Embroidered Foaming Cords For Midsoles

• US 20190014859A1
• Filed: 07/13/2017
• Published: 01/17/2019
• Est. Priority Date: 07/13/2017
• Status: Active Grant

• Current Assignee: Under Armour Incorporated
• Original Assignee: Under Armour Incorporated
• Inventors: Luedecke, Tom, Zhu, Carmen
• Granted Patent: US 11,033,073 B2
• Time in Patent Office: Days
• CPC Class Codes: A43B 13/04 Plastics, rubber or vulcanised fibre
• CPC Class Codes: A43B 13/125 characterised by the midsole or middle layer
• 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 13/188 Differential cushioning regions
• CPC Class Codes: B29D 35/0063 Moulds
• CPC Class Codes: D05C 17/00 Embroidered or tufted products; Base fabrics specially adapted for embroidered work; Inserts for producing surface irregularities in embroidered products layered products B32B; non-woven pile fabrics D04H11/00
• CPC Class Codes: D05C 7/08 for attaching cords, tapes, bands, or the like
• CPC Class Codes: D10B 2501/043 Footwear

Abstract

In one embodiment, a midsole for an article of footwear is described that includes a first foaming cord made of a first material and a second foaming cord made of a second material. The first material is different than the second material. The first foaming cord and the second foaming cord are embroidered into a shape of the midsole. The first foaming cord and the second foaming cord may be embroidered to a substrate material by thread. A midsole can include multiple layers of foaming cords. Customized midsoles may be formed by selective placement of one or more foaming cords in different locations or layers to provide different properties or characteristics to the midsole.

Claims

1. An article of footwear comprising:

an upper; and

a sole assembly;

wherein the sole assembly includes a midsole comprising at least a first foaming cord made of a first material and a second foaming cord made of a second material, the first material being different than the second material; and

wherein the first foaming cord and the second foaming cord are embroidered into a shape of the midsole.

2. The article of footwear according to claim 1, wherein the first material and the second material have different densities or compressibilities.

3. The article of footwear according to claim 1, wherein the first material is harder than the second material.

4. The article of footwear according to claim 1, wherein the first foaming cord is embroidered in a different region of the midsole than the second foaming cord.

5. The article of footwear according to claim 1, wherein the first foaming cord is embroidered in a different layer of the midsole than the second foaming cord.

6. The article of footwear according to claim 1, wherein the midsole further comprises a substrate material;

and

wherein the first foaming cord and the second foaming cord are embroidered to the substrate material by thread.

7. The article of footwear according to claim 1, wherein the sole assembly further comprises an outsole and an insole.

8. The article of footwear according to claim 7, wherein the second foaming cord is embroidered on top of the first foaming cord to form the insole;

and

wherein a third foaming cord is embroidered beneath the first foaming cord to form the outsole.

9. A midsole for an article of footwear, the midsole comprising:

a first foaming cord, the first foaming cord made of a first material; and

a second foaming cord, the second foaming cord made of a second material different from the first material; and

wherein the first foaming cord and the second foaming cord are embroidered to a substrate material by thread.

10. The midsole for an article of footwear according to claim 9, wherein the midsole includes a forefoot region, a midfoot region, and a heel region;

wherein the first foaming cord is embroidered to the substrate material in at least the forefoot region or the midfoot region to provide a first region of the midsole having a first level of compressibility; and

wherein the second foaming cord is embroidered to the substrate material in at least the heel region to provide a second region of the midsole having a second level of compressibility different than the first region.

11. The midsole for an article of footwear according to claim 9, wherein the first foaming cord is disposed along an outer perimeter of the midsole;

and

wherein the second foaming cord is disposed within the inner portion of the midsole.

12. The midsole for an article of footwear according to claim 9, wherein the second foaming cord is embroidered on top of the first foaming cord.

13. The midsole for an article of footwear according to claim 9, wherein the substrate material is dissolvable.

14. The midsole for an article of footwear according to claim 9, wherein the midsole comprises at least three layers of the first foaming cord and/or the second foaming cord.

15. A method of forming a midsole for an article of footwear, the method comprising:

embroidering a first foaming cord to a substrate material with a thread;

embroidering a second foaming cord to the substrate material with the thread;

wherein the first foaming cord and the second foaming cord are made of different materials.

16. The method of forming a midsole according to claim 15, further comprising:

determining a midsole arrangement;

wherein the step of embroidering the first foaming cord comprises embroidering the first foaming cord to the substrate material to form a first region of the midsole according to the determined midsole arrangement; and

wherein the step of embroidering the second foaming cord comprises embroidering the second foaming cord to the substrate material to form a second region of the midsole according to the determined midsole arrangement, the second region being different from the first region.

17. The method of forming a midsole according to claim 16, wherein the step of determining the midsole arrangement comprises using data associated with a foot of a wearer to determine the midsole arrangement.

18. The method of forming a midsole according to claim 15, further comprising removing the portion of the substrate material including the first foaming cord and the second foaming cord from the remaining substrate material to form a midsole preform.

19. The method of forming a midsole according to claim 18, further comprising:

placing one or more midsole preforms into a corresponding mold cavity in a mold; and

molding the one or more midsole preforms into midsoles by applying heat and/or pressure to cause the first foaming cord and the second foaming cord to expand.

20. The method of forming a midsole according to claim 15, further comprising embroidering at least one additional foaming cord on top of the first foaming cord or the second foaming cord to form a multiple layer midsole.