Articles and methods of manufacturing articles

• US 9,572,402 B2
• Filed: 10/21/2008
• Issued: 02/21/2017
• Est. Priority Date: 10/23/2007
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Jarvis, Kelly B.
• Primary Examiner(s): BELL, WILLIAM P
• Application Number:
  US12/255,496
• Publication Number:
  US 20090126225A1
• Time in Patent Office: 3,045 Days
• Field of Search: 121/42.P, 121/46.B, 121/46.C, 121/42.R, 36/28, 36/29, 36/35.B, 36/45, 36/30.R, 36/27, 36/30.A, 36/25.R, 264/113, 264/308, 264/401, 264/497
• US Class Current: 1/1
• CPC Class Codes: A43B 13/125 characterised by the midsole or middle layer
• CPC Class Codes: A43B 13/181 Resiliency achieved by the structure of the sole
• CPC Class Codes: A43B 13/41 combined with heel stiffener, toe stiffener, or shank stiffener
• CPC Class Codes: A43B 23/021 Leather
• CPC Class Codes: A43B 23/0215 Plastics or artificial leather
• CPC Class Codes: A43B 23/0245 characterised by the constructive form
• CPC Class Codes: A43B 9/02 Footwear stitched or nailed through
• CPC Class Codes: A43B 9/12 Stuck or cemented footwear
• CPC Class Codes: A43D 1/025 comprising optical means, e.g. mirrors, photo-electric cells, for measuring or inspecting feet
• CPC Class Codes: A43D 2200/60 Computer aided manufacture of footwear, e.g. CAD or CAM
• CPC Class Codes: B29C 64/00 Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
• CPC Class Codes: B29C 64/153 using layers of powder being selectively joined, e.g. by selective laser sintering or melting
• CPC Class Codes: B29C 65/48 using adhesives , i.e. using supplementary joining material; solvent bonding
• CPC Class Codes: B29C 65/62 Stitching
• CPC Class Codes: B29D 35/00 Producing footwear
• CPC Class Codes: B29D 35/122 Soles
• CPC Class Codes: B29D 35/126 Uppers
• CPC Class Codes: B29L 2031/504 Soles
• CPC Class Codes: B29L 2031/505 Uppers
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 80/00 : Products made by additive manufacturing

Abstract

Various articles, such as footwear, apparel, athletic equipment, watchbands, and the like, and methods of forming those articles are presented. The articles are generally formed, in whole or in part, using rapid manufacturing techniques, such as laser sintering, stereolithography, solid deposition modeling, and the like. The use of rapid manufacturing allows for relatively economical and time efficient manufacture of customized articles. Portions of the articles may be manufactured using rapid manufacturing and those portions may be joined with portions formed using conventional, non-rapid manufacturing techniques. The methods may also include performing a scan of an appropriate body part of a user, such as a foot, in order to create a customized article of footwear for the user.

Claims

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

forming at least one portion of an upper, the at least one portion of the upper being formed from a thermoplastic elastomer material fused together using a rapid manufacturing additive fabrication technique;

forming a midsole impact force attenuation system, the midsole impact force attenuation system being separate from the upper and being formed from a thermoplastic elastomer material fused together using the rapid manufacturing additive fabrication technique, wherein the midsole impact force attenuation system includes a plurality of interlocked links;

placing the midsole impact force attenuation system in a housing; and

engaging the at least one portion of the upper to the housing such that the housing is positioned to support a foot of a wearer of the article of footwear.

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

forming an upper portion using a non-rapid manufacturing technique;

forming a sole structure including;

forming a midsole impact force attenuation system from a thermoplastic elastomer material fused together using a rapid manufacturing additive fabrication technique, wherein the midsole impact force attenuation system includes a plurality of interlocking links, and

placing the midsole impact force attenuation system in a housing; and

engaging the sole structure with the upper portion such that the housing is positioned to support a foot of a wearer of the article of footwear.