Interwoven lattice structure for cushioning member

• US 10,231,511 B2
• Filed: 03/15/2017
• Issued: 03/19/2019
• Est. Priority Date: 05/08/2015
• Status: Active Grant

• Current Assignee: Under Armour Incorporated
• Original Assignee: Under Armour Incorporated
• Inventors: Guyan, Alan, Acevedo, John, Dirsa, David, Fallon, Kevin
• Primary Examiner(s): Bays, Marie D
• Application Number:
  US15/459,816
• Publication Number:
  US 20170181496A1
• Time in Patent Office: 734 Days
• Field of Search: 36 28, 36 25 R, 36 30 R, 36 31
• CPC Class Codes: A43B 1/0009 made at least partially of alveolar or honeycomb material
• CPC Class Codes: A43B 13/02 characterised by the material
• CPC Class Codes: A43B 13/125 characterised by the midsole or middle layer
• CPC Class Codes: A43B 13/14 characterised by the constructive form
• CPC Class Codes: A43B 13/181 Resiliency achieved by the structure of the sole
• CPC Class Codes: A43B 13/186 Differential cushioning region, e.g. cushioning located under the ball of the foot resilient heel not included in the sole A43B21/26; resilient supports for the heel of the foot A43B21/32
• CPC Class Codes: A43B 3/0052 X-shaped or cross-shaped
• CPC Class Codes: A43B 7/32 with shock-absorbing means resilient soles A43B13/18
• CPC Class Codes: A43D 999/00 Subject matter not provided for in other groups of this subclass
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing

Abstract

A cushioning member includes a first lattice structure and a second lattice structure. The first lattice structure includes a first network of struts and nodes with voids defined between the struts and nodes. The second lattice structure includes a second network of struts and nodes with voids defined between the struts and nodes. The first network of struts and nodes is interwoven with the second network of struts and nodes such that the first network of struts and nodes extends through the voids in the second network of struts and nodes.

Claims

1. An article of footwear comprising:

an upper; and

a sole member connected to the upper, the sole member including;

a first lattice structure including a first network of struts and nodes with voids defined between the struts and nodes, and

a second lattice structure including a second network of struts and nodes with voids defined between the struts and nodes, the first network of struts and nodes interwoven with the second network of struts and nodes such that the first network of struts and nodes extends through the voids in the second network of struts and nodes.

2. The article of footwear of claim 1 wherein each node is defined by at least two struts extending from said node, and wherein the first network of struts and nodes is independent of and disengaged from the second network of struts and nodes such that the first network of struts and nodes does not contact the second network of struts and nodes in the sole member.

3. The article of footwear of claim 2 wherein the first network of struts and nodes is interlocked with the second network of struts and nodes.

4. The article of footwear of claim 2 wherein the sole member further comprises a first plate, the first lattice structure connected to the first plate and the second lattice structure connected to the first plate.

5. The article of footwear of claim 4 wherein the first lattice structure, second lattice structure and the first plate are provided as a monolithic unitary construction.

6. The article of footwear of claim 1 wherein the sole member is a midsole and an outsole is connected to the midsole.

7. The article of footwear of claim 6 wherein the first lattice structure and the second lattice structure extend from a heel region of the midsole to a midfoot region of the midsole without extending to a forefoot region of the midsole.

8. The article of footwear of claim 1 wherein the struts in the first network of struts and nodes are configured as parallel wave structures in multiple layers, wherein the parallel wave structures in a first layer are transverse to the parallel wave structures in a second layer.

9. The article of footwear of claim 8 wherein the second network of struts and nodes is identical in configuration to the first network of struts and nodes.

10. The article of footwear of claim 1 wherein the sole member comprises an upper shelf and a lower platform and the first lattice structure and the second lattice structure are connected to and extend between the upper shelf and the lower platform.

11. A cushioning member comprising:

a first lattice structure including a first network of struts and nodes with voids defined between the struts and nodes, and

a second lattice structure including a second network of struts and nodes with voids defined between the struts and nodes, the first network of struts and nodes interwoven with the second network of struts and nodes such that the first network of struts and nodes extends through the voids in the second network of struts and nodes.

12. The cushioning member of claim 11 wherein each node is defined by at least two struts extending from said node, and wherein the first network of struts and nodes is independent of and disengaged from the second network of struts and nodes such that the first network of struts and nodes does not contact the second network of struts and nodes.

13. The cushioning member of claim 12 wherein the first network of struts and nodes is interlocked with the second network of struts and nodes.

14. The cushioning member of claim 12 further comprising an upper shelf and a lower platform, the first lattice structure and the second lattice structure connected to and extending between the upper shelf and the lower platform.

15. The cushioning member of claim 14 wherein the first lattice structure, second lattice structure and the plate member are provided as a unitary construction.

16. The cushioning member of claim 11 wherein the cushioning member is provided on an article of apparel.

17. The cushioning member of claim 16 wherein the article of apparel is an article of footwear and wherein the cushioning member is provided as a midsole of the article of footwear.

18. The cushioning member of claim 11 wherein the struts in the first network of struts and nodes are configured as parallel wave structures in multiple layers, wherein the parallel wave structures in a first layer are transverse to the parallel wave structures in a second layer.

19. A method of manufacturing a cushioning member, the method comprising:

printing a first lattice structure including a first network of struts and nodes with voids formed between the struts and nodes; and

simultaneous with printing the first lattice structure, printing a second lattice structure including a second network of struts and nodes with voids formed between the struts and nodes, the first network of struts and nodes interwoven with the second network of struts and nodes such that the first network of struts and nodes extends through the voids in the second network of struts and nodes.

20. The method of manufacturing a cushioning member of claim 19, the method further comprising printing a platform with the first lattice structure and the second lattice structure both connected to the platform, wherein each node is defined by at least two struts extending from said node, and wherein the first network of struts and nodes is independent of and disengaged from the second network of struts and nodes.