Method for forming three-dimensional structures with different material portions

• US 9,676,159 B2
• Filed: 05/09/2014
• Issued: 06/13/2017
• Est. Priority Date: 05/09/2014
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Sterman, Yoav, Waatti, Todd A.
• Primary Examiner(s): Lee, Edmund
• Application Number:
  US14/273,675
• Publication Number:
  US 20150321434A1
• Time in Patent Office: 1,131 Days
• Field of Search: None
• CPC Class Codes: A43B 13/26 projecting beyond the sole surface
• CPC Class Codes: A43B 5/00 Footwear for sporting purposes non-skid devices, e.g. ice-spurs or studs for football shoes, A43C15/00
• CPC Class Codes: A43C 15/162 characterised by the shape
• CPC Class Codes: A43C 19/00 Attachments for footwear, not provided for in other groups of this subclass
• CPC Class Codes: A43C 3/00 Hooks for laces making from sheet metal B21D53/46; Guards for hooks
• CPC Class Codes: B29C 37/0078 Measures or configurations for obtaining anchoring effects in the contact areas between layers surface shaping B29C59/00; B29C66/02 takes precedence
• CPC Class Codes: B29C 37/0085 by means of openings in the layers joining through openings B29C66/304
• CPC Class Codes: B29C 48/152 the inner surfaces thereof
• CPC Class Codes: B29C 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• CPC Class Codes: B29C 64/386 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B29C 70/745 Filling cavities in the preformed part for joining B29C70/84
• CPC Class Codes: B29D 35/12 Producing parts thereof, e.g. soles, heels, uppers, by a moulding technique
• CPC Class Codes: B29K 2021/00 Use of unspecified rubbers as moulding material
• CPC Class Codes: B29L 2031/50 Footwear, e.g. shoes or parts thereof
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing

Abstract

A system and method for forming 3D printed structures includes printing an outer shell portion and filling an interior of the outer shell portion to form an inner portion. The outer shell portion and inner portion may have differing material properties. The outer shell portion may be anchored to the base component.

Claims

1. A method of manufacturing a structure for permanent attachment to a base component of an article of apparel, comprising:

forming an outer shell portion of the structure on a surface of the base component by printing a first material onto the base component using a nozzle, wherein the outer shell portion is formed with at least one opening and wherein the outer shell portion is bonded to the base component; and

filling an interior of the outer shell portion by extruding a second material through the nozzle and into the at least one opening, thereby forming an inner portion of the structure.

2. The method according to claim 1, wherein the outer shell portion is more rigid than the inner portion.

3. The method according to claim 1, wherein the outer shell portion is less rigid than the inner portion.

4. The method according to claim 1, wherein the article of apparel is an article of footwear.

5. The method according to claim 1, wherein the outer shell portion is cured before the second material is extruded into the interior of the outer shell portion.

6. The method according to claim 1, wherein the first material has a first rigidity when the outer shell portion is cured and wherein the second material has a second rigidity when the inner portion is cured.

7. The method according to claim 6, wherein the second rigidity is greater than the first rigidity.

8. The method according to claim 7, wherein the first material is rubber and the second material is a plastic material.

9. The method according to claim 6, wherein the second rigidity is less than the first rigidity.

10. The method according to claim 9, wherein the first material is a plastic material and the second material is a foam material.

11. The method according to claim 1, wherein the first material and the second material are the same material.

12. The method according to claim 1, wherein the article of apparel is an article of footwear, the structure is a cleat member and the base component is a sole structure of the article of footwear.

13. The method according to claim 1, wherein the outer shell portion is formed using a filament fused fabrication printing process.

14. The method according to claim 1, wherein the method includes forming a portion of the structure extending outside of the outer shell portion, wherein the portion of the structure is formed from the second material.

15. The method according to claim 1, wherein the method includes forming several anchored portions on the second side of the base component, wherein the outer shell portion is integrally formed with each of the several anchored portions.

16. The method according to claim 1, wherein the outer shell portion helps to keep the inner portion in place on the base component.