[0001] Footwear tends to be mass produced with variance among a specific style or type of footwear typically being limited to size. Mass production of footwear is facilitated by industrial processes, such as injection molding, that are effective in keeping costs down when many of the same item are made.

BRIEF DESCRIPTION OF THE DRAWINGS

[0002] FIG. 1 is a bottom perspective view of an example midsole that includes a bridge component that joins other midsole components.

[0003] FIG. 2 is a bottom exploded perspective view of the example midsole of FIG. 1.

[0004] FIG. 3 is a top perspective view of the example midsole of FIG. 1.

[0005] FIG. 4 is a top exploded perspective view of the example midsole of

FIG. 1.

[0006] FIG. 5 is a perspective view of an example bridge component and example midsole components that include a protrusion and recess connection structure.

[0007] FIG. 6 is a partial cross-sectional view of an example edge and groove arrangement.

[0008] FIG. 7 is a perspective view of an example apparatus to manufacture an article of footwear including a midsole with a bridge component. [0009] FIG. 8 is a flowchart of an example method of making an article of footwear specific to a wearer using a midsole bridge.

[0010] FIG. 9 is a flowchart of an example method of making an article of footwear specific to a wearer using midsole bridges.

[0011] FIG. 10A is a schematic diagram of an example midsole with three midsole components joined by two bridge components.

[0012] FIG. 10B is a schematic diagram of an example midsole with midsole components joined by a bridge component with two rearward legs.

[0013] FIG. 10C is a schematic diagram of an example midsole with midsole components joined by a bridge component with two opposing legs.

[0014] FIG. 11 is a perspective view of an example article of footwear with a midsole including a bridge component that bonds midsole components.

DETAILED DESCRIPTION

[0015] Footwear often lacks customizable features, such as orthopedic performance characteristics, specific to an individual wearer or group of wearers. The mass production technologies that keep costs low also tend to inhibit wearer-specific customization.

[0016] A footwear midsole can provide various characteristics to an article of footwear. The midsole can be instrumental in the configuration of an orthopedic or other performance characteristic, such as rebound and energy transfer.

[0017] To provide customizability of characteristics, a midsole may be made of several partial midsole components, such as a forward component and a rearward component, which may be provided with different physical properties. Each component may be provided with a specific shape, material, and construction, which may be varied from component to component. As such, a midsole may be customized for a wearer or group of wearers by configuring and joining partial midsole components to form a complete midsole. [0018] A bridge component joins partial midsole components. The bridge component is located towards the underside of the midsole components and may be adjacent the outsole. The bridge component may serve to attach the midsole components and augment the characteristics provided to the completed midsole. A second bridge component may be located towards the upper side of the midsole components and may be adjacent the upper of the article of footwear. The second bridge component may also serve to attach the midsole components and further augment the characteristics provided to the completed midsole, such as arch support.

[0019] A bridge may provide additional orthopedic function to the midsole while aiding midsole manufacturing by joining midsole components.

[0020] A bridge may include a leg that provides a bonding surface to a midsole component. Bonding strength may be increased by a recess and protrusion structure. An edge of the leg may fit into a groove of the midsole component to provide securement. A bridge may have four legs in an H-like arrangement.

[0021] Midsole components may be made by three-dimensional (3D) printing, such as additive printing techniques, to allow for efficient customizability and reduced time of manufacture. Midsole components may be made by other techniques, such as injection molding and milling or machining.

[0022] Properties of a wearer’s foot may be captured using a digital acquisition technique, such as a pressure sensor array or optical scanner with a connected computing device. Foot property data, such as shape and pressure, may be used to select suitable midsole components, including a bridge, from a library. A selected midsole component may be pulled from a stock of premade components or 3D printed on demand. Additionally or alternatively, data for a midsole component may be generated using the foot property data, and the midsole component may be 3D printed on demand. [0023] The customized midsole formed from components selected or generated for the wearer or group of wearers may then be combined with an outsole and upper to form a customized article of footwear.

[0024] FIGs. 1-4 show an example midsole 100 for an article of footwear, such as a shoe. The midsole 100 may be positioned between an outsole and an upper to form the article of footwear.

[0025] The midsole 100 includes a forward midsole component 102, a rearward midsole component 104, and a bridge component 106. The bridge component 106 may attach the forward and rearward midsole components 102,

104 on outsole sides 110, 112 of the components 102, 104. The bridge component 106 may be considered a lower bridge component. The midsole 100 may further include an upper bridge component 108.

[0026] The components 102-108 may be shaped to provide support to a wearer’s foot. The shape, material, and construction of the components 102-108 may be selected to provide a desired performance for the wearer. For example, the components 102-108 may provide a customized orthopedic function, such as an orthopedic correction to address plantar fasciitis, pronation, supination, or similar concern. Additionally or alternatively, the components 102-108 may provide a customized energy transfer characteristic, rebound profile, or similar.

[0027] Each component 102-108 may provide support and other performance characteristic at its location. The forward midsole component 102 may provide a performance characteristic to the wearer’s forefoot. The rearward midsole component 104 may provide a performance characteristic to the wearer’s hindfoot or heel. The upper bridge component 108 may provide a performance characteristic to the wearer’s midfoot and arch. The lower bridge component 106 may provide a performance characteristic to the wearer’s midfoot. The lower bridge component 106 may provide stiffness to the forward and rearward midsole components 102, 104. [0028] Customization may be provided by selecting the components 102-108 from a library of modular components. Such a library may include premade components, computer aided design (CAD) data for components 102-108 to be made on demand, or a combination of such. Customization may be directed to an individual wearer or group of wearers. For example, with five variations of each of the four components 102-108, 625 unique combinations are possible, which may be sufficient to meet the needs of a population of wearers who may be categorized into as similar number of groups. If 300 variations of each of the four components 102-108 are provided, then the possible unique combinations outnumber the number of possible wearers, which is more than sufficient to provide individual customization. Of course, different numbers of variations of the components 102-108 may be provided.

[0029] Each of the components 102-108 may be made by injection molding, 3D printing, composite material manufacturing technique, or a combination of such. The components 102-108 may include materials such as polyurethane (PU), thermoplastic polyurethane (TPU), other plastics/polymers, synthetic or natural rubber, carbon fiber, metal, stamped metal, wood, formed wood, natural or synthetic fiber, or similar. In some examples, the components 102-108 are manufactured using a 3D printing technique. This enables rapid and efficient manufacture with a high degree of customizability. In other examples, the forward and rearward midsole components 102, 104 are injection molded and the lower bridge component 106 and/or the upper bridge component 108 is 3D printed. This may allow for a stock of various forward and rearward midsole components 102, 104 to be mass produced while further allowing a finer degree of customizability by way of the lower bridge component 106 and/or the upper bridge component 108. Other combinations of manufacturing techniques may be used to arrive at other balances between the efficiency of mass production and the customizability of 3D printing.

[0030] A 3D printing technique may be used to fuse material, such as powder, to form a printed component 102-108. In a suitable powder-bed material fusion printing system, layers of powder are progressively introduced and select portions of each layer are fused with the previous layer. Material fusion may be performed using an energy source, a light source, laser, electron beam, a chemical fusing agent, binding agent, curing agent, an energy absorbing fusing agent, or combination of such that may be jetted or sprayed (e.g., via a thermal or piezo inkjet-type printhead), or similar. Fused layers thereby form a printed article and unfused material may be recovered and recycled.

[0031] The forward and rearward midsole components 102, 104 may have a cellular or matrix structure that is gas-entraining. An example matrix construction 114 includes a 3D geometric lattice of linear members that connect at nodes. Air or other gas may permeate the forward and rearward midsole components 102, 104 to provide a customizable support or cushioning effect with a lightweight form. The forward and rearward midsole components 102,

104 may be made of foam.

[0032] The upper bridge component 108 may be made of foam or other construction discussed above for the components 102, 104.

[0033] The lower bridge component 106 may be formed of a relatively solid structure, such as solid plastic. The lower bridge component 106 may be formed of generally planar bodies. The solid planar construction of the lower bridge component 106 may provide for sturdy attachment to the forward and rearward midsole components 102, 104 as well as rigidity and resiliency to the midsole 100 at a location directly adjacent the outsole. In other examples, the lower bridge component 106 may be hollow, have hollow volumes, or may include openings.

[0034] The lower bridge component 106 is mated with the outsole side 110 of the forward midsole component 102 and the outsole side 112 of the rearward midsole component 104 to permanently attach the forward and rearward midsole components 102, 104. The lower bridge component 106 may be bonded to the forward and rearward midsole components 102, 104 by an adhesive or glue, by heat, or by other bonding technique. Because of the lower bridge component 106, the forward and rearward midsole components 102, 104 may not need to be bonded directly to each other. However, bonding the forward and rearward midsole components 102, 104 directly to each other may increase strength.

[0035] The lower bridge component 106 may include a body 116 extending within a gap 118 between the forward midsole component 102 and the rearward midsole component 104 when the components 102, 104 are brought together. The body 116 may include a ridge 120 that occupies the gap 118 to form a joint among the bridge component 106 and the midsole components 102, 104. The body 116 may fill the gap 118 completely. The lower bridge component 106 may thereby provide strength and sturdiness to the joint, which could otherwise be weak and a possible point of failure.

[0036] The lower bridge component 106 may include a forward leg 122 extending from the body 116 in a forward direction. As shown in FIG. 4, the forward leg 122 may be shaped to provide a planar surface 400 to contact the outsole side 110 of the forward midsole component 102. As shown in FIG. 2, the outsole side 110 may have a depression 126 to accommodate the forward leg 122, so that the outsole side of the midsole assembly is relatively flush. The forward leg 122 is large enough to provide sufficient contact surface area with the forward midsole component 102 to develop suitable bonding strength. In this example, the lower bridge component 106 includes two of such forward legs 122, 128 at opposite sides of the forward midsole component 102.

[0037] Similarly, the lower bridge component 106 may include a rearward leg 130 extending from the body 116 in a rearward direction. As shown in FIG. 4, the rearward leg 130 may be shaped to provide a planar surface 402 to contact the outsole side 112 of the rearward midsole component 104. As shown in FIG. 2, the outsole side 112 may have a depression 134 to accommodate the rearward leg 130, so that the outsole side of the assembly is relatively flush. The rearward leg 130 is large enough to provide sufficient contact surface area with the rearward midsole component 104 to develop suitable bonding strength. In this example, the lower bridge component 106 includes two rearward legs 130, 136 at opposite sides of the rearward midsole component 102.

[0038] In this example, the lower bridge component 106 includes four legs 122, 128, 130, 136 in an H-like arrangement with respect to the body 116. In other examples, the lower bridge component 106 may include more or fewer legs.

[0039] The legs 122, 128, 130, 136 may each have a shape, material, and construction to provide a desired performance characteristic to the midsole 100. For example, inside legs 122, 130 near the wearer’s arch may be made thicker and more rigid to provide greater stiffness to support the wearer’s arch.

[0040] The upper bridge component 108 is mated with the upper side 300 of the forward midsole component 102 and the upper side 302 of the rearward midsole component 104. The upper bridge component 108 may be bonded to the forward and rearward midsole components 102, 104 by an adhesive or glue, by heat, or by other bonding technique. The upper bridge component 108 may aid the permanent attachment of the forward and rearward midsole components 102, 104 provided by the lower bridge component 106.

[0041] The upper bridge component 108 may include a body 200 extending across the gap 118 formed between the forward midsole component 102 and the rearward midsole component 104 when the components 102, 104 are brought together. The body 200 may overlie the gap 118 completely and sandwich the gap 118 with the body 116 of the lower bridge component 106.

The upper bridge component 108 may thereby add strength and sturdiness to the joint formed where the components 102, 104 meet.

[0042] The joint 304, circled in FIG. 3, is a localized region where the forward and rearward midsole components 102, 104 and the lower and upper bridge components 106, 108 meet and may be mutually bonded.

[0043] The upper bridge component 108 may include a forward leg 202 extending from the body 200 in a forward direction. The forward leg 202 may be shaped to fit within a recess or pocket 404 in the forward midsole component 102, so as to provide the desired performance characteristic as well as enough contact surface area to develop sufficient bonding strength. In this example, the upper bridge component 108 includes two forward legs 202, 204 at opposite sides of the forward midsole component 102.

[0044] Similarly, upper bridge component 108 may include a rearward leg 206 extending from the body 200 in a rearward direction. The rearward leg 206 may be shaped to fit within a recess 406 in the rearward midsole component 104, so as to provide the desired performance characteristic as well as enough contact surface area to develop sufficient bonding strength. In this example, the upper bridge component 108 includes two rearward legs 206, 208 at opposite sides of the rearward midsole component 104.

[0045] In this example, the upper bridge component 108 includes four legs 202-208 in an H-like arrangement with respect to the body 200. In other examples, the upper bridge component 108 may include more or fewer legs.

[0046] The legs 202-208 may each have a shape, material, and construction to provide a desired performance characteristic to the midsole 100. For example, inside legs 204, 206 may be made of relatively dense material to provide greater support to the wearer’s arch. A leg 202-208 may have a lobe like shape.

[0047] As shown in FIG. 5, a lower bridge component 500 may include protrusions 502 (or raised areas or bosses) to mate with complementary recesses 504 (or holes) on an outsole side 506 of a forward midsole component 508 and/or to mate with complementary recesses 510 (or holes) on an outsole side 512 of a rearward midsole component 514. The protrusions 502 and recesses 504, 510 may be shaped to provide a snap fit. The protrusions 502 and recesses 504, 510 may provide increased surface area for adhesive, glue, or other bonding technique. In other examples, recesses 504, 510 are provided to the lower bridge component 500 and protrusions 502 are provided to the forward and rearward midsole components 508, 514. In still other examples, protrusions 502 and recesses 504, 510 are arranged on the lower bridge component 500 and forward and rearward midsole components 508, 514 according to another pattern.

[0048] As shown in FIG. 2, an inner edge 210 of a leg 128 of the lower bridge component 106 may be shaped to mate with a groove 212 on the forward midsole component 102 defined by an edge of a depression 214 in the forward midsole component 102. The groove 212 may provide an undercut that prevents the forward leg 128 from lifting out of or being laid into the depression 214. The groove 212 may constrain the forward leg 128 of the lower bridge component 106 to be slid into/out of the depression 214 in a direction along the length of the leg 128. An inner edge of any of the forward legs 122, 128, may be shaped to mate with such a complementary groove. In this example, all inner edges of both forward legs 122, 128 as so shaped to mate with grooves at the depressions.

[0049] Similarly, any of the rearward legs 130, 136 of the lower bridge component 106 may be shaped to mate with a complementary groove on the rearward midsole component 104, in the manner as described above.

[0050] FIG. 6 shows a cross-section of an example edge and groove arrangement to prevent the detachment of the lower bridge component 106 from a forward or rearward midsole component 102, 104. A forward or rearward midsole component 102, 104 defines a depression 600 to accommodate a leg of a bridge component 106. An inner edge of the depression is shaped to define a groove 602 to fit a complementarily shaped outer edge 604 of the bridge component 106. As such, the bridge component 106 cannot be readily detached from the forward or rearward midsole component 102, 104 in the direction of an axis 606 perpendicular to the plane of the midsole/outsole.

[0051] With reference back to FIGs. 1-4, the forward midsole component 102 may be slid 220 onto the lower bridge component 106, the rearward midsole component 104 may be slid 222 onto the lower bridge component 106, and the upper bridge component 108 may be lowered 224 onto the subassembly of the midsole components 102, 104 and lower bridge component 106.

[0052] FIG. 7 shows an example apparatus 700 to assembly a midsole of an article of footwear, such as a shoe. The apparatus 700 may be used with a carousel-type machine that rotates among a plurality of different stations. The apparatus includes a frame 702.

[0053] The frame 702 defines a cavity 708. The frame 702 may include opposing side frames 710, 712 and a bottom frame 714. The frame 702 receives a last 716 that carries an upper 718 of an article of footwear that is under manufacture to enable the bonding of a midsole to the upper 718. The side frames 710, 712, bottom frame 714, and the last 716 may be movable with respect to each other to open and close the cavity 708. The opposing side frames 710, 712, bottom frame 714, and upper 718 as carried by the last 716 may be brought into mutual engagement to close the cavity 708.

[0054] An outsole 720 may be inserted into the cavity 708. Then, various components 722, 724, 726, 728 of a midsole may be assembled and bonded to the outsole 720. Examples of midsole components include a forward midsole component 722, a rearward midsole component 724, a lower bridge component 726, and an upper bridge component 728.

[0055] The last 716 may then be lowered to bond the upper 718 to the assembled midsole, thereby completing an article of footwear.

[0056] FIG. 8 shows an example method 800 of manufacturing an article of footwear that includes a midsole with a bridge to attach different midsole components. The method 800 may be performed with the example apparatus 700 of FIG. 7. The method 800 may be performed with other apparatuses. FIGs. 1-6 may be referenced for example midsole structures. The method begins at block 802.

[0057] At block 804, data of a wearer’s foot is captured. This may be done with a pressure sensor array, a 3D scanner or camera system, and/or other biometric measurement technique to capture the shape and/or other properties of the foot. Such captured data may be used to determine the structure and composition of the midsole to be manufactured and, particularly, an orthopedic characteristic of the midsole.

[0058] At block 806, midsole components are selected or generated based on the data captured for the wearer’s foot. An orthopedic analysis of the wearer may be performed to configure the midsole components. The shape, material, and construction of each component may be selected as specific to the wearer or group to which the wearer belongs. A midsole component may be selected from a library 808 of modular components or created on-demand, such as by 3D printing.

[0059] A library 808 may include a stock of premade components, pre generated CAD data useable to make components, parametric CAD models, or a combination of such. Parametric CAD may be used, where a parameter from the wearer’s captured foot data is used to modify a CAD model to generate customized CAD data. Frequently used components may be premade and stocked using mass production techniques, such as injection molding. Components that are used less often may be created on demand, such as by 3D printing.

[0060] A material for a midsole component may be selected for properties such as resiliency, density, color, stiffness, weight, and so on. The material may be selected in conjunction with the construction (e.g., cellular, matrix, etc.) and shape of the component to meet the orthopedic characteristic determined for the wearer. The construction of a midsole component may be selected for properties such as resiliency, density, stiffness, weight, and so on. The shape of a midsole component may be selected to provide the characteristics afforded by the material and construction to an appropriate location at the wearer’s foot. Hence, the midsole of the footwear may be customized to the wearer.

[0061] The configured midsole components include first and second components and a bridge that is to join the first and second components. In various examples, the first and second components are forefoot and hindfoot components. In other examples, different components may be located at different positions at the midsole.

[0062] At block 810, a planar surface of a selected bridge component is bonded to an outsole. An adhesive or glue may be sprayed onto the outsole and/or bridge component to achieve bonding.

[0063] At block 812, a bottom of a first midsole component and a bottom of a second midsole component are bonded to the bridge component and to the outsole. The first and second midsole components overlap with both the bridge component and the outsole, so that the components may be mutually bonded to the outsole. An adhesive or glue may be sprayed onto the outsole, first component, second component, and/or bridge component to achieve bonding.

[0064] The bonded first and second midsole components and bridge component form a customized midsole.

[0065] At block 814, an upper is bonded to top surface of the midsole, as defined by the top surfaces of the first midsole component and the second midsole component, so as to complete this stage in the manufacture of the article of footwear. The method 800 ends at block 816. Additional manufacturing may be performed, such as the insertion of an insole, laces, fasteners, and so on.

[0066] FIG. 9 shows an example method 900 of manufacturing an article of footwear that includes a midsole with a pair of bridge components. The method 900 may be performed with the example apparatus 700 of FIG. 7. The method 900 may be performed with other apparatuses. FIGs. 1-6 may be referenced for example midsole structures. The method 800 of FIG. 8 may be referenced for detail not repeated here. The method begins at block 902.

[0067] At block 804, data of a wearer’s foot is captured, and at block 806, midsole components are selected or generated based on the captured data. [0068] The configured midsole components include first and second components, a lower bridge components that is to join the first and second components, and an upper bridge component that provides a further characteristic to the midsole and that may provide further joining of the first and second components. In various examples, the first and second components are forefoot and hindfoot components. In other examples, different components may be located at different positions at the midsole.

[0069] At block 904, before the bottom of the first midsole component and the bottom of the second midsole component are bonded to the outsole, the first midsole component and the second midsole component are mechanically secured to the bridge component. This may include sliding an edge of the bridge component into a securing groove on any number midsole components.

In addition or alternatively, a recess and protrusion arrangement on the bridge and midsole components may be snapped together. Prior to mechanically securing the bridge component and first and second midsole components, the components may be sprayed with an adhesive or glue.

[0070] At block 904, any number of bridge components may be used to join the first and second midsole components, as discussed. For example, upper and lower bridge components may sandwich first and second midsole components to overlie or cover the joint formed by abutting the first and second midsole components.

[0071] At block 906, the midsole assembly formed at block 904 is bonded to an outsole.

[0072] At block 908, an upper is bonded to top surface of the midsole assembly, so as to complete this stage in the manufacture of the article of footwear. The method 900 ends at block 910. Additional manufacturing may be performed, such as the insertion of an insole, laces, fasteners, and so on.

[0073] FIGs. 10A-10C show that various midsole components and bridge components are contemplated. [0074] In FIG. 10A, a midsole 1000 includes three midsole components, such as heel, middle, toe components 1002, 1004, 1006, separated by two bridge components 1008, 1010. The bridge components 1008, 1010 may be upper and/or lower bridge components.

[0075] In FIG. 10B, a midsole 1020 includes two midsole components 1022, 1024 separated by a bridge component 1026 that includes two rearward legs and no forward leg.

[0076] In FIG. 10C, a midsole 1030 includes two midsole components 1032, 1034 separated by a bridge component 1036 that includes one forward leg and one rearward leg.

[0077] FIG. 11 shows an example of an article of footwear 1100 that may be made using the techniques discuss herein. The article of footwear 1100 may include an upper 1102 and outsole 1104 bonded to a midsole 1106. The midsole 1106 may include a bridge component 1108, 1110 that join other midsole components 1112, 1114 and together form a combined midsole assembly with a desired customized performance characteristic, tailored to an individual wearer or group of wearers.

[0078] In view of the above, it should be apparent that the techniques described herein provide for readily customizable midsoles specific to a single wearer or group of wearers. A bridge may be used to join modular midsole components with different characteristics. The bridge may itself provide a characteristic to the midsole. As such, a readily customizable and manufacturable midsole may be provided.

[0079] It should be recognized that features and aspects of the various examples provided above can be combined into further examples that also fall within the scope of the present disclosure. In addition, the figures are not to scale and may have size and shape exaggerated for illustrative purposes.