper of the footwear article; and securing the second cable to couple the midsole carrier component to the upper.
[0155] Clause 40. The method according to any one of Clauses 38 to 39, wherein the midsole carrier component is coupled to the midsole core component without an adhesive, and wherein the midsole carrier component is secured to the upper without an adhesive.
[0156] Clause 41. The method according to any one of Clauses 38 to 40, wherein: the sidewall includes a heel portion, the heel portion includes a second sidewall aperture; and the method further includes: positioning a heel stabilizer adjacent to the heel portion; passing the first cable through the heel stabilizer and through the second sidewall aperture; and passing the second cable through the heel stabilizer and through a second aperture in the shoe upper.
[0157] Clause 42. The method according to any one of Clauses 38 to 41, wherein the first cable passes through the second sidewall aperture before passing through the aperture in the recessed portion.
[0158] Clause 43. The method according to any one of Clauses 38 to 42, wherein: the sidewall includes a forefoot portion, the forefoot portion includes a third sidewall aperture; and the method further includes: positioning a toe cap adjacent to the forefoot portion; passing the first cable through the toe cap and through the third sidewall aperture; and passing the second cable through the toe cap and through a third aperture in the shoe upper.
[0159] Clause 44. The method according to any one of Clauses 38 to 43, further includes, after passing the second cable through the toe cap and through the third aperture in the shoe upper, passing the second cable through a tubular sheath in the toe cap front portion of the shoe upper.
[0160] Clause 45. The method according to any one of Clauses 38 to 44, wherein: the aperture in the recessed portion includes an aperture on the inner side of the midsole carrier member and an aperture on the outer side of the midsole carrier member; the first cable passes through either the aperture on the inner side of the midsole carrier member or the aperture on the outer side of the midsole carrier member before passing through the toe cap; and the first cable passes through the other of the aperture on the inner side of the midsole carrier member and the aperture on the outer side of the midsole carrier member after passing through the toe cap.
[0161] Clause 46. The method according to any one of Clauses 38 to 45, further includes: positioning an outsole member in the recessed portion of the midsole carrier member before positioning the midsole core member in the recessed portion; and inserting an attachment friction lug of the outsole member into a through hole of the midsole carrier member, the attachment friction lug protruding beyond the ground-facing surface of the midsole carrier member.
[0162] Clause 47. A method of recycling a footwear article, the method comprising: removing a cable from the footwear article, wherein: removing the cable decouples an upper of the footwear article from a sole component of the footwear article; and the upper comprises a first material in composition, and the sole component comprises a second material in composition, the second material being different from the first material and comprising a foamed material; pooling the upper with a first article comprising the first material in composition; generating a yarn comprising the first material from the upper and the first article; pooling the sole component with a second article comprising the second material in composition; and generating a recycled foam material from the sole component and the second article.
[0163] Clause 48. The method according to clause 47, wherein: the sole component is fixed to a second sole component via a second cable when assembled in the footwear article; the method further comprises removing the second cable from the sole component and the second sole component; and removing the second cable decouples the sole component from the second sole component.
[0164] Clause 49. The method according to any one of clauses 47 to 48, wherein the second sole component comprises the second article.
[0165] Clause 50. The method according to any one of clauses 47 to 49, wherein the second sole component comprises a third material, the third material being different from the first material and different from the second material.
[0166] Clause 51. The method according to any one of clauses 47 to 50, wherein: the second sole component comprises a heel stabilizer or a toe; and the third material comprises thermoplastic polyurethane (TPU).
[0167] Clause 52. The method according to any one of clauses 47 to 51, wherein the third material comprises rubber.
[0168] Clause 53. The method according to any one of clauses 47 to 52, wherein: the sole component is a midsole component comprising through-holes; the footwear article comprises an outsole component, the outsole component comprising attachment friction lugs that frictionally engage in the through-holes without an adhesive; the method further comprises removing the attachment friction lugs from the through-holes; and removing the attachment friction lugs from the through-holes decouples the outsole component from the midsole component.
[0169] Clause 54. A method of manufacturing a footwear article, the method comprising: passing a first cable through a plurality of sidewall apertures in a sidewall of a midsole carrier member and through a plurality of apertures in an upper of the footwear article; and securing the first cable to couple the midsole carrier member to the upper.
[0170] Clause 55. The method according to clause 54, wherein the method further comprises: positioning a midsole core member in a recessed portion of the midsole carrier member, wherein the sidewall forms a perimeter around the recessed portion; passing a second cable through an aperture in the recessed portion of the midsole carrier member and through an aperture in the midsole core member; and securing the second cable to couple the midsole carrier member to the midsole core member.
[0171] Clause 56. A method comprising: obtaining a first shoe component comprising a first material; obtaining a second shoe component comprising a second material different from the first material; recycling the first shoe component using a first process; and recycling the second shoe component using a second process different from the first process.
[0172] Clause 57. The method according to claim 56, wherein the first shoe component comprises an upper.
[0173] Clause 58. The method according to any one of clauses 56 to 57, wherein the second shoe component comprises a component of a sole.
[0174] Clause 59. The method according to any one of clauses 56 to 58, wherein the first process comprises shredding, regranulating, or a combination thereof.
[0175] Clause 60. The method according to any one of clauses 56 to 59, wherein the second process comprises shredding, grinding, regranulating, or a combination thereof.
[0176] Clause 61. The method according to any one of clauses 56 to 60, wherein the method further comprises harvesting the first shoe component that is not contaminated with materials other than the first material.
[0177] Clause 62. The method according to any one of clauses 56 to 61, wherein the method further comprises harvesting the second shoe component that is not contaminated with materials other than the second material.
[0178] Clause 63. A footwear article, comprising: an upper that at least partially surrounds a foot receiving cavity; a sole attached to the upper; and the sole comprising: a midsole carrier member that includes: an upper surface facing the foot receiving cavity; a lower surface facing away from the foot receiving cavity; a midsole layer between the upper surface and the lower surface; and a through hole extending from the upper surface, through the midsole layer, to the lower surface; an outsole member having a portion positioned adjacent to the upper surface and including attachment friction lugs that are positioned in the through hole and project away from the foot receiving cavity and beyond the lower surface; a midsole core member adjacent to the portion of the outsole member and the upper surface, the portion of the outsole member being positioned between the upper surface and the midsole core member; and a cable that extends through at least the midsole carrier member and the midsole core member and attaches at least the midsole carrier member and the midsole core member.
[0179] Clause 64. The footwear article according to Clause 63, further comprising: a toe and heel stabilizer attached to the midsole carrier member via the cable.
[0180] Clause 65. The footwear article according to any one of Clauses 63 to 64, wherein the midsole carrier member includes: a first through hole for receiving the cable; a second through hole for receiving the cable; and a groove located in the lower surface and connecting the first through hole for receiving the cable to the second through hole for receiving the cable, wherein the cable passes through the groove from the first through hole for receiving the cable to the second through hole for receiving the cable.
[0181] Clause 66. The footwear article according to any one of Clauses 63 to 65, wherein the midsole core member includes: a first through hole for receiving the cable; a second through hole for receiving the cable; a second upper surface facing the foot receiving cavity; and a groove located in the second upper surface and connecting the first through hole for receiving the cable to the second through hole for receiving the cable, wherein the cable passes through the groove from the first through hole for receiving the cable to the second through hole for receiving the cable.
[0182] Clause 67. The footwear article according to any one of Clauses 63 to 66, wherein: the through hole includes a first width; and the attachment friction lug includes a second width that is greater than the first width.
[0183] Clause 68. The footwear article according to any one of Clauses 63 to 67, wherein: the upper surface includes a recess; and the midsole core member is nested in the recess.
[0184] Article 69. The footwear article according to any one of Articles 63 to 68, wherein the midsole carrier member and the midsole core member are coupled to each other via the cable and without any chemical adhesive or thermal bonding structure.
[0185] Article 70. The footwear article according to any one of Articles 63 to 69, wherein the upper is coupled to the sole via a second cable and without any chemical adhesive or thermal bonding structure.
[0186] Article 71. A footwear article, comprising: an upper that at least partially surrounds a foot receiving cavity; a sole that includes: a midsole carrier member that includes an upper surface and a through hole, the upper surface facing the foot receiving cavity; an outsole member that is positioned between the upper surface and the foot receiving cavity and includes attachment friction lugs positioned in the through hole; a midsole core member that is disposed between the outsole member and the foot receiving cavity; and a cable that extends through at least the midsole core member and the midsole carrier member and attaches at least the midsole core member and the midsole carrier member.
[0187] Article 72. The footwear article according to Article 71, further comprising a toe cap attached to the midsole carrier member via the cable.
[0188] Article 73. The footwear article according to any one of Articles 71 to 72, further comprising a heel stabilizer attached to the midsole carrier member via the cable.
[0189] Article 74. The footwear article according to any one of Articles 71 to 73, wherein the midsole carrier member includes: a lower surface facing away from the foot receiving cavity; a groove located in the lower surface; and the cable positioned in the groove.
[0190] Article 75. The footwear article according to any one of Articles 71 to 74, wherein the midsole core member includes: a second upper surface facing the foot receiving cavity; a groove located in the upper surface; and the cable positioned in the groove.
[0191] Article 76. The footwear article according to any one of Articles 71 to 75, wherein: the through hole includes a first width; the attachment friction lugs include peripheral ribs; and the peripheral ribs include a second width that is greater than the first width.
[0192] Article 77. The footwear article according to any one of Articles 71 to 76, wherein: the upper surface includes a recess; and the midsole core member is nested in the recess.
[0193] Article 78. The footwear article according to any one of Articles 71 to 77 further includes a toe and heel stabilizer coupled to the midsole carrier member via the cable, wherein: the midsole carrier member and the midsole core member include a foamed material; the toe and the heel stabilizer include a thermoplastic polymer; the outsole member includes rubber; and the cable attaches the midsole carrier member to the toe, the heel stabilizer, the midsole core member, and the outsole member without an adhesive.
[0194] Article 79. The footwear article according to any one of Articles 71 to 78, wherein: the upper surface includes a recessed portion; the through hole is positioned at the bottom of the recessed portion; and the outsole member includes a protruding portion surrounding the attachment friction lug, and the protruding portion corresponds to the contour of the recessed portion.
[0195] Article 80. A method includes: positioning an outsole member adjacent to an upper surface of a midsole carrier member, the outsole member including an attachment friction lug; inserting the attachment friction lug through a through hole of the midsole carrier member, wherein the attachment friction lug protrudes beyond a lower surface of the midsole carrier member; stacking a midsole core member on top of the outsole member such that the outsole member is positioned between the midsole carrier member and the midsole core member; and passing a cable through a first set of through holes in the midsole core member and a second set of through holes in the midsole carrier member.
[0196] Article 81. The method according to Article 80 further includes: positioning the cable in a first groove, the first groove being positioned on an upper surface of the midsole core member and connecting a first through hole and a second through hole in the first set of through holes; and positioning the cable in a second groove, the second groove being positioned on a lower surface of the midsole carrier member and connecting a first through hole and a second through hole in the second set of through holes.
[0197] Article 82. The method according to any one of Articles 80 to 81 further includes attaching the midsole carrier member to the midsole core member using only the cable and without any chemical adhesive or thermal bonding structure.
[0198] Article 83. A footwear article includes: an upper that at least partially surrounds a foot receiving cavity; a sole that includes: a midsole carrier member that includes an upper surface and a through hole, the upper surface facing the foot receiving cavity; and an outsole member that is positioned between the upper surface and the foot receiving cavity and includes an attachment friction lug that is interlocked in the through hole; and a cable that extends through the midsole carrier member and secures the midsole carrier member to one or more other components of the footwear article.
[0199] Clause 84. The footwear article according to clause 83, wherein: the through-hole includes a first width; the attachment friction lug includes a peripheral rib; and the attachment friction lug includes a second width at a portion associated with the peripheral rib, the second width being greater than the first width.
[0200] Clause 85. The footwear article according to any one of clauses 83 to 84, wherein: the upper surface includes a recessed portion; the through-hole is positioned at the bottom of the recessed portion; and the outsole member includes a protruding portion surrounding the attachment friction lug, the protruding portion corresponding to the contour of the recessed portion.
[0201] Clause 86. The footwear article according to any one of clauses 83 to 85, wherein the cable secures the midsole load-bearing member to the outsole member.
[0202] Clause 87. The footwear article according to any one of clauses 83 to 86, wherein the midsole load-bearing member is secured to the outsole member without any chemical adhesive or heat-bonding structure.
[0203] Clause 88. The footwear article according to any one of clauses 83 to 87, further comprising a toe cap attached to the midsole load-bearing member via the cable.
[0204] Clause 89. The footwear article according to any one of clauses 83 to 88, further comprising a heel stabilizer attached to the midsole load-bearing member via the cable.
[0205] Clause 90. A footwear article, comprising: an upper that at least partially surrounds a foot receiving cavity; a sole that includes: a midsole load-bearing member that includes an upper surface facing the foot receiving cavity; a midsole core member disposed between the upper surface of the midsole load-bearing member and the foot receiving cavity; and a cable that extends through at least the midsole core member and the midsole load-bearing member and attaches at least the midsole core member and the midsole load-bearing member.
[0206] Clause 91. The footwear article according to clause 90, wherein the midsole core member includes: a second upper surface facing the foot receiving cavity; a groove in the upper surface; and the cable positioned in the groove.
[0207] Clause 92. The footwear article according to any one of clauses 90 to 91, wherein: the upper surface includes a recess; and the midsole core member is nested in the recess.
[0208] Clause 93. The footwear article according to any one of Clauses 90 to 92 further includes a toe and heel stabilizer coupled to the midsole carrier member via the cable, wherein: the midsole carrier member and the midsole core member comprise a foamed material; the toe and the heel stabilizer comprise a thermoplastic polymer; and the cable attaches the midsole carrier member to the toe, the heel stabilizer, and the midsole core member without an adhesive.
[0209] Clause 94. The footwear article according to any one of Clauses 1 to 11, wherein: the spacer knitted fabric includes a first thickness at a first location at the intersection of the longitudinal centerline and the lateral centerline of the footwear article; the spacer knitted fabric includes a second thickness at a second location on the longitudinal centerline and closer to the toe portion of the footwear article than the first location; and the first thickness is greater than the second thickness.
[0210] Clause 95. The footwear article according to any one of Clauses 1 to 11 and 94, wherein: the spacer knitted fabric includes a first thickness at a first location at the intersection of the longitudinal centerline and the lateral centerline of the footwear article; the spacer knitted fabric includes a second thickness at a second location on the lateral centerline and closer to the outer side of the footwear article than the first location; and the first thickness is greater than the second thickness.
[0211] Clause 96. The footwear article according to any one of Clauses 12 to 18, wherein the lacing system includes a plurality of anchors that threadedly receive the cable, and wherein the plurality of cable anchors are integrally knitted with the upper.
[0212] Clause 97. The footwear article according to Clause 96, wherein at least some of the plurality of anchors are positioned on the outer side of the upper.
[0213] As used herein, the recitation “and / or” with respect to two or more elements shall be construed to mean only one element or a combination of elements. For example, “element A, element B, and / or element C” may include only element A, only element B, only element C, element A and element B, element A and element C, element B and element C, or elements A, B, and C. Further, “at least one of element A or element B” may include at least one of element A, at least one of element B, or at least one of element A and at least one of element B. Further, “at least one of element A and element B” may include at least one of element A, at least one of element B, or at least one of element A and at least one of element B.
[0214] This detailed description is provided to meet statutory requirements. However, this description is not intended to limit the scope of the present disclosure. Instead, the claimed subject matter may be embodied in different ways and in combination with other current or future technologies to include different steps, different combinations of steps, different elements, and / or different combinations of elements that are similar or equivalent to those described in the present disclosure. The examples herein are intended to be illustrative in all respects and not restrictive. In this sense, alternative examples or embodiments may become apparent to those of ordinary skill in the art to which the present subject matter pertains without departing from the scope of the subject matter.
Claims
1. An article of footwear, comprising: A shoe upper, the shoe upper including a sole portion that at least partially surrounds a foot receiving cavity, the sole portion including an interstitial knitted fabric at least partially positioned between the foot receiving cavity and one or more cables, wherein the one or more cables couple components of the footwear together.
2. The footwear article according to claim 1, wherein the footwear article further comprises a sole, and wherein: The sole includes one or more components coupled together by a first cable of the one or more cables; and the interstitial knitted fabric is positioned between the foot receiving cavity and the first cable.
3. The footwear of claim 2, further including a second cable of the one or more cables, the second cable coupling the shoe upper to the sole about a perimeter of the sole portion.
4. The footwear article according to claim 3, further comprising: A heel stabilizer; and a toe, wherein the first cable and the second cable each pass through both the heel stabilizer and the toe.
5. The footwear article according to claim 3, wherein: The one or more components of the sole are coupled together via the first cable and without a chemical adhesive or a heat bonding structure; and the shoe upper is coupled to the sole via the second cable and without a chemical adhesive or a heat bonding structure.
6. The footwear article according to claim 1, wherein: The interstitial knitted fabric includes a first knitted layer, a second knitted layer, and a plurality of tying yarns in an interstitial space between the first knitted layer and the second knitted layer; the first knitted layer is positioned closer to a sole of the footwear than the second knitted layer; and a cable of the one or more cables extends through the first knitted layer and into the interstitial space.
7. The footwear of claim 1, wherein a diameter of a cable of the one or more cables is at least about 1.2 mm.
8. The footwear article according to claim 1, wherein: The interstitial knitted fabric includes a first thickness at a first location at an intersection of a longitudinal midline of the footwear and a transverse midline of the footwear; the interstitial knitted fabric includes a second thickness at a second location on the longitudinal midline and closer to a toe portion of the footwear than the first location; and the first thickness is greater than the second thickness.
9. The footwear article according to claim 1, wherein: The interstitial knitted fabric includes a first thickness at a first location at an intersection of a longitudinal midline of the footwear and a transverse midline of the footwear; the interstitial knitted fabric includes a second thickness at a second location on the transverse midline and closer to an outer side of the footwear than the first location; and the first thickness is greater than the second thickness.
10. A footwear article, comprising: A sole; a shoe upper, the shoe upper including a lower peripheral edge, wherein the lower peripheral edge overlaps the sole; and a cable, the cable passing through the lower peripheral edge and through the sole to couple the shoe upper to the sole, wherein the cable includes at least a portion of a lacing system associated with the footwear.
11. The footwear of claim 10, further including an interstitial knitted fabric knitted integrally with the lower peripheral edge and including a sole portion of the footwear.
12. The footwear article according to claim 11, wherein: The spacer knitted fabric includes a first knitted layer, a second knitted layer, and a plurality of tying yarns in the gap space between the first knitted layer and the second knitted layer; the first knitted layer is positioned closer to the sole than the second knitted layer; and the cable extends through the first knitted layer and into the gap space.
13. The footwear article according to claim 10, wherein the upper is coupled to the sole via the cable and without chemical adhesives or thermally bonded structures.
14. The footwear article according to claim 10, wherein the cable passes through a plurality of tubular sheaths positioned on the outward-facing surface of the upper.
15. The footwear article according to claim 10, wherein the lacing system includes a plurality of anchors that threadedly receive the cable, and wherein the plurality of cable anchors are integrally knitted with the upper.
16. The footwear article according to claim 15, wherein at least some of the plurality of anchors are positioned on the outer side of the upper.
17. A footwear article, comprising: Sole; Upper, the upper including a portion that overlaps the sole; Heel stabilizer, the heel stabilizer being at least partially positioned between the portion of the upper and the sole; Toe, the toe being at least partially positioned between the portion of the upper and the sole; And a cable, the cable passing through the portion of the upper, the heel stabilizer, the sole, and the toe.
18. The footwear article according to claim 17, wherein the sole includes a sidewall, wherein the portion of the upper overlaps the sidewall, wherein the heel stabilizer is at least partially positioned between the portion of the upper and the sidewall, and wherein the toe is at least partially positioned between the portion of the upper and the sidewall.
19. The footwear article according to claim 17, wherein the heel stabilizer includes a higher tear strength than the sole, and wherein the toe includes a higher tear strength than the sole.
20. The footwear article according to claim 19, wherein the sole includes ethylene vinyl acetate (EVA) foam, and the heel stabilizer and the toe include thermoplastic polyurethane (TPU).
21. The footwear article according to claim 17, wherein: The sole includes a plurality of components; the plurality of components of the sole are coupled via a second cable; and the second cable passes through the heel stabilizer and the toe.
22. The footwear article according to claim 21, wherein: The sole includes a sidewall; the portion of the upper overlaps the sidewall; the upper at least partially surrounds a foot receiving cavity; and the upper includes a spacer knitted fabric that is integrally knitted with the portion of the upper that overlaps the sidewall, and the spacer knitted fabric is positioned between the second cable and the foot receiving cavity.
23. The footwear article according to claim 17, wherein: The upper further includes a front panel of the upper, the front panel of the upper including a plurality of tubular sheaths; and the cable passes through the plurality of tubular sheaths and includes at least a portion of a lacing system configured to adjust the fit of the upper.
24. The footwear article according to claim 17, wherein the upper is coupled to the sole, the heel stabilizer, and the toe box via the cable and without chemical adhesives or heat-bonding structures.
25. A footwear article, comprising: An upper, the upper including an inner portion, an outer portion, and an insole portion; a sole, the sole including a midsole carrier member, a midsole core member, and one or more outsole members, the one or more outsole members being at least partially positioned between the midsole carrier member and the midsole core member and extending through the midsole carrier member to form ground-contacting elements; A first cable, the first cable passing through the upper and the midsole carrier member and coupling the upper to the sole; And a second cable, the second cable passing through the midsole carrier member and the midsole core member and coupling the midsole carrier member to the midsole core member.
26. The footwear article according to claim 25, further comprising a heel stabilizer, the heel stabilizer being at least partially positioned between a heel portion of the midsole carrier member and a heel portion of the upper, wherein the first cable and the second cable pass through the heel stabilizer and couple the heel stabilizer to the upper and the midsole carrier member without chemical adhesives or heat-bonding structures.
27. The footwear article according to claim 25, further comprising a toe box, the toe box being at least partially positioned between a forefoot portion of the midsole carrier member and a forefoot portion of the upper, wherein the first cable and the second cable couple the toe box to the upper and the midsole carrier member without chemical adhesives or heat-bonding structures.
28. The footwear article according to claim 25, wherein: The upper includes a tubular sheath, the tubular sheath being disposed on a dorsal portion of the upper and knitted integrally with the upper; and the first cable passes through the tubular sheath and includes at least a portion of a closure mechanism associated with the footwear article.
29. The footwear article according to claim 25, wherein: The one or more outsole members include attachment friction lugs positioned in through-holes of the midsole carrier member; and the one or more outsole members are at least partially fixed between the midsole carrier member and the midsole core member via the second cable and without chemical adhesives or heat-bonding structures.
30. The footwear article according to claim 25, wherein: The upper at least partially surrounds a foot-receiving cavity; the midsole core member includes an upper surface facing the foot-receiving cavity, at least a portion of the second cable extending along the upper surface; and the insole portion includes a spacer knitted fabric that covers the upper surface and the second cable and is fixed in place via the first cable.
31. The footwear article according to claim 25, wherein the upper is coupled to the sole without chemical adhesives or heat-bonding structures, and wherein the midsole carrier member is coupled to the midsole core member without chemical adhesives or heat-bonding structures.
32. A method of manufacturing a footwear article, the method comprising: Position the midsole core member in a recessed portion of the midsole carrier member, wherein the midsole carrier member includes sidewalls forming a perimeter around the recessed portion; Thread a first cable through an aperture in the recessed portion of the midsole carrier member and through an aperture in the midsole core member; and secure the first cable to couple the midsole carrier member to the midsole core member.
33. The method according to claim 32, wherein the method further comprises: Thread a second cable through a first sidewall aperture in the sidewall of the midsole carrier member and through a first aperture in the upper of the footwear; and secure the second cable to couple the midsole carrier member to the upper.
34. The method of claim 33, wherein the midsole carrier member is coupled to the midsole core member without an adhesive, and wherein the midsole carrier member is secured to the upper without an adhesive.
35. The method according to claim 33, wherein: The sidewall includes a heel portion that includes a second sidewall aperture; and the method further includes: positioning a heel stabilizer adjacent the heel portion; threading the first cable through the heel stabilizer and through the second sidewall aperture; and threading the second cable through the heel stabilizer and through a second aperture in the upper.
36. The method of claim 35, wherein the first cable passes through the second sidewall aperture before passing through the aperture in the recessed portion.
37. The method according to claim 33, wherein: The sidewall includes a forefoot portion that includes a third sidewall aperture; and the method further includes: positioning a toe box adjacent the forefoot portion; threading the first cable through the toe box and through the third sidewall aperture; and threading the second cable through the toe box and through a third aperture in the upper.
38. The method according to claim 37, further comprising: After threading the second cable through the toe box and through the third aperture in the upper, thread the second cable through a tubular sheath in a toe cap portion of the upper.
39. The method according to claim 38, wherein: The aperture in the recessed portion includes an aperture on an inner side of the midsole carrier member and an aperture on an outer side of the midsole carrier member; the first cable passes through either the aperture on the inner side of the midsole carrier member or the aperture on the outer side of the midsole carrier member before passing through the toe box; and the first cable passes through the other of the aperture on the inner side of the midsole carrier member and the aperture on the outer side of the midsole carrier member after passing through the toe box.
40. The method according to claim 33, further comprising: Before positioning the midsole core member in the recessed portion, position an outsole member in the recessed portion of the midsole carrier member; and insert attachment friction lugs of the outsole member into through-holes of the midsole carrier member, the attachment friction lugs protruding beyond a ground-facing surface of the midsole carrier member.
41. A method for recycling footwear products, the method comprising: Remove a cable from the footwear article, wherein: removing the cable decouples an upper of the footwear article from a sole component of the footwear article, and the upper compositionally includes a first material and the sole component compositionally includes a second material, wherein the second material includes a foamed material and is different from the first material; pool the upper with a first article that compositionally includes the first material; generate a yarn that includes the first material from the upper and the first article; pool the sole component with a second article that compositionally includes the second material; and generate a recycled foam material from the sole component and the second article.
42. The method according to claim 41, wherein: The sole component is fixed to a second sole component via a second cable when assembled in the footwear article; the method further includes removing the second cable from the sole component and the second sole component; Removing the second cable decouples the sole component from the second sole component; and the second sole component includes the second article.
43. The method according to claim 41, wherein: The second sole component includes a heel stabilizer or a toe; and the second sole component includes thermoplastic polyurethane (TPU).
44. The method according to claim 41, wherein: The sole component is a midsole component that includes through-holes; the footwear article includes an outsole component that includes attachment friction lugs that frictionally engage in the through-holes without an adhesive; the method further includes removing the attachment friction lugs from the through-holes; and removing the attachment friction lugs from the through-holes decouples the outsole component from the midsole component.
45. A footwear article, comprising: An upper that at least partially surrounds a foot receiving cavity; A sole coupled to the upper, the sole including: a midsole carrier component that includes: an upper surface facing the foot receiving cavity; a lower surface facing away from the foot receiving cavity; a through-hole extending from the upper surface to the lower surface; an outsole component that has a portion positioned adjacent to the upper surface and includes attachment friction lugs that are positioned in the through-holes and project away from the foot receiving cavity and beyond the lower surface; and a midsole core component adjacent to the portion of the outsole component and the upper surface, the portion of the outsole component being positioned between the upper surface and the midsole core component.
46. The footwear article according to claim 45, further comprising: A cable that extends through at least the midsole carrier component and the midsole core component and attaches at least the midsole carrier component and the midsole core component.
47. The footwear article according to claim 46, further comprising: A toe and a heel stabilizer attached to the midsole carrier component via the cable.
48. The footwear article according to claim 46, wherein the midsole load-bearing member comprises: A first through-hole for receiving the cable; A second through-hole for receiving the cable; And a groove located in the lower surface and connecting the first through-hole for receiving the cable to the second through-hole for receiving the cable, wherein the cable passes through the groove from the first through-hole for receiving the cable to the second through-hole for receiving the cable.
49. The footwear article according to claim 46, wherein the midsole core component comprises: A first through-hole for receiving the cable; A second through-hole for receiving the cable; A second upper surface facing the foot receiving cavity; and a groove located in the second upper surface and connecting the first through-hole for receiving a cable to the second through-hole for receiving a cable, wherein the cable passes from the first through-hole for receiving a cable through the groove to the second through-hole for receiving a cable.
50. The footwear article according to claim 46, wherein the midsole carrier member and the midsole core member are coupled to each other via the cable and without any chemical adhesive or thermally bonded structure.
51. The footwear article according to claim 45, wherein the upper is coupled to the sole via a second cable and without any chemical adhesive or thermally bonded structure.
52. The footwear article according to claim 45, wherein: The through-hole includes a first width; and the attachment friction lug includes a second width greater than the first width.
53. The footwear article according to claim 45, wherein: The upper surface of the midsole carrier member includes a recess; and the midsole core member is nested in the recess.
54. A method, comprising: Position an outsole member adjacent to the upper surface of the midsole carrier member, the outsole member including attachment friction lugs; Insert the attachment friction lugs through the through-holes of the midsole carrier member, wherein the attachment friction lugs protrude beyond the lower surface of the midsole carrier member; stack a midsole core member on top of the outsole member such that the outsole member is positioned between the midsole carrier member and the midsole core member; and pass a cable through a first set of through-holes in the midsole core member and a second set of through-holes in the midsole carrier member.
55. The method according to claim 54, further comprising: Position the cable in a first groove, the first groove being positioned on the upper surface of the midsole core member and connecting a first through-hole and a second through-hole in the first set of through-holes; and position the cable in a second groove, the second groove being positioned on the lower surface of the midsole carrier member and connecting a first through-hole and a second through-hole in the second set of through-holes.
56. The method according to claim 54, further comprising: Attach the midsole carrier member to the midsole core member only with the cable and without any chemical adhesive or thermally bonded structure.
57. A footwear product, comprising: An upper that at least partially surrounds a foot receiving cavity; and a sole coupled to the upper, the sole including: a midsole carrier member including an upper surface that faces the foot receiving cavity; a midsole core member disposed between the upper surface of the midsole carrier member and the foot receiving cavity; and a cable that extends through at least the midsole core member and the midsole carrier member and attaches at least the midsole core member and the midsole carrier member.
58. The footwear article according to claim 57, wherein the midsole core member comprises: A second upper surface facing the foot receiving cavity; A groove in the upper surface of the midsole carrier member; and the cable positioned in the groove.
59. The footwear article according to claim 57, wherein: The upper surface of the midsole carrier member includes a recess; and the midsole core member is nested in the recess.
60. The footwear article according to claim 57, further comprising a toe and heel stabilizer coupled to the midsole carrier member via the cable.
61. The footwear article according to claim 60, wherein: The midsole carrier member and the midsole core member each include a foamed material; and the toe and the heel stabilizer each include a thermoplastic polymer.
62. The footwear article according to claim 60, wherein the cable attaches the midsole carrier member to the toe, the heel stabilizer, and the midsole core member without an adhesive. The footwear article according to claim 57, further comprising: An outsole member, the outsole member being positioned between the midsole carrier member and the midsole core member.
64. The footwear article according to claim 63, wherein the cable secures the midsole carrier member to the outsole member.