Footwear with padding and mid-sole structure and method of making the same

Abstract

To provide a method for manufacturing an article of footwear.SOLUTION: There is provided a method for manufacturing an article of footwear, comprising the steps of: positioning an upper on a shoe last, which defines openings connected by one or more channels in the shoe last; injecting a material through the one or more channels in the shoe last; and forming a structure on the upper with the material.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] FIELD OF THE DISCLOSURE

[0002] Embodiments of the present invention relate generally to footwear components, and more specifically to footwear components made from polymeric materials injected through various ports in a 3D body, such as a shoe last. [Background technology]

[0002] Injection molding is used in the manufacture of footwear to create various footwear components such as midsoles, outsoles, and spike plates. In known uses of injection molding, material is injected through the ingate of a set of mold plates and shaped based on the style of the mold plates. These systems lack the flexibility to creatively shape and mold footwear components, and thus have manufacturing limitations (e.g., limitations on the shape of the mold plates, limitations on materials suitable for processing, etc.). Furthermore, the processing is cumbersome and time-consuming. Thus, there is a need to improve the molding of footwear components in an efficient, customizable, and rapid manner. Summary of the Invention

[0003] Footwear having padding and midsole structures, as well as methods of making such footwear components, are disclosed. In some embodiments, the footwear components are made from at least one polymeric material injected through various ports of a 3D body, such as a shoe last. The footwear components include, but are not limited to, midsoles, heel counters, ankle and heel padding, medial and lateral supports, and other internal or external structures. In some embodiments, the footwear components are made by injecting at least one polymeric material through a shoe last having channels in its structure. In some embodiments, the channels include openings through which the material can be expelled to form the desired footwear components. In some embodiments, the footwear components are formed on and around a 3D footwear upper component, such as a knitted sock or similar material.

[0004] In some embodiments, a method of manufacturing an article of footwear includes positioning an upper on a last. In some embodiments, the last defines openings connected by one or more channels in the last. In some embodiments, a method of manufacturing an article of footwear includes injecting a material through the one or more channels in the last and forming a structure in the upper with the material.

[0005] In some embodiments, the structure includes a midsole. In some embodiments, the structure includes padding for the upper. In some embodiments, the openings include an inlet at the top of the last and an outlet at the bottom of the last.

[0006] In some embodiments, the method includes customizing the structure based on data associated with the wearer. In some embodiments, customizing the structure includes customizing a position of the structure. In some embodiments, customizing the structure includes customizing a shape of the structure. In some embodiments, customizing the structure includes customizing a material of the structure. In some embodiments, the method includes customizing the upper based on data associated with the wearer.

[0007] In some embodiments, the last defines a cavity in a bottom portion of the last. In some embodiments, the cavity extends across a majority of the length of the last and a majority of the width of the last. In some embodiments, forming a structure in the upper includes forming an insole in the cavity.

[0008] In one embodiment, the last includes a pattern having at least one of engraved and embossed features.

[0009] In some embodiments, a method of manufacturing an article of footwear includes positioning an upper on a last, injecting a material through the last, and forming the padding of the upper and a midsole with the material in a single continuous process. In some embodiments, the method includes injecting a second material through the last. In some embodiments, the method includes using a modular appendage to shape the padding of the upper. In some embodiments, the method includes obtaining foot data associated with a wearer. In some embodiments, the method includes using the foot data associated with the wearer to customize the padding of the midsole and the upper.

[0010] In some embodiments, the article of footwear includes an upper, a single-injection midsole and padding disposed on the upper. In some embodiments, the single-injection midsole and padding are distinct from the upper. In some embodiments, the padding is disposed on an exterior side of the upper. In some embodiments, the padding is disposed on an interior side of the upper. In some embodiments, the padding is customized based on foot data associated with a wearer. In some embodiments, the midsole includes multiple materials. In some embodiments, the midsole includes multi-density materials.

[0011] In some embodiments, the last includes a body defining a channel extending from an inlet opening to an outlet opening. In some embodiments, the body of the last defines a plurality of channels. In some embodiments, the last includes one or more patterns on an exterior surface of the body. In some embodiments, the pattern is embossed on the exterior surface. In some embodiments, the pattern is engraved on the exterior surface. In some embodiments, the pattern includes embossed and engraved features. In some embodiments, the pattern includes ridges, i.e., raised structures. In some embodiments, the pattern is disposed in one or more of the heel region, midfoot region, and forefoot region. In some embodiments, the pattern is disposed in one or more of the toe box, vamp, quarter, or tongue regions of the last.

[0012] The accompanying drawings, which are incorporated herein and constitute a part of the specification, illustrate the present invention and, together with the description, further explain the principles of the invention and enable one skilled in the relevant art to make and use the invention. [Brief description of the drawings]

[0013] [Figure 1] FIG. 1 shows a side view of a shoe last according to one embodiment. [Diagram 2] FIG. 2 illustrates a method of making an article of footwear according to one embodiment. [Diagram 3] FIG. 3 shows a perspective view of a shoe last having an ankle padding pattern according to one embodiment. [Figure 4] FIG. 4 shows a side view of a last with an ankle padding pattern and internal channels according to one embodiment. [Diagram 5] FIG. 5 illustrates a side view of an upper according to one embodiment. [Figure 6] FIG. 6 illustrates a perspective view of a shoe last having a midfoot support pattern according to one embodiment. [Figure 7] FIG. 7 shows a side view of a last having a midfoot support pattern and an internal channel according to one embodiment. [Figure 8] FIG. 8 shows a perspective view of a shoe last having a forefoot pattern according to one embodiment. [Figure 9] FIG. 9 shows a side view of a last having a forefoot pattern and an internal channel according to one embodiment. [Figure 10] FIG. 10 shows a side view of a last having an internal channel according to one embodiment. [Figure 11] FIG. 11 shows a side view of a last having a sole pattern and an internal channel according to one embodiment. [Figure 12] FIG. 12 illustrates a front view of a last having a sole pattern and an internal channel according to one embodiment. [Figure 13] FIG. 13 illustrates a side view of an article of footwear according to one embodiment. [Figure 14]FIG. 14 shows a perspective view of a last having modular appendages according to one embodiment. [Figure 15] FIG. 15 illustrates a side view of an article of footwear according to one embodiment. [Figure 16] FIG. 16 illustrates a side view of an upper according to one embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] The present invention will now be described in detail with reference to embodiments thereof, as illustrated in the accompanying drawings, where like reference numerals are used to indicate corresponding or functionally similar elements. References to "one embodiment," "embodiment," "exemplary embodiment," and the like indicate that the embodiment being described may include a particular feature, structure, or characteristic, but not all embodiments may necessarily include that particular feature, structure, or characteristic. Moreover, such phrases do not necessarily refer to the same embodiment. In addition, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is believed to be within the knowledge of one of ordinary skill in the art to affect such feature, structure, or characteristic in connection with other embodiments, whether or not expressly stated.

[0015] The terms "invention" or "present invention" as used herein are open-ended terms and are not intended to refer to any one embodiment of a particular invention, but include all possible embodiments as described in this application.

[0016] The following examples are illustrative rather than limiting of the invention. Other suitable modifications and adaptations of a variety of situations and parameters normally encountered in the art will be apparent to those skilled in the art and are within the spirit and scope of the invention.

[0017] The present invention provides footwear having a padding and midsole structure, a method for making the padding and midsole structure, and a shoe last for making the padding and midsole structure. In some embodiments, the provided footwear may be an athletic shoe. For example, the provided footwear may be a running shoe, a soccer shoe, a basketball shoe, a football shoe, a tennis shoe, or any other athletic shoe. In some embodiments, the provided footwear may be a non-athletic shoe.

[0018] In some embodiments, a last is provided that defines openings connected by one or more channels. Polymeric material can be injected through the openings and channels to form structures at various locations in the upper. For example, footwear components can be formed around and around a 3D upper component, such as a knitted sock. In some embodiments, complex shapes can be formed on the medial and / or lateral sides of the upper with the use of the last. In some embodiments, tools (i.e., appendages) external to the last can aid in forming the footwear components and directing the polymeric material through the channels.

[0019] In some embodiments, the last 10 is used to create padding and midsole structures, for example as shown in FIG. 1. The structures may be used for comfort, fit, support, tactile feedback, stiffness, flexibility, or other purposes as part of an upper or sole of an article of footwear. In some embodiments, the last 10 includes one or more ports or openings 12, 13 (see FIG. 3). In some embodiments, the openings 12 comprise an inlet port. In some embodiments, the openings 13 comprise an outlet port. In some embodiments, the openings 12, 13 are connected by one or more channels 11 in the last 10 (see FIG. 4). In some embodiments, the channels 11 are disposed in an interior portion of the last 10. In some embodiments, the channels 11 and openings 12, 13 form a network of pathways through which a material, such as a polymeric material, may flow. In some embodiments, the one or more channels 11 may intersect such that a material may flow from one pathway to another.

[0020] In some embodiments, the polymeric material is transferred to the inlet opening 12 through a soft nozzle cover. The soft nozzle cover may be made of silicone or a similar elastomeric material. In some embodiments, the soft nozzle cover expands within the inlet opening 12 to create an airtight seal between the nozzle and the inlet opening 12. In some embodiments, other devices or methods may be used to create a seal between the nozzle and the inlet opening 12. For example, an O-ring may be used to facilitate a seal between the nozzle and the inlet opening 12.

[0021] In some embodiments, the injection opening 12 is disposed on a flat surface of the last 10. In some embodiments, the injection opening 12 is disposed on an upper portion of the last 10 above the last, for example as shown in FIG. 3. Other arrangements of the injection opening 12 are also possible. The exhaust opening 13 can be disposed in a variety of locations (e.g., anywhere where a footwear component is desired to be made). In some embodiments, one or more exhaust openings 13 are disposed on the exterior side of the last 10. In some embodiments, one or more exhaust openings 13 are disposed on the medial side of the last 10. In some embodiments, one or more exhaust openings 13 are disposed on the bottom side of the last 10. In some embodiments, one or more exhaust openings 13 are disposed on the upper side of the last 10 (e.g., above the forefoot). In some embodiments, one or more exhaust openings 13 are disposed in the heel area of ​​the last 10. In some embodiments, one or more exhaust openings 13 are disposed in the toe area of ​​the last 10. Combinations of these locations may also be used. Other arrangements of the discharge opening 13 are also possible (eg, at the bump, quarter, tongue, etc.).

[0022] In some embodiments, the injection opening 12 is disposed at the top of the last 10 and the drain opening 13 is disposed at the bottom of the last 10. In some embodiments, the injection opening 12 is disposed at the bottom of the last 10 and the drain opening 13 is disposed at the top of the last 10. In some embodiments, the injection opening 12 or the drain opening 13 is disposed between the top and bottom of the last 10.

[0023] In some embodiments, the polymeric material comprises polyurethane foam. In some embodiments, the polyurethane foam (or other polymeric material) can be a single density. In some embodiments, the polyurethane foam (or other polymeric material) can be a multi-density material. In some embodiments, the polymeric material comprises silicone, urethane, thermoplastic polyurethane, thermoplastic polymer, elastomer, or other liquid plastic. Other materials, such as air or other gases, can also be injected through the channels 11 and openings 12, 13. For example, certain additives can be injected with the polymeric material to accelerate or slow down the curing process of the polymeric material.

[0024] In some embodiments, the last 10 includes one or more patterns embossed and / or engraved into areas of the last 10. The patterns may be disposed in one or more of the heel area, midfoot area, and forefoot area. The patterns may be disposed on the top, bottom, or sides of the last 10.

[0025] In some embodiments, the last 10 includes one or more engraved features 14 (e.g., cavities or recesses) on the exterior surface of the last 10. In some embodiments, the last 10 includes one or more embossed features 15 on the exterior surface of the last 10. In some embodiments, the engraved features 14 and / or embossed features 15 form various patterns on the last 10. In some embodiments, the engraved features 14 and / or embossed features 15 are disposed at or near the discharge opening 13. In some embodiments, the discharge opening 13 is disposed within the engraved features 14. In some embodiments, the discharge opening 13 is surrounded by the embossed features 15. In some embodiments, the ridges, i.e., raised structures 45 of the embossed features 15 (or edges 44 of the engraved features 14) define enclosed areas and may help control flashing of the polymeric material as it is injected through the channels 11 and the discharge openings 13. In one embodiment, the engraved features 14 and / or embossed features 15 define recessed areas, as shown, for example, in FIG.

[0026] In some embodiments, the engraved features 14 and / or embossed features 15 are configured to facilitate the formation of footwear components. For example, the last 10 in FIG. 1 includes ankle padding pattern 16 having engraved features 14 and embossed features 15, and a midfoot support pattern 17 having engraved features 14 and embossed features 15. In some embodiments, the ankle padding pattern 16 is configured to form ankle padding 36 with polymeric material injected through the channels 11 and openings 13 (see FIG. 5). In some embodiments, the midfoot support pattern 17 is configured to form a midfoot support cage 67 with polymeric material injected through the channels 11 and openings 13 (see FIG. 16).

[0027] In some embodiments, the engraved features 14 are used to form interior padding and support. In some embodiments, the embossed features 15 are used to form components that provide tactile texture and / or 3D design. In some embodiments, the engraved features 14 and / or embossed features 15 are used to form exterior components. The pattern on the last 10 can be formed with only the engraved features 14, only the embossed features 15, or a combination of the engraved features 14 and the embossed features 15. In some embodiments, the edges of the embossed features 15 create a seal around a portion of the 3D footwear upper component disposed on the last 10 to prevent polymeric material from seeping outside the engraved features 14 and embossed features 15.

[0028] In some embodiments, the last 10 may include other patterns instead of or in addition to the ankle padding pattern 16 and the midfoot support pattern 17. Additionally, in some embodiments, different configurations of the ankle padding pattern 16 and / or the midfoot support pattern 17 may be used. In some embodiments, the last 10 may include embossed and / or engraved patterns in the toe box, vamp, quarter, tongue, or other areas of the last 10. As described in more detail below, the last 10 may be configured to provide a customized article of footwear having customized padding and other structures. Thus, a wide variety of last configurations and features are possible.

[0029] In some embodiments, the shoe last 10 is used to make articles of footwear and footwear components. For example, a method 20 for making an article of footwear is shown in FIG. 2. The operations of method 20 described below are exemplary. In some embodiments, additional operations may be part of the method. In some embodiments, not all of the operations shown in FIG. 2 are completed. In some embodiments, the order of operations may differ from the order shown in FIG. 2.

[0030] In some embodiments, in operation 21, data associated with the wearer is obtained. In some embodiments, the data includes the wearer's foot data, performance data, and other data related to creating a customized article of footwear for the wearer. In some embodiments, the data may be obtained by performing a foot scan (e.g., using a camera and / or sensors) to evaluate the wearer's foot profile. In some embodiments, the wearer's foot strike profile is measured and analyzed (e.g., using an accelerometer or other sensor) to generate an ideal profile for the wearer. The data may be obtained in other ways. In some embodiments, the data may be obtained in a retail environment. In some embodiments, the data may be obtained in a manner as described in U.S. Patent Application No. 15 / 478902, filed April 4, 2017, and published as U.S. Patent Application Publication No. 2017 / 0280828A1, the disclosure of which is incorporated herein by reference in its entirety. Data obtained using one or more of these methods may be used to customize an article of footwear for a particular wearer.

[0031] In one embodiment, in operation 22, a shoe last (such as shoe last 10) is created. In one embodiment, the configuration of the shoe last is based on the data obtained in operation 21. Thus, the shoe last may be customized for a particular wearer. In one embodiment, the shoe last is created based on a predefined digital shoe last as described in U.S. Patent Application No. 15 / 478902, filed April 4, 2017, and published as U.S. Patent Application Publication No. 2017 / 0280828A1, the disclosure of which is incorporated herein by reference in its entirety. The predefined digital shoe last may be altered based on the wearer's foot data.

[0032] In some embodiments, the last is created with openings and channels (such as those described above for last 10) to form a network of pathways through which the polymeric material can be injected. In some embodiments, the last is created with a pattern on the last (such as those described above for last 10). In some embodiments, the modified last can be used to determine the placement of patterns on the last (such as padding patterns or support patterns) and also sole designs for a particular wearer. The modified last can also be used to determine other parameters for the patterns on the last including, for example, the number of patterns on the last, the size of the patterns on the last, and the shape of the patterns on the last.

[0033] In some embodiments, in act 23, an upper (such as upper 31 (see FIG. 5)) is created. In some embodiments, the upper is primarily a knit material. In some embodiments, the upper is made of a 3D knit material. In some embodiments, the upper can be made of woven, non-woven, knitted and other types of textile materials. In some embodiments, the upper can be made of leather. In some embodiments, the construction of the upper is based on the data obtained in act 21. For example, the type of material, the physical properties of the material and other parameters can be based on the data obtained in act 21.

[0034] In some embodiments, the upper is positioned on the last in operation 24. In some embodiments, the upper is positioned on the last with its medial side facing the last. In some embodiments, the upper is positioned on the last with its exterior side facing the last (i.e., inside-out).

[0035] In some embodiments, in operation 25, a material is injected through the last. In some embodiments, the material is a polymeric material. In some embodiments, two or more materials are injected through the last, either simultaneously or sequentially. In some embodiments, the material is injected through an injection opening (e.g., opening 12). In some embodiments, injection opening 12 is disposed on the top surface of last 10 (see FIG. 3). In some embodiments, the material travels through injection opening 12 to one or more channels 11. Channels 11 may form a network of pathways to divert material to one or more discharge openings 13 in various areas of last 10.

[0036] In some embodiments, in act 26, structures (e.g., padding, support, midsole, etc.) are formed in the upper (e.g., upper 31) from polymeric material. In some embodiments, the structures may be formed on the medial side of the upper. In some embodiments, the structures may be formed on the lateral side of the upper. In some embodiments, structures such as the padding and midsole of the upper are formed in a single continuous process. In some embodiments, the structures are formed simultaneously. For example, the midsole and ankle padding may be formed simultaneously with a single injection of polymeric material. In some embodiments, the structures may be formed sequentially (e.g., ankle padding is formed after the midsole). In some embodiments, the structures are customized based on the data obtained in act 21. For example, the position, shape, size and / or material of the structures may be customized.

[0037] The upper, now including additional structure or footwear components, may be removed from the last after the structure is formed. Additional operations may be performed as described above. For example, in one embodiment, the last may be cleaned after injection is complete and the upper is removed.

[0038] Examples of various lasts, footwear components, and articles of footwear are shown in Figures 3-13. In some embodiments, the features shown on the lasts, footwear components, and articles of footwear of Figures 3-13 may be combined or varied to produce other variations of the lasts, footwear components, and articles of footwear. For example, the ankle padding pattern 16 of Figure 3 and the midfoot support pattern 17 of Figure 6 may be included in a single last. Other combinations and variations are possible. These variations may depend on customization for a particular wearer, as discussed above.

[0039] In some embodiments, the last 10, as shown, for example, in Figures 3 and 4, includes an inlet opening 12 and a drain opening 13. A channel 11 connects the inlet opening 12 with the drain opening 13. As shown in Figure 4, the channel 11 is an internal channel (shown by a dotted line) disposed within the last 10. In some embodiments, the inlet opening 12, the drain opening 13, and the channel 11 form a network of pathways through the last to direct the polymeric material to various locations on the last. In some embodiments, the inlet opening 12 is disposed in the upper portion of the last 10, for example, in a portion of the last 10 associated with an opening in the upper to accommodate a wearer's foot, as shown, for example, in Figure 3. In some embodiments, the last 10 includes a structure 42 surrounding the inlet opening 12, as shown, for example, in Figure 4. The structure 42 can be configured to hold the polymeric material just before it enters the inlet opening 12.

[0040] In some embodiments, the last 10 includes an ankle padding pattern 16. While FIG. 3 shows a lateral ankle padding pattern 16 on the last 10, the last 10 may additionally or alternatively include a medial ankle padding pattern 16. In some embodiments, the medial ankle padding pattern 16 may be disposed higher on the last 10 than the lateral ankle padding pattern 16. In some embodiments, the ankle padding pattern 16 includes two discharge openings 13. In some embodiments, the last 10 includes a channel 11 that extends downwardly from the injection opening 12. In some embodiments, the channel 11 splits into two channels 11, one for each discharge opening 13. In some embodiments, when the last 10 includes a medial and lateral ankle padding pattern 16, the channel 11 may split into four channels 11.

[0041] Different numbers and configurations of channels 11 are included based on the number and location of the exhaust openings 13. In one embodiment, the ankle padding pattern 16 includes both engraved features 14 and embossed features 15. In one embodiment, the ankle padding pattern 16 is configured to create ankle padding 36 when polymeric material is transferred through the channels 11 to the exhaust openings 13 (see FIG. 5).

[0042] In one embodiment, the last 10 may be used to create an upper 31, as shown in FIG. 5. A base layer 32 is placed around the periphery of the last 10. In one embodiment, the base layer 32 comprises a textile material, such as a knit or woven material. In one embodiment, the base layer 32 comprises a three-dimensional knit textile material. In one embodiment, a polymeric material is transferred through the channels 11 to the discharge openings 13 when the base layer 32 is disposed on the last 10. In one embodiment, the polymeric material adheres to the base layer 32 as it solidifies or hardens to form ankle padding 36.

[0043] In some embodiments, the polymeric material seeps through the base layer 32 to form ankle padding 36 on an exterior surface of the base layer 32. In some embodiments, the polymeric material forms ankle padding 36 on an interior surface of the base layer 32. In some embodiments, the base layer 32 may be placed on the inside or outside of the last 10, such that the ankle padding 36 is formed on the exterior surface of the base layer 32 without passing through the base layer 32. After the ankle padding 36 is formed, the upper 31 (including the base layer 32 and ankle padding 36) may be removed from the last 10.

[0044] In some embodiments, as shown, for example, in Figures 6 and 7, the last 10 includes an inlet opening 12, a drain opening 13, and a channel 11 connecting the inlet opening 12 to the drain opening 13. As shown in Figure 7, the channel 11 is an interior channel (shown by a dotted line) disposed within the last 10. In some embodiments, the inlet opening 12 is disposed in an upper portion of the last 10, e.g., in a portion of the last 10 associated with an opening in the upper to accommodate a wearer's foot, as shown in Figure 6. In some embodiments, the last 10 includes a structure 42 surrounding the inlet opening 12, as shown, for example, in Figure 7. The structure 42 can be configured to retain the polymeric material just before it enters the inlet opening 12.

[0045] In some embodiments, the last 10 includes a midfoot support pattern 17. While FIG. 6 shows a lateral midfoot support pattern 17 on the last 10, the last 10 may additionally or alternatively include a medial midfoot support pattern 17. In some embodiments, the midfoot support pattern 17 includes one exhaust opening 13. In some embodiments, the midfoot support pattern 17 includes two or more exhaust openings 13. In some embodiments, the last 10 includes a channel 11 that extends from the inlet opening 12 directly to the exhaust opening 13. In some embodiments, when the last 10 includes a medial and lateral midfoot support pattern 17, the channel 11 may split into two channels 11, one leading to the medial midfoot support pattern 17 and the other leading to the lateral midfoot support pattern 17. In some embodiments, the midfoot support pattern 17 includes both engraved features 14 and embossed features 15. In one embodiment, the midfoot support pattern 17 is configured to create a midfoot support cage 67 when polymer material is transferred through the channels 11 to the discharge opening 13 (see FIG. 16).

[0046] In one embodiment, the last 10 may be used to create an upper that includes a midfoot support cage 67, similar to that described above with respect to the upper 31 that includes ankle padding 36. The last 10 may also be used to create an upper that has both the midfoot support cage 67 and ankle padding 36 (or has other footwear components).

[0047] In some embodiments, as shown, for example, in Figures 8 and 9, the last 10 includes an inlet opening 12, a drain opening 13, and a channel 11 connecting the inlet opening 12 to the drain opening 13. As shown in Figure 9, the channel 11 is an internal channel (shown by a dotted line) disposed within the last 10. In some embodiments, the inlet opening 12 is disposed in an upper portion of the last 10, e.g., in a portion of the last 10 associated with an opening in the upper to accommodate a wearer's foot, as shown in Figure 8. In some embodiments, the last 10 includes a structure 42 surrounding the inlet opening 12, as shown, for example, in Figure 9. The structure 42 can be configured to retain the polymeric material just before it enters the inlet opening 12.

[0048] In one embodiment, the last 10 includes a forefoot pattern 18. The forefoot pattern 18 is shown in FIG. 9 in a plan view for clarity only. The forefoot pattern 18 is disposed across the top of the last 10 in the forefoot region, as shown in FIG. 8. In one embodiment, the forefoot pattern 18 includes one exhaust opening 13. In one embodiment, the forefoot pattern 18 includes two or more exhaust openings 13, as shown in FIG. 8. In one embodiment, the last 10 includes a channel 11 that extends from the injection opening 12 directly to the exhaust opening 13. In one embodiment, the forefoot pattern 18 includes both engraved features 14 and embossed features 15. In one embodiment, the forefoot pattern 18 is configured to create proprioceptive features on the forefoot of the upper when polymeric material is transferred through the channel 11 to the exhaust opening 13.

[0049] In one embodiment, last 10 may be used to create an upper that includes forefoot proprioceptive features, similar to that described above with respect to upper 31 that includes ankle padding 36. Last 10 may also be used to create an upper that has both forefoot proprioceptive features and additional components (such as midfoot support cage 67 and / or ankle padding 36).

[0050] In some embodiments, a shoe last 10 may be used to make a sole 39, for example as shown in Figures 10-12. The shoe last 10 may include one or more injection openings 12 and one or more exhaust openings 13. In some embodiments, the shoe last 10 includes two injection openings 12, each positioned at the top of the shoe last 10, e.g., at a portion of the shoe last 10 associated with an opening in the upper to accommodate a wearer's foot, as shown in Figure 10. In some embodiments, the shoe last 10 includes two exhaust openings 13 disposed at a bottom portion of the shoe last 10. In some embodiments, the shoe last 10 includes one or more channels 11 connecting the injection openings 12 to the exhaust openings 13. In some embodiments, the shoe last 10 includes two channels 11. As shown in Figure 10, the channels 11 are internal channels (shown by dotted lines) disposed within the shoe last 10. In some embodiments, the exhaust openings 13 are disposed directly below the injection openings 12, such that the channels 11 are vertical when the shoe last 10 is upright.

[0051] In some embodiments, sole 39 comprises a midsole. In some embodiments, the upper is formed on last 10 (as described above for upper 31), and sole 39 may be formed while the upper is further disposed on last 10. In some embodiments, polymeric material seeps through the upper (after migrating through channel 11) to form sole 39.

[0052] In some embodiments, as shown in Figures 11 and 12, the last 10 includes a sole pattern 19. In some embodiments, the sole pattern 19 is disposed on a bottom portion of the last 10. In some embodiments, the sole pattern 19 comprises a cavity that extends across most of the length of the last 10 and most of the width of the last 10. In some embodiments, the sole pattern 19 can be used to form an insole. A base layer can be placed around the periphery of the last 10 (as described above with respect to the upper 31). A polymeric material can then be moved through one or more channels 11 to fill the sole pattern 19 on the medial side of the base layer. As shown in Figures 11 and 12, the channels 11 are interior channels (shown in dotted lines) disposed within the last 10. The resulting upper with the embedded insole can be removed for incorporation into an article of footwear.

[0053] An article of footwear 30 made on last 10 (as described above) is shown, for example, in FIG. 13. Article of footwear 30 includes upper 31 and sole 39. In some embodiments, upper 31 includes base layer 32 and one or more footwear components. The footwear components may be internal or external components, including those components described above, as well as other components made by the methods described above. For example, in FIG. 13, upper 31 includes medial ankle padding 36. In some embodiments, ankle padding 36 and midsole 39 are formed in a single injection of polymeric material through last 10. Thus, ankle padding 36 and sole 39 may be a single injection midsole and padding disposed on upper 31. The single injection midsole and padding may be different from upper 31.

[0054] In some embodiments, modular appendages are used to aid in forming footwear components with polymeric material injected through the last 10. For example, as shown in FIG. 14, modular appendages 40 may aid in forming ankle padding 36 having ankle padding pattern 16. In some embodiments, modular appendages 40 interface with an exterior surface of the last 10. For example, an interior surface of modular appendages 40 may correspond in shape to the exterior surface of the last 10. In some embodiments, base layer 32 is disposed between the last 10 and modular appendages 40. In some embodiments, modular appendages 40 aid in preventing polymeric material from seeping through base layer 32 to better form the internal footwear components.

[0055] The modular attachments may be of various shapes and sizes to allow for greater customization for a particular wearer. The shape and size of the modular attachments may depend on the location of the footwear component for which they are being made. The modular attachments may be used to tailor the level of padding to a particular footwear component.

[0056] In some embodiments, modular appendage 40 may include features (e.g., cavities or recesses) on its interior surface. In some embodiments, this configuration facilitates forming the external footwear component. For example, polymeric material may seep through base layer 32 and fill the cavities or recesses in modular appendage 40. The shape of the cavities or recesses molds the external footwear component into a desired shape.

[0057] In some embodiments, multiple modular appendages 40 are used. For example, two modular appendages 40 may be attached to one another to surround the last 10 during the injection process to help form a footwear component. In some embodiments, the modular appendages may be disposed between the last 10 and the base layer 32.

[0058] In some embodiments, modular appendages are used to span and / or channel polymeric material to and from desired areas of last 10. In some embodiments, modular appendages 40 may include channels. For example, polymeric material may be injected through modular appendages 40 to form footwear components.

[0059] In some embodiments, the article of footwear 50 may be made with a sole 52 having dual densities, as shown, for example, in Figure 15. For example, the sole 52 may be comprised of a first density material 53 and a second density material 54. In some embodiments, the first density material 53 and the second density material 54 are injected sequentially (in any order) through the last 10. In some embodiments, the first density material 53 and the second density material 54 are injected simultaneously.

[0060] In some embodiments, the configuration of last 10 facilitates a dual density sole 52. For example, last 10 may include a first opening having a channel oriented toward an outlet in a heel portion of the last and a second opening having a channel oriented toward an outlet in a forefoot portion of the last. Different materials may be directed through each channel to form the dual density sole 52. In some embodiments, different materials may be directed through a single channel to form the dual density sole 52.

[0061] Creating a dual density sole 52 (or a sole having more than two densities) facilitates customization of the article of footwear 50 for a particular wearer.

[0062] In some embodiments, other components may be made of more than one material, as shown, for example, in FIG. 16. In some embodiments, upper 61 includes heel component 65, toe component 66, and midfoot support cage 67. Heel component 65, toe component 66, and midfoot support cage 67 may each be formed of materials injected through last 10 as described above with respect to other components. In some embodiments, heel component 65, toe component 66, and midfoot support cage 67 each have dual densities. For example, heel component 65, toe component 66, and midfoot support cage 67 may be constructed of first density material 62 and second density material 63. In some embodiments, first density material 62 and second density material 63 are injected through last 10 sequentially (in either order). In some embodiments, first density material 62 and second density material 63 are injected simultaneously.

[0063] Various embodiments described herein provide improved footwear manufacturing that allows for shaping footwear components in an efficient, customizable, and rapid manner. Internal and / or external footwear components for comfort, support, fit, stiffness, flexibility, and / or tactile feedback can be created directly on the upper. These components can be precisely formed in a customized manner by injecting material through a last that has an internal network of pathways (e.g., inlets, channels, and outlets) to various areas of the upper. The last can include features engraved and / or embossed on its exterior surface to form the footwear components. In some embodiments, modular appendages can be used to assist in the formation of the footwear components. Other variations are possible. For example, instead of a last, a similar foot shape or molding tool can be utilized to form the footwear components in a similar manner.

[0064] In a further embodiment, a method of manufacturing an article of footwear includes positioning an upper on a last, the last defining openings connected by one or more channels in the last, injecting material through the one or more channels in the last, and forming a structure in the upper with the material.

[0065] In a further embodiment, the structure comprises a midsole.

[0066] In a further embodiment, the structure comprises padding of the upper.

[0067] In a further embodiment, the openings include an inlet at the top of the last and an outlet at the bottom of the last.

[0068] In a further embodiment, the method further comprises customizing the structure based on data associated with the wearer.

[0069] In a further embodiment, the last defines a cavity in a bottom portion of the last.

[0070] In a further embodiment, the cavity extends across most of the length of the last and most of the width of the last.

[0071] In a further embodiment, forming a structure in the upper comprises forming an insole in the cavity.

[0072] In a further embodiment, the last includes a pattern having at least one of engraved and embossed features.

[0073] In a further embodiment, a method of manufacturing an article of footwear includes positioning an upper on a last, injecting material through the last, and forming the padding and midsole of the upper with the material in a single continuous process.

[0074] In a further embodiment, the method further comprises the step of injecting a second material through the last.

[0075] In a further embodiment, the method further comprises using the modular appendages to shape the padding of the upper.

[0076] In a further embodiment, the method further comprises obtaining foot data associated with the wearer.

[0077] In a further embodiment, the method further comprises using the foot data associated with the wearer to customize padding of the midsole and upper.

[0078] In a further embodiment, an article of footwear comprises an upper, and a single injection midsole and padding disposed on the upper, the single injection midsole and padding being distinct from the upper.

[0079] In a further embodiment, the padding is disposed on the outside of the upper.

[0080] In a further embodiment, the padding is disposed on the medial side of the upper.

[0081] In a further embodiment, the padding is customized based on foot data associated with the wearer.

[0082] In a further embodiment, the midsole comprises multiple materials.

[0083] In a further embodiment, the midsole comprises a multi-density material.

[0084] The foregoing description of specific embodiments makes clear the general nature of the invention fairly fully that others, by applying knowledge within the skill of the art, may readily modify and / or adapt such specific embodiments to various applications without undue experimentation and without departing from the general concept of the invention. Such adaptations and modifications are therefore intended to be within the meaning and equivalents of the disclosed embodiments, based on the teaching and guidance presented herein. It should be understood that the words or technical terms herein are for the purpose of illustration and not of limitation, as the words or technical terms herein will be interpreted by those skilled in the art in light of the teaching and guidance.

[0085] The breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents.

[0086] The present invention includes the following embodiments.

[0087] [1] 1. A method of manufacturing an article of footwear, comprising: positioning an upper on a last, the last defining openings connected by one or more channels in the last; injecting material through the one or more channels in the last; forming a structure in the upper with the material; A method for providing the above. [2] The method of [1], wherein the structure comprises a midsole. [3] The method of [1], wherein the structure comprises upper padding. [4] The method of claim 1, wherein the opening comprises an inlet at a top of the last and an outlet at a bottom of the last. [5] The method of [1], further comprising customizing the structure based on data associated with a wearer. [6] The method of [1], wherein the last defines a cavity in a bottom portion of the last. [7] The method of claim 6, wherein the cavity extends across a majority of the length of the last and a majority of the width of the last. [8] The method of [7], wherein the step of forming the structure in the upper comprises the step of forming an insole in the cavity. [9] The method of [1], wherein the last comprises a pattern having at least one of engraved and embossed features.

[10] 1. A method of manufacturing an article of footwear, comprising: Positioning the upper on a shoe last; injecting material through the last; forming the padding and midsole of an upper from said material in a single continuous process; A method for providing the above.

[11] The method of

[10] , further comprising the step of injecting a second material through the last.

[12] The method of

[10] , further comprising the step of using modular appendages to shape the padding of the upper.

[13] The method of

[10] , further comprising the step of acquiring foot data associated with the wearer.

[14]

[13] The method of

[13] , further comprising using the foot data associated with the wearer to customize padding of the midsole and the upper.

[15] Upper and A single-injection midsole and padding disposed on the upper; An article of footwear comprising: The article of footwear, wherein the single injection midsole and padding are distinct from the upper.

[16] The article of footwear of

[15] , wherein the padding is disposed on the outside of the upper.

[17] The article of footwear of

[15] , wherein the padding is disposed inside the upper.

[18] The article of footwear of

[15] , wherein the padding is customized based on foot data associated with a wearer.

[19] The article of footwear of

[15] , wherein the midsole comprises multiple materials.

[20] The article of footwear of

[15] , wherein the midsole comprises a multi-density material.

Claims

1. 1. A method of manufacturing an article of footwear, comprising: positioning an upper on a last, the last defining an inlet opening and an outlet opening connected by a channel within the last, the outlet opening disposed within a midfoot support pattern having engraved and / or embossed features formed on an exterior surface of the last, the last being disposed within a base layer of the upper; injecting a polymeric material through the injection opening and through the channel to form a midfoot support cage disposed inside the upper, the polymeric material flowing out the discharge opening, filling spaces between the features and an inner surface of the base layer with the polymeric material, and solidifying or hardening the polymeric material to adhere to the base layer, thereby forming the midfoot support cage; A method for providing

2. The polymeric materials are a first polymeric material and a second polymeric material, the first polymeric material having a density different from a density of the second polymeric material; The method of claim 1 , wherein the injecting step comprises sequentially injecting the first polymer material and the second polymer material.

3. The method described in claim 1, wherein the midfoot support pattern is disposed on the outside or inside of the shoe last.

4. The midfoot support pattern is disposed on the lateral or medial side of the shoe last, 2. The method of claim 1, wherein the channel splits into two channels, one leading to the exhaust opening in the lateral midfoot support pattern and the other leading to the exhaust opening in the medial midfoot support pattern.

5. The method of claim 1, further comprising customizing the midfoot support cage based on data associated with the wearer.

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