Footwear with padding and midsole structure and method of making same

Abstract

A method for manufacturing an article of footwear is provided. [Solution] A method of manufacturing an article of footwear is provided, comprising the steps of 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.

Description

[Technical Field]

[0001] FIELD OF THE INVENTION Embodiments of the present invention relate generally to footwear components, and more particularly 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 ingates 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, resulting in manufacturing limitations (e.g., limitations on the shape of the mold plates, limitations on materials optimal for processing, etc.). Furthermore, the process is cumbersome and time-consuming. Therefore, there is a need for improved 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 for fabricating such footwear components, are disclosed. In some embodiments, the footwear components are fabricated from at least one polymer material injected through various ports in a 3D body, such as a shoe last. Footwear components include, but are not limited to, midsoles, heel counters, ankle and heel padding, medial and lateral supports, and other interior or exterior structures. In some embodiments, the footwear components are fabricated by injecting at least one polymer material through a shoe last having channels within its structure. In some embodiments, the channels include openings through which the material can be expelled to form the desired footwear component. 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 a 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 an 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 some embodiments, the last includes a pattern having at least one of engraved and embossed features.

[0009] In some embodiments, a method for manufacturing an article of footwear includes positioning an upper on a last, injecting a material through the last, and forming the upper's padding and 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 modular appendages to shape the upper's padding. 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 midsole and upper padding.

[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 the exterior of the upper. In some embodiments, the padding is disposed on the interior of the upper. In some embodiments, the padding is customized based on foot data associated with the 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 the inlet opening to the 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 the 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 art to make and use the invention. [Brief explanation of the drawings]

[0013] [Figure 1] FIG. 1 shows a side view of a shoe last according to one embodiment. [Figure 2] FIG. 2 illustrates a method of manufacturing an article of footwear according to one embodiment. [Figure 3] FIG. 3 shows a perspective view of a shoe last with 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. [Figure 5] FIG. 5 shows a side view of an upper according to one embodiment. [Figure 6] FIG. 6 shows 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 shoe 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 shoe last having an internal channel according to one embodiment. [Figure 11] FIG. 11 shows a side view of a shoe last with a sole pattern and internal channel according to one embodiment. [Figure 12] FIG. 12 shows a front view of a last with a sole pattern and internal channel according to one embodiment. [Figure 13] FIG. 13 illustrates a side view of an article of footwear according to an embodiment. [Figure 14]FIG. 14 shows a perspective view of a shoe 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 shows a side view of an upper according to one embodiment. DETAILED DESCRIPTION OF THE INVENTION

[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," etc., indicate that the described embodiment may include a particular feature, structure, or characteristic, but not all embodiments necessarily include that particular feature, structure, or characteristic. Moreover, such phrases do not necessarily refer to the same embodiment. Furthermore, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is believed to be within the knowledge of one skilled 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 variations and adaptations of the variety of circumstances 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] Embodiments of the present invention provide footwear having padding and a 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 shoe last is provided that defines openings connected by one or more channels. Polymer 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 within 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 using the last. In some embodiments, tools (i.e., appendages) external to the last can help form the footwear components and direct the polymer material through the channels.

[0019] In some embodiments, last 10 is used to create padding and midsole structures, as shown, for example, in FIG. 1 . The structures may be used as part of the upper or sole of an article of footwear for comfort, fit, support, tactile feedback, stiffness, flexibility, or other purposes. In some embodiments, last 10 includes one or more ports or openings 12, 13 (see FIG. 3 ). In some embodiments, opening 12 comprises an injection port. In some embodiments, opening 13 comprises an evacuation port. In some embodiments, openings 12, 13 are connected by one or more channels 11 in last 10 (see FIG. 4 ). In some embodiments, channel 11 is disposed in an interior portion of last 10. In some embodiments, channel 11 and openings 12, 13 form a network of pathways through which a material, such as a polymeric material, may flow. In some embodiments, one or more channels 11 may intersect to allow material to 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 the 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 the upper portion of the last 10 above the last, as shown, for example, in FIG. 3. Other arrangements of the injection opening 12 are also possible. The exhaust opening 13 can be disposed in various locations (e.g., anywhere it is desired to create a footwear component). 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 locations of the discharge opening 13 are also possible (eg, in the bump, quarter, tongue, etc.).

[0022] In some embodiments, the fill opening 12 is located in the top of the last 10 and the drain opening 13 is located in the bottom of the last 10. In some embodiments, the fill opening 12 is located in the bottom of the last 10 and the drain opening 13 is located in the top of the last 10. In some embodiments, the fill opening 12 or the drain opening 13 is located 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, last 10 includes one or more patterns embossed and / or engraved into areas of 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 last 10.

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

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

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

[0028] In some embodiments, last 10 may include other patterns instead of or in addition to ankle padding pattern 16 and midfoot support pattern 17. Furthermore, in some embodiments, different configurations of ankle padding pattern 16 and / or midfoot support pattern 17 may be used. In some embodiments, last 10 may include embossed and / or engraved patterns in the toe box, vamp, quarter, tongue, or other areas of last 10. As described in more detail below, last 10 may be configured to provide a customized article of footwear having customized padding and other structures. Accordingly, 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 acquired. 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 acquired by performing a foot scan (e.g., using a camera and / or sensors) to assess 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 also be acquired in other ways. In some embodiments, the data may be acquired in a retail environment. In some embodiments, the data may be acquired in a manner as described in U.S. Patent Application No. 15 / 478,902, filed April 4, 2017, and published as U.S. Patent Application Publication No. 2017 / 0280828 A1, the disclosure of which is incorporated herein by reference in its entirety. Data acquired 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 last 10) is created. In one embodiment, the configuration of the last is based on the data obtained in operation 21. Thus, the last may be customized for a particular wearer. In one embodiment, the last is created based on a predefined digital shoe last, as described in U.S. Patent Application No. 15 / 478,902, 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 modified based on the wearer's foot data.

[0032] In some embodiments, the last is fabricated with openings and channels (such as those described above for last 10) to form a network of pathways through which polymer material can be injected. In some embodiments, the last is fabricated with patterns 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 lateral 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 form a network of pathways that can divert material to one or more discharge openings 13 in various regions of last 10.

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

[0037] The upper, now including additional structure or footwear components, may be removed from the last after the structure is formed. As noted above, additional operations may be performed. For example, in some embodiments, 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 in Figures 3-13 can 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 can be included on a single last. Other combinations and variations are possible. These variations can depend on customization for a particular wearer, as discussed above.

[0039] In some embodiments, a last 10, such as that shown in FIGS. 3 and 4, includes an inlet opening 12 and an outlet opening 13. A channel 11 connects the inlet opening 12 with the outlet opening 13. As shown in FIG. 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 outlet opening 13, and the channel 11 form a network of pathways through the last for directing 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 in FIG. 3. In some embodiments, the last 10 includes a structure 42 surrounding the inlet opening 12, as shown in FIG. 4. The structure 42 can be configured to retain the polymeric material just before it enters the inlet opening 12.

[0040] In some embodiments, last 10 includes ankle padding pattern 16. While FIG. 3 shows lateral ankle padding pattern 16 on last 10, last 10 may additionally or alternatively include medial ankle padding pattern 16. In some embodiments, medial ankle padding pattern 16 may be disposed higher on last 10 than lateral ankle padding pattern 16. In some embodiments, ankle padding pattern 16 includes two drain openings 13. In some embodiments, last 10 includes a channel 11 extending downward from inlet opening 12. In some embodiments, channel 11 splits into two channels 11, one for each drain opening 13. In some embodiments, if last 10 includes medial and lateral ankle padding patterns 16, 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 discharge openings 13. In some embodiments, ankle padding pattern 16 includes both engraved features 14 and embossed features 15. In some embodiments, ankle padding pattern 16 is configured to create ankle padding 36 when polymeric material is transferred through channels 11 to discharge openings 13 (see FIG. 5).

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

[0043] In some embodiments, the polymeric material permeates through the base layer 32 to form ankle padding 36 on the exterior surface of the base layer 32. In some embodiments, the polymeric material forms the ankle padding 36 on the 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 the ankle padding 36) may be removed from the last 10.

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

[0045] In some embodiments, last 10 includes midfoot support pattern 17. While FIG. 6 shows lateral midfoot support pattern 17 on last 10, last 10 may additionally or alternatively include medial midfoot support pattern 17. In some embodiments, midfoot support pattern 17 includes one discharge opening 13. In some embodiments, midfoot support pattern 17 includes two or more discharge openings 13. In some embodiments, last 10 includes channel 11 extending from inlet opening 12 directly to discharge opening 13. In some embodiments, when last 10 includes medial and lateral midfoot support patterns 17, channel 11 may split into two channels 11, one leading to medial midfoot support pattern 17 and the other leading to lateral midfoot support pattern 17. In some embodiments, 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 some embodiments, last 10 may be used to make an upper that includes midfoot support cage 67, similar to that described above with respect to upper 31 that includes ankle padding 36. Last 10 may also be used to make an upper that has both midfoot support cage 67 and ankle padding 36 (or other footwear components).

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

[0048] In one embodiment, last 10 includes forefoot pattern 18. Forefoot pattern 18 is shown in FIG. 9 in a plan view for clarity only. Forefoot pattern 18 is disposed across the top of last 10 in the forefoot region, as shown in FIG. 8. In one embodiment, forefoot pattern 18 includes one exhaust opening 13. In one embodiment, forefoot pattern 18 includes two or more exhaust openings 13, as shown in FIG. 8. In one embodiment, last 10 includes channels 11 that extend from injection openings 12 directly to exhaust openings 13. In one embodiment, forefoot pattern 18 includes both engraved features 14 and embossed features 15. In one embodiment, forefoot pattern 18 is configured to create proprioceptive features on the forefoot of the upper when polymeric material is transferred through channels 11 to exhaust openings 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, such as those shown in FIGS. 10-12, can be used to make a sole 39. The shoe last 10 can 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., in a portion of the shoe last 10 associated with an opening in the upper to accommodate a wearer's foot, as shown in FIG. 10. In some embodiments, the shoe last 10 includes two exhaust openings 13 disposed at the 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 FIG. 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 can be formed while the upper is still disposed on last 10. In some embodiments, polymeric material seeps through the upper (after traveling through channel 11) to form sole 39.

[0052] In some embodiments, as shown in FIGS. 11 and 12 , last 10 includes sole pattern 19. In some embodiments, sole pattern 19 is disposed on the bottom portion of last 10. In some embodiments, sole pattern 19 comprises a cavity extending across a majority of the length of last 10 and a majority of the width of last 10. In some embodiments, sole pattern 19 can be used to form an insole. A base layer can be placed around the periphery of last 10 (as described above with respect to upper 31). Polymer material can then be moved through one or more channels 11 to fill sole pattern 19 on the medial side of the base layer. As shown in FIGS. 11 and 12 , channels 11 are internal channels (shown by dotted lines) disposed within 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 with 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 described above and 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 from polymeric material injected through last 10. For example, as shown in FIG. 14 , modular appendage 40 can aid in forming ankle padding 36 having ankle padding pattern 16. In some embodiments, modular appendage 40 interfaces with the exterior surface of last 10. For example, the interior surface of modular appendage 40 can correspond in shape to the exterior surface of last 10. In some embodiments, base layer 32 is disposed between last 10 and modular appendage 40. In some embodiments, modular appendage 40 helps prevent polymeric material from seeping through base layer 32 to better form the internal footwear components.

[0055] The modular appendages may be of various shapes and sizes to allow for greater customization for a particular wearer. The shape and size of the modular appendages may depend on the location of the footwear component for which they are being made. The modular appendages may be used to adjust the level of padding for 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 outer 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 outer footwear component to 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 desired areas of last 10 and to divert and / or channel polymeric material from desired areas. 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, an 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 either 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 with a channel directed toward an outlet in the heel portion of the last and a second opening with a channel directed toward an outlet in the forefoot portion of the last. Different materials may be directed through each channel to form dual-density sole 52. In some embodiments, different materials may be directed through a single channel to form 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 two or more materials, 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 composed 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 the molding of 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 carved and / or embossed features 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 similarly form the footwear components.

[0064] In a further embodiment, a method of manufacturing an article of footwear comprises the steps of 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 the 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 comprises a pattern having at least one of engraved and embossed features.

[0073] In a further embodiment, a method of manufacturing an article of footwear comprises the steps of 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 the 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 different 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 descriptions of specific embodiments make fairly complete the general nature of the invention such 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 range of equivalents of the disclosed embodiments, based on the teaching and guidance presented herein. It should be understood that the language or terminology herein is for the purpose of illustration and not of limitation, as the language or terminology 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 the 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 [2] The method of claim 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 the top of the last and an outlet at the bottom of the last. [5] 10. The method of claim 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] [6] The method of [6], wherein the cavity extends across a majority of the length of the last and a majority of the width of the last. [8] [7] The method of [7], wherein the step of forming the structure in the upper includes the step of forming an insole in the cavity. [9] 10. The method of claim 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

[11] The method of

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

[12]

[10] The method of

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

[13]

[10] 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 the 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 different from the upper.

[16] The article of footwear according to

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

[17]

[15] The article of footwear according to

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

[18]

[15] The article of footwear of

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

[19]

[15] The article of footwear of

[15] , wherein the midsole comprises multiple materials.

[20]

[15] 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 the upper on a last, the last defining a first inlet opening and a first outlet opening connected by a first channel in the last, the first outlet opening located within an engraved and / or embossed feature formed on an exterior surface of the last, the last being disposed within a base layer of the upper; injecting a first polymeric material through the first injection opening and through the first channel to form ankle padding disposed inside the upper, the first polymeric material flowing out the first discharge opening, filling spaces between the features and an inner surface of the base layer with the first polymeric material, and solidifying or curing the first polymeric material to adhere to the base layer to form the ankle padding; A method comprising:

2. The shoe mold further defines a second inlet opening and a second outlet opening connected by a second channel within the shoe mold; 10. The method of claim 1, further comprising injecting a second polymeric material from the second injection opening through the second channel, wherein the second polymeric material seeps through the base layer of the upper to form a midsole.

3. 3. The method of claim 2, wherein the second inlet opening is located in the top of the last and the second outlet opening is located in the bottom of the last.

4. The method of claim 1 , further comprising customizing the ankle padding based on data associated with a wearer.

5. The method of claim 1 , wherein the last defines a cavity in a bottom portion of the last.

6. 6. The method of claim 5, wherein the cavity extends across a majority of the length of the last and a majority of the width of the last.

7. The shoe mold further defines a third injection opening and a third discharge opening connected by a third channel within the shoe mold, the third discharge opening being located within the cavity; 7. The method of claim 6, further comprising the step of injecting a third polymeric material through the third injection opening and the third channel to form an insole in the cavity, the third polymeric material flowing out the third discharge opening, filling the space between the cavity and the inner surface of the base layer with the third polymeric material, and solidifying or curing the third polymeric material to adhere to the base layer to form the insole.

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