Article Of Footwear With Extruded Components

• US 20150040428A1
• Filed: 08/08/2014
• Published: 02/12/2015
• Est. Priority Date: 08/09/2013
• Status: Active Grant

• Current Assignee: Reebok International Limited (Authentic Brands Group, LLC)
• Original Assignee: Reebok International Limited (Authentic Brands Group, LLC)
• Inventors: DAVIS, Paul, ANDREWS, Mike, SIMONE, Dustin
• Granted Patent: US 10,945,488 B2
• Time in Patent Office: Days
• US Class Current: 36/83
• CPC Class Codes: A43B 13/023 Soles with several layers of the same material
• CPC Class Codes: A43B 13/12 Soles with several layers of different materials
• 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 23/0245 characterised by the constructive form
• CPC Class Codes: B29C 64/106 using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
• CPC Class Codes: B29C 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• CPC Class Codes: B29D 35/142 Soles
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing

Abstract

The disclosed embodiments relate to portions of an article of footwear formed from an extruded member. In certain embodiments, a sole or portion of a sole can be formed from one or more extruded members. In certain embodiments, the extruded member can be a single, continuous piece of solid material. In certain embodiments, a sole for an article of footwear can be fashioned from an extruded member formed in a controlled geometric pattern. In certain embodiments, the sole can include one or more layers.

Claims

1. A sole for an article of footwear, the sole comprising:

one or more solid extruded members formed in a controlled geometric pattern having one or more layers.

2. The sole of claim 1, comprising a single solid extruded member forming a plurality of layers.

3. The sole of claim 1, wherein a first layer comprises a first solid extruded member and a second layer comprises a second solid extruded member.

4. The sole of claim 1, wherein a first layer runs in a transverse direction of the sole and a second layer runs in a lengthwise direction of the sole.

5. The sole of claim 1, wherein a first layer runs in a lengthwise direction of the sole and a second layer runs in a transverse direction of the sole.

6. The sole of claim 1, wherein a first layer and a third layer run in a first direction and a second layer runs in a second direction.

7. The sole of claim 1, wherein a rearfoot area of the sole comprises more layers than a midfoot area and forefoot area of the sole.

8. The sole of claim 1, wherein a rearfoot area of the sole comprises a coiled shape.

9. The sole of claim 1, wherein at least one layer comprises a pattern having one or more gaps between the one or more solid extruded members.

10. The sole of claim 1, wherein at least one layer comprises a pattern having a plurality of undulations.

11. The sole of claim 10, wherein each undulation contacts an adjacent undulation.

12. The sole of claim 10, wherein the undulations run in a transverse direction of the sole.

13. The sole of claim 10, wherein each undulation forms a loop.

14. The sole of claim 10, wherein the undulations extend from a medial side to a lateral side of the sole.

15. The sole of claim 1, wherein a first portion of the solid extruded member comprises a first thickness and a second portion of the solid extruded member comprises a second thickness.

16. The sole of claim 1, wherein a first portion of the solid extruded member comprises a first density and a second portion of the solid extruded member comprises a second density.

17. The sole of claim 1, wherein a first portion of the solid extruded member comprises a first material and a second portion of the solid extruded member comprises a second material.

18. The sole of claim 1, wherein the solid extruded member comprises thermoplastic.

19. The sole of claim 1, wherein the solid extruded member comprises foam.

20. The sole of claim 1, wherein the solid extruded member comprises a substantially circular cross-section.

21. The sole of claim 1, further comprising a support member.

22. The sole of claim 21, wherein the support member is located between a first and second layer of the one or more solid extruded members.

23. The sole of claim 21, wherein the support layer is located in a rearfoot area of the sole.

24. The sole of claim 1, further comprising an insole attached to a top surface of the one or more solid extruded members and an outsole attached to a bottom surface of the one or more solid extruded members.

25. The sole of claim 1, wherein the one or more solid extruded members are extruded directly onto an upper surface of an outsole.

26. A method of manufacturing a sole for an article of footwear, the method comprising:

extruding one or more solid elongated members in a controlled geometric pattern.

27. The method of claim 26, wherein extruding one or more solid elongated members comprises forming a plurality of layers.

28. The method of claim 26, wherein extruding one or more solid elongated members comprises extruding a single, continuous elongated member.

29. The method of claim 26, wherein the solid elongated member is extruded directly onto an upper surface of an outsole.

30. An article of footwear, comprising:

an upper; and

a sole attached to the upper, the sole comprising a single, continuous piece of extruded material.