ARTICLE OF FOOTWEAR HAVING A POLYGON LUG SOLE PATTERN

• US 20140352083A1
• Filed: 08/14/2014
• Published: 12/04/2014
• Est. Priority Date: 02/28/2007
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: AVAR, Eric P., HOFFER, Kevin W., HATFIELD, Tobie D.
• Granted Patent: US 10,278,456 B2
• Time in Patent Office: Days
• US Class Current: 12/142.R
• CPC Class Codes: A43B 1/0009 made at least partially of alveolar or honeycomb material
• CPC Class Codes: A43B 13/141 with a part of the sole being flexible, e.g. permitting articulation or torsion
• CPC Class Codes: A43B 13/16 Pieced soles with several layers of different material A43B13/12
• CPC Class Codes: A43B 13/184 the structure protruding from the outsole
• 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 13/223 Profiled soles
• CPC Class Codes: A43B 13/26 projecting beyond the sole surface
• CPC Class Codes: A43D 86/00 Machines for assembling soles or heels onto uppers, not provided for in groups A43D25/00 - A43D83/00, e.g. by welding
• CPC Class Codes: B29D 35/06 having soles or heels formed and joined on to preformed uppers using a moulding technique, e.g. by injection moulding, pressing and vulcanising
• CPC Class Codes: B29D 35/122 Soles

Abstract

Articles of footwear, including athletic footwear, include one or more of: (a) an upper; (b) a sole structure including a midsole and an outsole, the outsole having a plurality of polygonal lugs arranged about a base surface of the outsole. The outsole may include one or more regions wherein the characteristics of a portion of the lugs within a region differ from the characteristics of a portion of the lugs in another region. The lugs may differ, for example based on size, construction and/or spacing between the lugs. Methods of manufacturing such articles of footwear also are disclosed.

Claims

1. A method of manufacturing an article of footwear, comprising:

providing a mold of a first portion of the article of footwear, the mold defining a plurality of lugs having a uniform, polygonal shape, wherein the distal ends of the lugs are not in contact with each other;

filling the mold with a polyurethane;

removing excess polyurethane from the mold;

adding a second portion of the article of footwear to the mold; and

applying at least one of heat and pressure to engage the first portion and the second portion.

2. The method of manufacturing an article of footwear of claim 1, wherein the second portion of the article of footwear includes a textile portion of an upper.

3. The method of manufacturing an article of footwear of claim 1, wherein the second portion of the article of footwear includes a leather portion of an upper.

4. The method of manufacturing an article of footwear of claim 1, wherein the second portion of the article of footwear includes a portion of a midsole.

5. A method of manufacturing a portion of an article of footwear, comprising:

providing a mold of a first portion of the article of footwear, the mold defining a plurality of hexagonal lugs wherein the hexagonal lugs are sized or spaced from one another to provide regions of different impact-attenuation characteristics, wherein the plurality of hexagonal lugs includes a first hexagonal lug having two adjacent sides nested within an area defined by sides of two adjacent hexagonal lugs, and wherein the distal ends of the lugs are not in contact with each other;

filling the mold with a polyurethane; and

removing excess polyurethane from the mold.

6. The method of manufacturing a portion of an article of footwear of claim 5 further comprising:

adding a second portion of the article of footwear to the mold, and

7. The method of manufacturing a portion of an article of footwear of claim 5 further comprising:

applying at least one of heat and pressure to engage the first portion and the second portion.

8. The method of manufacturing a portion of an article of footwear of claim 6, wherein the second portion of the article of footwear includes a portion of an upper.

9. The method of manufacturing a portion of an article of footwear of claim 6, wherein the second portion of the article of footwear includes a portion of a midsole.

10. The method of manufacturing a portion of an article of footwear of claim 5, wherein the hexagonal lugs are non-uniformly sized.

11. A method of manufacturing a portion of an article of footwear, comprising:

providing a mold of an outsole of the article of footwear, the mold defining a first region including a first plurality of polygonal lugs arranged in a central portion of the outsole and a second region including a second plurality of polygonal lugs being arranged around a periphery of the central portion, and wherein the distal ends of the lugs are not in contact with each other;

filling the mold with a polyurethane; and

removing excess polyurethane from the mold.

12. The method of manufacturing a portion of an article of footwear of claim 11 further comprising:

adding a second portion of the article of footwear to the mold, and

applying at least one of heat and pressure to engage the first portion and the second portion.

13. The method of manufacturing a portion of an article of footwear of claim 12, wherein the second portion of the article of footwear includes a textile portion of an upper.

14. The method of manufacturing a portion of an article of footwear of claim 12, wherein the second portion of the article of footwear includes a leather portion of an upper.

15. The method of manufacturing a portion of an article of footwear of claim 12, wherein the second portion of the article of footwear includes a portion of a midsole.

16. The method of manufacturing a portion of an article of footwear of claim 11, wherein the first plurality polygonal lugs have a hollow construction and a first wall thickness and the second plurality of polygonal lugs have a hollow construction and a second wall thickness.

17. The method of manufacturing a portion of an article of footwear of claim 16, wherein the first wall thickness is between 3 mm and 20 mm.

18. The method of manufacturing a portion of an article of footwear of claim 16, wherein the second wall thickness is between 1 mm and 5 mm.

19. The method of manufacturing a portion of an article of footwear of claim 11, wherein the first plurality polygonal lugs have first spacing arrangement and the second plurality of polygonal lugs have a second spacing arrangement.

20. The method of manufacturing a portion of an article of footwear of claim 19, wherein the first spacing arrangement includes more closely positioned lugs than the second spacing arrangement.