This disclosure generally relates to assembling an article of footwear, to a kit and use thereof for assembling an article of footwear, to an article of footwear and manufacture of components for an article of footwear.

Examples of articles of footwear include shoes, sandals, boots and the like. Articles of footwear typically include at least an upper and a sole, which are bound together during manufacture. An upper can be made from various materials such as leather, textiles and/or synthetic materials such as plastics. A sole is typically made from more hardwearing materials, e.g. rubber or a hardwearing synthetic material. The upper and the sole can comprise layers of (different) materials.

Various techniques may be used to attach together the upper and the sole. These techniques include stitching, gluing, merging the materials under heat and/or pressure, and so on. Such techniques can require the use of special machinery and may be labour intensive. As a consequence, these techniques are often costly and time consuming. For manufacture to be economically viable, production of a large volume of a particular model of footwear in a large production unit may be required. This can result considerable wastage of resources, for example if consumer demand for the model of footwear falls short of expectations. Thus, there is a desire for flexibility in the size of production runs. It would be desirable to able to produce articles of footwear as close as possible to the place of sale, and in volumes matching consumer demand. In may also be desirable in certain occasions be able to produce just one component, one pair of components or a few pairs of components, for example a pair of replacement uppers or uppers of different design and/or colour, for an article of footwear.

Further, ecological aspects of footwear manufacture and lifecycle are becoming increasingly important considerations. For example, it is desirable to use as little energy, materials and/or chemicals (particularly adhesives) as possible during manufacture. It is also desirable to provide articles of footwear which may be easily recycled at the end of their useful lives. US2010/0024251 discloses a system for attaching a shoe upper to a shoe bottom through the use of elastic loops attached to the perimeter edge of the upper. The elastic loops are fitted to corresponding channels molded into the sidewall and lower surface of the shoe bottom. US2016/0331064 discloses attaching an upper to an outsole by elastic insertion pieces. The elastic insertion pieces are formed around the entire periphery of the upper and inserted through insertion holes formed on the outer edge of the outsole. Locking holes at the ends of the insertion pieces can be locked into locking protrusions extending from the outsole.

According to an aspect there is provided a method of assembling an article of footwear, the article of footwear comprising an upper including at least one tab having an aperture for receiving a protruding fastener element and a sole component comprising a first sole part having a first surface and a second surface and a second sole part under the first sole part having a third surface, wherein the first sole part provides at least one slot extending from the first surface for receiving the at least one tab, and the first sole part and/or the second sole part comprises at least one protruding fastener element, the method comprising: inserting the at least one tab into the at least one slot; positioning the at least one protruding fastener element into the aperture of the at least one tab; holding the at least one tab between surfaces of the first sole part and the second sole part and/or surfaces of the at least one slot to hold the at least one protruding fastener element in the aperture; and attaching the second surface of the first sole part to the third surface of the second sole part to form the article of footwear.

According to an aspect there is provided a sole part for an article of footwear, the sole part comprising at least one slot extending from a first surface of the sole part for receiving at least one tab of an upper and at least one protruding fastener element for insertion into an aperture of the at least one tab.

The at least one slot and the at least one protruding fastener element can be configured such that when the at least one tab is inserted into the at least one slot and the at least one tab is positioned over the protruding fastener element, the at least one protruding fastener element connects to the aperture of the tab, and the at least one tab is held between surfaces of the first sole part and the second sole part and/or surfaces of the at least one slot to hold the at least one protruding fastener element in the aperture, and the second surface of the sole part is configured to be attached on top of another sole part.

According to an aspect there is provided an article of footwear, comprising: an upper comprising at least one tab having an aperture; and a sole component comprising a first sole part having a first surface and a second surface, and a second sole part having a third surface the second sole part being provided under the first sole part, wherein the first sole part and/or the second sole part comprises at least one protruding fastener element, the first sole part comprises at least one slot extending from the first surface, the at least one tab being received by the at least one slot, the aperture receives the protruding fastener element and forms a connection between the upper and the sole component, the at least one tab is held between surfaces of the first sole part and the second sole part and/or surfaces of the at least one slot to hold the at least one protruding fastener element in the aperture, and the second surface is attached to the third surface.

The tabs, slots and protruding fastener elements cooperate to form connections between the upper and the first sole part. The connections are mechanical, being formed by positioning the tab such that the protruding fastener element is received in the aperture of the tab. This may simplify the assembly of the article of footwear, and reduce the need for the use of stitching, adhesives, or heat. Enclosing the connection by sandwiching the connection between a second surface (e.g. a bottom surface) of the first sole part and a third surface (e.g. a top surface or lateral surface) of the second sole part may strengthen the connection, for example by preventing the tab from working loose.

The positioning may include inserting a protruding fastener element into the aperture of the at least one tab. Alternatively or additionally, the attaching may include inserting a protruding fastener element into the aperture of the at least one tab.

The second surface may be a bottom surface of the first sole part, and the third surface may be a top surface of the second sole part. Alternatively, or in addition, lateral surfaces of the first sole part and the second sole part may be attached to each other and the tabs placed between the lateral surfaces. A lateral surface may be a rim of the second sole part. At least one slot may be a blind slot. At least one protruding fastener element may extends substantially sideways from a surface of a blind slot. In the method the at least one blind slot may be opened for inserting of the at least one tab, placing the at least on tab into the opened at least one blind slot, and closing the at least one blind slot to hold the at least at least one protruding fastener in the aperture.

A surface of at least one slot may be locked to one end of a substantially sideways extending at least one protruding fastener element after positioning the at least one protruding fastener element into the aperture.

The at least one tab may be formed integrally to the upper. This may simplify the construction of the upper, and the article of footwear and/or ensure a strong connection between the at least one tab and the body of the upper. This may also reduce the overall number of components. The robustness of the article may also be improved, because no joint between the tab and the remainder of the upper is required. The tab may be formed from the upper material, or some layers thereof. The tab may be integrated with the upper material by means of additive manufacturing technologies such as 3D printing where added material is fused with the base upper material. Moulding may also be used.

The at least one tab can be configured to have a thickness which is smaller than a thickness of a remainder of the upper. This may make it easier to insert the tabs into the slots, and/or make it easier to position correctly the upper, particularly if the upper is a leather upper.

In accordance with an aspect, the upper comprises cutaway portions arranged between adjacent tabs. The cutaway portions may increase the flexibility of the tabs and/or the upper as a whole.

The bottom surface of the first sole part may include at least one protruding fastener element. In this arrangement, the positioning operation may include folding the tab such that the aperture receives the protruding fastener element, thereby forming a connection attaching the upper to the first sole part.

Alternatively or additionally, the top surface of the second sole part may include at least one protruding fastener element. In this arrangement, the operation of attaching the bottom surface of the first sole part to a top surface of the second sole part further comprises inserting the protruding fastener element into the aperture. At !east one protruding fastener e!ement may extend substantially sideways between the first and second sole parts.

The first sole part and/or the second sole part may include at least one socket for receiving a protruding fastener element provided on the other of the first and second sole parts. In this way, the at least one protruding fastener element may be used to connect together the first and second sole parts as well as connecting the upper to the sole component.

The first sole part may comprise an insole or a foot bed. The second sole part may be an outsole.

Use of plural tabs, slots and protruding fastener elements may provide a stronger connection between the upper and the first sole part than the use of a single tab, slot and protruding fastener element.

A surface of the first sole part and a surface of the second sole part are attached via a snap fit. This may allow the first sole part and the second sole part to be attached together without the use of adhesives, stitching, or other fixing techniques. The snap fit may alternatively be used in combination with any such fixing technique. An example of a snap fit is an annular snap fit.

The at least one slot may be spaced from a perimeter of the first sole part. In this arrangement, the slot surrounds the tab in the assembled article of footwear. This may increase the strength or durability of the connections between the footwear upper and the first sole part, because the at least one slot restricts the movement of the at least one tab. Alternatively, the at least one slot may be at a perimeter of the first sole part. This may allow for easier insertion of the at least one tab into the at least one slot and/or manufacture of the slot.

The at least one tab may include a fold. In accordance with an aspect, the first surface of the first sole part and/or the second surface of the second sole part further comprises at least one recess configured to receive one folded tab. The recess may be configured to restrict lateral movement of the tab relative to the sole component in the assembled article of footwear. This may increase the robustness of the connections between the upper and the sole component. In those arrangements where the upper comprises a plurality of tabs, the first and/or second sole parts may include a plurality of such recesses. According to a more specific example, the bottom surface and/or a lateral surface of an insole and/or the upper surface of an outsole further comprises at least one recess. The recess may restrict the lateral movement of the tabs, making the connections between the footwear upper and the insole more robust. If the upper comprises a plurality of tabs, a plurality of such recesses may be present. The at least one tab can be arranged in the at least one recess.

The first sole part may comprise a rim extending from the bottom surface of the first sole part at a perimeter thereof. Alternatively, the second sole part may include a rim extending from the top surface of the second sole part at a perimeter thereof. A rim may be useful for aligning the first sole part with the second sole part. A rim may be configured to provide an interference fit between the first and second sole parts. In aspects where the first surface is a lateral surface, the second surface may be an inner surface of a rim.

The at least one protruding fastener element may be formed integrally to the sole part. This may simplify manufacture and assembly, by restricting the overall number of components. This may allow the sole part to be manufactured as a single piece, for example by moulding.

It is contemplated that the method may include any combination of the features of the above-described aspects.

Control data for manufacture of a component for an article of footwear may be received from a remote server apparatus. Manufacture of a component such as the upper by a manufacturing device may then be controlled based on the received control data. At least one fastening tab of an upper may be manufactured based on the received control data.

The first and/or second sole part may include at least one socket for receiving a protruding fastener element on the other of the first and second sole parts. In this arrangement, the protruding fastener element connects the first and second sole parts as well as connecting the upper to the sole component.

The appearance of the article of footwear may be improved, by allowing the upper to lie flush against the first sole part when the at least one tab is received in the at least one slot. This may allow for easier assembly of the article of footwear.

The aperture may comprise reinforcing means, such as eyelets or reinforcing stitching. If the upper is formed of a textile, then the weave of the textile may be configured to reinforce the aperture. The reinforcing means may improve the durability of the connections, by reducing wear on the material of the tabs.

The at least one slot may be spaced from a perimeter of the first sole part. In this arrangement, the at least one slot provides a closed loop for receiving the at least one tab. This may hold the at least one tab in position, thereby improving the strength of the connections between the upper and the insole.

In accordance with an aspect, the upper, the first sole part and the second sole part are attached without adhesive, cement and/or stitching. For some applications, avoiding the use of adhesive, cement and stitching is advantageous. For example, since mechanical connections can be undone without requiring for example the use of solvents or the like, disassembly of the article of footwear for recycling purposes is also facilitated. In alternative arrangements, an adhesive, cement and/or stitching may be used to attach together any of the upper, the first sole part and the second sole part. Using a conventional fixing technique in combination with the mechanical connections provided herein may, for example, provide a more durable article of footwear.

In accordance with a yet further aspect a method of manufacturing a first component for an article of footwear comprising at least one fastening member for interlocking with a second component of the article of footwear is provided. The method comprises sending, from a local control apparatus of a manufacturing device, a request for control data for use in manufacture of the first component to a remote control data management apparatus, the request comprising information for identifying the article of footwear, and receiving, from the remote control data management apparatus, the requested control data, and thereafter controlling the operation of the manufacturing device using the received control data to produce at least the at least one fastening member of the first component.

An apparatus for controlling a manufacturing device for manufacture of a first component for an article of footwear comprising at least one fastening member for interlocking with a second component of the article of footwear may also be provided. The apparatus is configured to send a request for control data for use in manufacture of the first component to a remote control data management apparatus, the request comprising information for identifying the article of footwear, receive, from the remote control data management apparatus, the requested control data, and control the manufacturing device based on the received control data to produce at least the at least one fastening member of the first component.

According to an aspect an additive manufacturing device is controlled based on the received control data. At least one fastening member may be 3D printed on a base material based on the control data.

At least one fastening tab member of an upper may be produced using the control data.

The request may comprise information of a desired pattern and/or shape to be produced in manufacture of the first component. Control data for manufacture of a desired pattern and/or shape may then be generated accordingly by the remote server apparatus, and send is response to the controller of the manufacturing device. The manufacturing device may then be controlled based on the control data to produce the desired pattern and/or shape on the first component.

A replacement upper may be produced using the received control data.

The manufacturing device may comprise an additive manufacturing device, for example a 3D printing apparatus, the control apparatus being configured to control additive manufacturing based on the control data. The apparatus may be configured to control 3D printing of at least one fastening member on a base material. The apparatus may be configured to control manufacturing of at least one fastening tab member of an upper using the control data.

Related aspects of the invention provide a kit for assembly of an article of footwear comprising the sole part as described immediately above, the upper and the other sole part; and the use of the kit to assemble an article of footwear. The other sole part may be in particular a second sole part as described with reference to the method or article of footwear aspects. The upper may be an upper as described with reference to the method or article of footwear aspects. The kit may be used to assemble an article of footwear in accordance with the method aspect of the invention.

The present invention will become more fully understood from the detailed description of certain examples and the accompanying drawings, in which:

FIGURE 1 is a photograph of an assembled article of footwear in accordance with a first embodiment of the invention; FIGURE 2 is a photograph of the article of footwear of Fig. 1 in a partially- assembled state in which an upper is being attached to an insole;

FIGURE 3 is a photograph of the bottom surface of the insole of the article of Figs. 1 and 2;

FIGURE 4 is a photograph of the article of footwear of Fig. 1 in a partially- assembled state in which the outsole is being connected to an insole having an attached upper;

FIGURE 5 is a schematic cross-section (not to scale) showing connections between an upper, a first sole part and a second sole part in accordance with a second embodiment of the invention;

FIGURE 6 is a schematic cross-section showing connections between an upper, a first sole part and a second sole part in accordance with a third embodiment of the invention;

FIGURE 7 is a flow chart outlining the steps of a method of assembling an article of footwear;

FIGURE 8 is a schematic view of a system for producing components of footwear based on control data from a remote database;

FIGURE 9 is a flow chart outlining the steps of a method of producing components of footwear based on control data from a remote database;

FIGURE 10 shows a partially sectioned view of an article of footwear according to a further example, and

FIGURE 11 is a further schematic cross-section showing an arrangement comprising use of at least one blind slot for connecting an upper and a sole, and

FIGURE 12 is a flow chart outlining the method associated with Figure 1 1 .

The present invention generally relates to a method of assembling an article of footwear, producing components for an article of footwear, and to the article of footwear thus obtained.

Directional terms such as“top”,“bottom”, and“lateral” are used herein for convenience of description. The frame of reference is that of the assembled article of footwear, with the bottom surface of the article being the surface that is intended to contact the ground when the article is worn and the top of a sole component of the article being the surface towards the foot. For the avoidance of any doubt, this terminology is not intended to limit the orientation of the article in an external frame of reference.

Examples of articles of footwear include shoes, boots and sandals. Such articles typically comprise an upper and a sole component. Typically, the sole component comprises two or more parts, often an insole and an outsole. A midsole may also be provided. These components serve different functions, and as such are often constructed from differing materials having differing properties. Recycling an article of footwear at the end of its useful service life may require the different materials to be separated from one another.

The word“upper” is used herein in the sense of “an upper of an article of footwear”, i.e. the portion of an article of footwear which covers the user’s foot when the article is worn. An upper may be a single component, or may include multiple components.

A first exemplary embodiment of an article of footwear according to the invention will now be explained with reference to Figures 1 to 4.

Figure 1 shows an assembled article of footwear 100. Figures 2 to 4 show the same article of footwear in partially-assembled states. The article of footwear 100 comprises an upper 10, a first sole part and a second sole part. In the present example, the first sole part is an insole 20 and the second sole part is an outsole 30. The upper 10, insole 20 and outsole 30 are separate components, which have been assembled together. The second sole part may also comprise, e.g., a midsole or another sole component under the first sole part,

The upper 10 may be formed of any suitable material or combination of materials. Uppers are generally pliable, to allow for comfortable walking when the article of footwear is worn. Examples of materials useful for constructing uppers include textiles, natural or synthetic leather, and combinations thereof. In the present example, upper 10 is of leather.

As shown more clearly in Figure 2, the upper 10 comprises a plurality of tabs 12. A tab is a flap or extension which is foldable and which is configured to be inserted into a complimentary slot 22 in the insole 20. In the example of Figure 2 the slot extend through sole part 22, as indicated by the dotted line. However, according to a possibility the slot may also be a blind slot. The illustrated tabs are generally rectangular extensions having chamfered corners. However, this is not the only possibility, and at least a part of the tap can be of a different shape. For example, the at least a part of the tap can have oval cross-section. Each tab 12 comprises an aperture 14. The tabs 12 and apertures 14 will be used to connect the upper 10 to the insole 20.

The tabs 12 are formed integrally to the upper 10, and extend from the perimeter of the upper 10. In the example of Figure 1 the tabs are cut from the same material as the upper. The tabs can only comprise some but not all layers of the upper material. The tabs can be cut or otherwise manufactured from the same material as the upper using various techniques, such as punching, laser or water jet cutting and so forth. Another example of producing integrated tabs is described with reference to Figure 10.

The tabs 12 are distributed along an edge of the upper 10, which edge will contact the insole 20 in the assembled article of footwear 100. As shown in Figure 1 , the tabs can be distributed only along the length of the edge of the upper material. The number of tabs and the relative positions of the tabs may be selected as appropriate, depending for example on the size of the tabs and the size of the article of footwear and the width of the parts of the upper engaging with the sole. As shown in Figure 1 , it is not necessary to have tabs around the entire periphery of the sole at areas which are free of upper material.

The illustrated tabs 12 can have a thickness which is smaller than the thickness of the remainder of the upper 10. This allows the article of footwear to be assembled more consistently, by ensuring that the tabs 12 will extend into slots 22 of insole 20 only to a predetermined extent. The thickness of the tabs may be reduced also to make them easier to fold than the remainder of the upper.

Cutaway portions 16 are arranged between adjacent tabs along the edge of the upper. The cutaway portions can be provided to improve the flexibility of the upper. This enables the tabs 12 to be inserted more easily into the slots 22. The cutaway portions also allow the upper to bend and flex more easily when the article of footwear is worn. The tabs may further include score lines (not pictured) to make the tabs easier to fold.

The apertures 14 according to the example take the form of plain holes. The apertures 14 are sized and positioned to receive complementary fastener pins 24 provided on a bottom surface 28 of insole 20. Insole 20 comprises a plurality of slots 22 for receiving the tabs 12 of the upper 10. The slots extend substantially vertically from the top to the bottom of the midsole i.e. in the direction of the upper material. This allows threading of the tabs 12 into the slots 22 without a need to fold the tabs as this stage.

The insole 20 has a bottom surface 28 provided with a plurality of protruding fastener elements 24. The protruding fastener elements 24 are arranged to be received by the apertures 14 of the tabs 12.

As shown in Figure 2, slots 22 take the form of elongate holes. The slots 22 are advantageously sized such that the edges of the tabs 12 will lie flush against the edges of the slots 22 in the assembled article of footwear 100. In this example, slots 22 are spaced from the perimeter of the insole 20. The slots 22 extend from a top surface of insole 20 to a bottom surface 28 of insole 20. The top surface of insole 20 is the surface which will contact the foot of a user when the assembled article of footwear is worn. The bottom surface 28 of insole 20 is the surface which will attach to the outsole 30 in the assembled article of footwear 100.

The bottom surface 28 of the insole 20 comprises a plurality of protruding fastener element 24. A protruding fastener element 24 can be any type of protrusion, such as a pin or a peg, which may be received by the apertures 14 of the tabs 12 of the upper 10 to hold the tab 12 in place. In the illustrated article, protruding fastener elements 24 are generally cylindrical pegs. The protruding fastener elements 24 are formed integrally to the insole 20.

Each protruding fastener element 24 may be associated with a recess 26. The recesses 26 are configured to receive the tabs 12. The recesses 26 restrict lateral movement of tabs 12 in the assembled article of footwear. This may improve the durability of the connections between the upper 10 and the insole 20 in the assembled article of footwear 100, for example by preventing fraying of the apertures 14. The recesses may also aid in the alignment of the upper 10 relative to the sole parts 20, 30.

The bottom surface 28 of the insole 20 further comprises channels 29. The channels 29 allow the insole 20 to be connected to the outsole 30 via a snap fit. As shown in Figure 3, the channels 29 are circular and are configured to provide an annular snap fit with complementary projections 32 disposed on the outsole 30. The channels may however take any appropriate form. The bottom surface 28 of the inso!e 20 may a!ternatively or additionally include protrusions for connecting to complementary channels on the outsole via a snap fit.

A rim 23 may be provided that extends from the perimeter of the bottom surface 28. The rim 23 may be useful for aligning the insole 20 with the outsole 30 when assembling the article of footwear 100. The rim 23 may also help to attach the outsole 30 to the insole 20 by providing an interference fit.

The structure of the second sole part, illustrated by outsole 30, complements that of the first sole part. The outsole 30 will have a top surface which is attachable to the bottom surface 28 of the insole 20. In this example, the outsole will generally have a bottom surface for contacting the ground when the article of footwear 100 is worn.

The bottom surface 28 of the insole 20 and the top surface of the outsole 30 are configured to attach via a snap fit, more specifically an annular snap fit. To this end, the bottom surface of the insole comprises a plurality of circular channels 29, and the upper surface of the outsole with a plurality of complementary annular projections 32. This configuration is illustrated in Figure 3. In the assembled article of footwear, the projections 32 are received in the channels 29 so as to fix the outsole 30 to the insole 20.

Figure 5 shows in cross-section another exemplary embodiment of an article of footwear 200. Article of footwear 200 is constructed using similar principles to the article of footwear according to the first embodiment, but has an alternative arrangement of the first sole part and second sole part.

Article of footwear 200 comprises an upper 210, a first sole part 220 and a second sole part 230. As in the first embodiment, upper 210 comprises a tab 212 having an aperture 214. The tab 212 is received by a slot 222 provided in the first sole part 220. As above, the slot 222 extends from top to bottom of the first sole part 220, allowing the tab being threaded into it unfolded.

According to this example the protruding fastener element is arranged on an upper surface of the second sole part 230, rather than a lower surface of the first sole or midsole part. A recess 234 for receiving the tab 212 is also provided on the second sole part 230.

A mechanical connection between the sole component and the upper is formed in essentially the same way as for the first embodiment. Again, a protruding fastener element forms a connection between a sole component and a folded tab provided on the upper. The connection is sandwiched between that sole component, or the midsole part, and a further sole component, or the outsole part, improving the mechanical strength of the connection.

Figure 5 further illustrates that a protruding fastener element 232 may be used to form a connection between the second sole part 230 and the first sole part 220. This connection is achieved by including a socket 224 in the bottom surface of the first sole part 220. The socket 224 receives an end of protruding fastener element 232. The end of the protruding fastener element 232 is flared. This helps to hold in place the tab 212, as well as connecting together the first sole part 220 and the second sole part 230. A snap fit may be provided between the free end of the protruding element and the co-operating sole part.

Figure 5 further illustrates a rim 226 extending from a perimeter of first sole part 220. Rim 226 is useful for aligning the first and second sole parts when assembling the article of footwear 200. The rim 226 may further provide an interference fit between the first and second sole parts. An adhesive or cement may be applied to an inner surface of the rim, to fix the rim 226 to a perimeter of first sole part 220.

Figure 6 shows, in cross-section, a further exemplary embodiment of an article of footwear 300. The article of footwear 300 differs from the articles of footwear of the first and second embodiments in that the protruding fastener element is provided on a lateral surface of the first sole part, and in that the tab is not folded at all. Also, in the example the at least one slot for receiving the at least one tab 312 is provided in the form of a groove at the side of the first sole part 320. The groove extends from the top surface to the bottom surface of the sole part and provides three sides of the tap receiving aperture of the sole. The fourth side wall of the aperture is provided by the side wall 332 of the second sole part 330. The article of footwear 300 can otherwise be constructed in a similar manner to the articles of footwear according to the first and second embodiments.

More particularly, an article of footwear 300 can include an upper 310, a first sole part 320 and a second sole part 330. The upper 310 comprises a tab 312 which is received in a slot 322 provided as a recess of groove in the lateral surface of the periphery of the first sole part 320. The slot extends from the top to the bottom of the first sole part. The tab 312 has an aperture 314 which receives a protruding fastener element 324. The protruding fastener element 324 extends from the lateral surface of the first sole part 320.

Second sole part 330 can include a peripheral wall or rim 332 extending from a perimeter of the second sole part 330. The tab 312 is held between the peripheral wall or rim 332 of the second sole part 330 and the lateral surface of the first sole part 320. Thus, in contrast to the first and second embodiments, the tab is held between lateral surfaces rather than between top and bottom surfaces and there is no need to fold the tab in any direction. This may be useful in increasing the durability of the tabs.

It is noted that a groove is not necessary in all variations. The tab can simply be sandwiched between the lateral surfaces of sole parts 320 and 330.

In this example, peripheral wall or rim 332 also comprises a socket 334 which receives an end of the protruding fastener element 324. The peripheral wall or rim 332 is also configured to allow the second sole part to be connected to the first sole part by a snap fit.

Figure 6 further illustrates a snap fit between the first sole part and a second sole part. The first sole part 320 comprises a channel 320 which receives a complementary annular projection 336 which extends from the second sole part 330.

The article of footwear 300 may be constructed by attaching the tab 312 of the upper 310 to the protruding fastener element 324 of the first sole part 320. The second sole part 330 may then be attached to the first sole part. In an example, the second sole part is resiliently flexible. The peripheral wall 332 of the second sole part is flexed outwardly and the second sole part is positioned over the first sole part while the peripheral wall 332 is held under flexion. The annular projection 336 is forced into channel 320. The peripheral wall 332 is then allowed to relax, and snaps on to first sole part 320, yielding the assembled article of footwear 300.

Figure 7 shows a flow chart summarising the steps of a method of assembling an article of footwear. At operation 400, in order to connect together the upper and first sole part (in this example, the insole), the tabs 12 are inserted into the complementary slots 22. Figure 2 shows a partially-assembled article of footwear, in which only some of the tabs 12 have been inserted into the complementary slots 22. As shown in Figure 2, this operation results in the tab 12 protruding from the bottom surface 28 of the insole 20. According to an alternative, at least some of the slots can be blind slots.

Figure 1 1 shows a sectioned view further example of an attachment arrangement 400 where at least one of slot extending from a surface 421 , preferably top surface, of a first sole part 420 comprises a blind slot 422. The blind slot can be provided in the sole part material as shown in Figure 1 1. One or more of blind slot may also be provided by the rim type solution of Figure 6. That is, at least one of the side surfaces cam be provided by a separate rim type element.

At least one protruding fastener element 424 extends substantially sideways from a surface 423 of the blind slot. A tab 410 comprising an aperture 414 at the free end thereof is inserted into the slot and positioned on the protruding fastener element 424.

For the insertion, the at least one blind slot can be opened by folding one side surface 432 of the sole part as indicated by double headed arrow 433. After placing the at least on tab into the opened at least one blind slot, the at least one blind slot can be closed to hold the at least at least one protruding fastener in the aperture.

A second surface of the at least one slot 422 can be locked to the free end 425 of the substantially sideways extending at least one protruding fastener element 424 after positioning the protruding fastener element into the aperture 414. A snap fit may be used for the locking.

The second sole part, e.g. a midsole or an outsole, can be assembled at the bottom the first sole part, e.g. by means of a snap fit.

At operation 402, the tab is then positioned to receive a protruding fastener element. The positioning may, for example, include folding the tab. In one example, if the first sole part comprises a protruding fastener element as in article of footwear 100, then the positioning operation 402 may comprise folding the tab such that the aperture 14 of the tab 12 receives the corresponding protruding fastener element 24, forming a connection 12a attaching the upper 10 to the insole 20. In an alternative configuration, positioning operation 402 comprises arranging the tab for receiving a protruding fastener element as part of a subsequent operation such as locating the second sole part relative to the first sole part.

The inserting operation 400 and positioning operation 402 can generally be performed by hand without requiring the use of specialised equipment. The inserting operation 400 and the positioning operation 402 may be performed sequentially for each tab in turn, as illustrated in Figure 3. This may make it easier to insert the later tabs into the slots, because once one or more connections has been formed the upper is held in position relative to the insole. Alternatively, all of the tabs may be inserted into the corresponding slots before any of the tabs are folded. In some examples folding of the tap is not necessary.

At operation 404, the second sole part 30 is attached to the first sole part 20. If the second sole part comprises protruding fastener elements, as in article of footwear 200, then this operation may further include inserting the protruding fastener elements into the tabs of the upper. Operation 404 sandwiches the connections between the second sole part and the first sole part, as illustrated by connection 12a in Figure 3, thereby improving the mechanical strength of the connections and fixing securely the upper to the first sole part. The first sole part can be provided by a midsole and the second sole part by an outsole.

Figure 12 shows the method of the alternative described with reference to Figure 1 1 . The at least one blind slot can be opened at 450, e.g., by bending one side surface of the sole part, as indicated by the double headed arrow 433 in Figure 1 1 . The at least on tab can be inserted at 452 into the opened at least one blind slot, and the aperture can be placed on a protruding fastening element in the at least one blind slot at 454. The slot can then be closed at 456 to hold the at least at least one protruding fastener in the aperture.

The inserting, positioning and attaching operations may be carried out simultaneously to one another. For example, as is shown in Figure 2, the operations of inserting 400 the tabs, positioning 402 the tabs, and connecting 404 the second sole part may be carried out for portions of the article of footwear in turn. In other words, the operation of attaching the second sole part 404 may be commenced before the insertion 400 and positioning 402 operations have been completed for all of the tabs.

To facilitate recycling of the article of footwear at the end of its service life, the upper, first sole part and second sole part may be separated from one another. The second sole part is removed as appropriate depending on the manner in which the first sole part was attached to the second sole part, e.g. by releasing the snap fit. The first sole part and the upper are separated by removing the protruding fastener elements from the apertures, and then pulling the tabs out of the slots.

Various modifications may be made to the above described method and articles of footwear. For example, the illustrated upper is an upper for a sandal but the same principles may however be applied to any style of footwear having an upper and a sole component comprising two sole parts. The shape of the tabs is not limited to that shown in the Figures. Tabs of any appropriate shape may be used. It is not essential for the tabs to have a smaller thickness than the remainder of the upper of the item of footwear.

Although the illustrated example uses a plurality of tabs, slots and fastener elements, a connection between an upper and a side part may be formed using a single tab, a single slot and a single fastener element. This applies in particular to articles of footwear having uppers which require only one point of connection with the sole component. For example, a single tab may be used when the article of footwear is a mule (i.e. an article having an upper that covers only the front of the foot). Other styles of upper which do not require multiple points of connection to the sole component are possible. The size of the tab may be adjusted to achieve a strong connection. It is even possible to use the method of the invention in conjunction with other fixing techniques.

The cutaway portions may be omitted, particularly if the upper is formed of a textile or soft leather. The shape and configuration of the cutaway portions is not limited to that shown in the drawings, and alternative configurations are possible. The inclusion of score lines is optional.

The illustrated tabs are formed integrally to the remainder of the upper. This may be advantageous, and may for example simplify construction of the upper. The tabs may also be provided as components which are attached to a body of the upper using stitching, an adhesive, a weld, or the like.

The illustrated tabs extend from a perimeter of the upper. This may improve the appearance of the article of footwear. The configuration of the tabs is not particularly limited, provided that the tabs can be inserted into the slots and the tabs have apertures for receiving the protruding fastener elements.

In the illustrated examples, apertures 14 are simple holes. In a variant, the apertures 14 may include reinforcing means, such as eyelets, to improve the durability of the tabs 12. Eyelets may reduce wear of the material used to form the tabs 12.

The illustrated insole 20 is just one example of a first sole part. The shape and configuration of the first sole part may be selected as appropriate, depending on the style of article of footwear desired. The first sole part may be a foot bed, for example.

The slots need not necessarily be elongate slots as shown in the figures. The slots may have any shape, provided that they can receive the tabs. The slots need not be spaced from the perimeter of the first sole part, and might for example take the form of channels in the perimeter of the first sole part. However, arrangements where the slots surround the tabs are preferred since this may provide an article having an improved appearance and/or may improve the strength of the connections between the first sole part and the upper.

The configuration of the protruding fastener element is not limited to that shown in the drawings. For example, it is not essential for the fastener pins to be moulded integrally to the insole. Protruding fastener elements may be provided on one or both of the first sole portion and the second sole portion. The inclusion of sockets for receiving the protruding fastener elements is optional. If present, the sockets may be included on one or both of the second sole portions as appropriate depending on the configuration of the first and second sole portions. In general, a protruding fastener element may have a flared end. The flared end may be useful for insertion into a socket and/or for retaining a tab on the protruding fastener element.

The inclusion of recesses for receiving the tabs in the bottom surface of the first sole part is optional. The recesses may be omitted.

Rim 23 is optional, and may be omitted. A rim may extend from a perimeter of the upper surface of the outsole, instead of from the insole, to produce the same effect as rim 23. The rim, where present, need not necessarily provide an interference fit.

The second sole part may be attached to the first sole part by any suitable means, for example using an adhesive, stitching, or a weld. However, for ease of recycling, the use of a snap fit is preferred. The snap fit is not necessarily an annular snap fit as illustrated. A cantilever snap fit may be used. A torsional snap fit may be used, in particular if the sole parts do not include a rim.

Although the above-described embodiments do not require the use of adhesives, cements, stitching, or welds, mechanical connections formed in accordance with the invention may be used in combination with these or any other conventional fixing technique.

A sole part for an article of footwear may thus be provided, which sole part comprises at least one slot for receiving at least one tab of an upper; and has a first surface including at least one protruding fastener element for insertion into an aperture of the at least one tab; wherein the at least one slot and the at least one protruding fastener element are configured such that when the at least one tab is inserted into the at least one slot and the at least one tab is positioned over the protruding fastener element, the at least one protruding fastener element connects to the aperture of the tab; and wherein the first surface of the sole part is configured to be attached to another sole part so as to hold the at least one tab between the sole part and the other sole part.

A kit comprising first and second sole parts as provided herein along with an upper may also be provided. The kit may be used to assemble an article of footwear, for example using the method described above. It will be readily understood that the preferred features of the upper, first sole part and second sole part described with reference to the method and article of footwear aspects apply also to the kit aspect.

It is contemplated that the kit may include a plurality of interchangeable uppers for example having different ornamental designs and/or a plurality of sole parts having for example different ornamental designs. By“interchangeable” it is meant that the uppers of the kit all have the same configuration of tabs, and the sole components of the kit all have the same arrangement of slots and protruding fastener elements, such that any upper of the kit may be used with any sole component of the kit of a matching shoe size. This may allow articles of footwear to be assembled on location at a retail store depending on the demand for a specific model, or even allow a consumer to assemble customised articles of footwear themselves. For example, a single insole and outsole design may be supplied with a plurality of different uppers. This would allow the assembly of a selection of models of footwear from a reduced selection of components. In this way, even if a particular upper design provided to be unpopular at a specific retail outlet, the insoles and outso!es could still be re-used with an alternative upper.

An example is given below with reference to Figures 8 - 10 how a consumer him/herself or another remote user may prepare a component such as the supper or parts thereof based on control data from a remote database.

In accordance with an aspect control instructions for manufacture of interlocking components for articles of footwear can be delivered via a data communication system, for example via an Internet Protocol (SP) based data communication system. A recipient of the control data can use the data to produce a new component for the footwear. For example, a user such as a consumer or a shop assistant can download via a data network connection from a server control data for a computer controlled manufacturing apparatus and use the control data to produce a replacement upper with fitting fastening tab members.

It is possible to produce an upper component with tab members, at least in part, by means of additive manufacturing based on control data downloaded from a server. An example of additive manufacturing technologies is three-dimensional (3D) printing. Use of control data from a source database holding the original designs can be used to ensure that the fastening members of the upper component fit with the receiving members at the sole component. Also, use of control data from a reliable source can assist in controlling the quality and durability of replacement uppers.

Figure 8 illustrates an example of a system where data for controlling 3D printing apparatus 70 can be downloaded from a control data managing web server 80 via a data network 86. The server 86 can comprise a database 81 of control instructions for various styles and sizes of footwear. Components such as at least one data processor 82, 83 for handling storage of the control data and serving incoming requests for the control data and an interface 84 for connecting to the data network are also provided.

3D printing is an additive manufacturing technology where material is laid down by progressively adding material to form a product of desired shape, size and appearance. In this specification term ‘3D printing’ is used to refer to additive manufacturing processes that can be used to create physical objects from digital control data. The additive manufacturing processes can be arranged to re-form a raw material by the addition of energy and positioning in a controlled manner. The control is provided by an appropriate control unit based on the digital control data. A variety of 3D printing processes are available. Also, a variety of stock materials (polymers, metals, ceramics, etc.) in differing forms (e.g. liquids, powders, granules, and filament) are available for 3D printing. Non-limiting examples of 3D printed materials for providing the herein described components of footwear can comprise e.g. thermoplastic polyurethane, TPU, or thermoplastic elastomer, TPE. Materials can be appropriately adapted for 3D printing of the herein described components. A specific example for additive manufacturing process is fused deposition modelling (FDM). FDM uses heat to melt a thermoplastic polymer filament which is then extruded through a fine nozzle to lay a bead of material in the areas required for the form of a finished object.

In the example of the process of 3D printing illustrated in Figure 8 a 3D print head 71 lays down thin layers of material 74 on a work piece 76. The work piece can be laid on a base 75. The additive process, such as operation and movement of the 3D print head 71 on a guide arrangement 72 relative to the component 76 to be manufactured, and/or possibly movement of the support 75 on which the printing of the component takes place, can be controlled by one or more controller units 73 based on downloaded control data.

The control apparatus 73 can be for example integrated with, coupled to and/or otherwise controlling the 3D printing apparatus 70, a robot or another actuator device. For this purpose the control apparatus comprises at least one memory, at least one data processing unit, and input/output interface arrangement. Via the interface arrangement the control apparatus can be connected to the devices such as the 3D printing apparatus and/or the data communication system 86 for communication with the control data management system 80. The control apparatus can be configured to execute an appropriate software code to provide control functions required by processes described herein.

The thickness of the added material is grown to a desired thickness under control by the control apparatus 73 according to the control data from the server 80. In accordance with an aspect the control data comprises instructions for producing appropriately shaped tabs 77 and apertures 78 (shown by dashed lines) for providing fastening members of an upper component 76 as described above for interlocking with a sole component.

Figure 8 also shows a user terminal apparatus 87 connected to the control apparatus 73 of the printing apparatus 70. A user can use an input device, for example a keyboard 89 and display 88 to request for appropriate control data. For example, the user can be displayed a selection menu for making an order of control data for an upper component.

For example, a user at home or shop or elsewhere where he/she has access to the 3D printing apparatus 70 can be presented a component ordering web page on the screen of the user terminal 87 for connecting to the control data management server 80. The web page can comprise a selection menu enabling the user to select from various options. The user may be prompted to input information regarding e.g. the shoe style, size, model, and/or type, a specific code and so on so that the server can identify the particular article of footwear. According to a possibility a picture taken by digital camera, for example a camera connected to the user terminal, or a camera of a mobile phone, laptop or tablet computer is used for identifying the footwear. According to a possibility the server is configured to utilise image recognition techniques to determine the footwear in question from an image send together with a request for a component. A bar code reader or other code reader may be used to read a code from a label of the footwear. The user terminal may be provided with an application configured to assist in the identification of the footwear and processing and sending a request for appropriate control data.

According to a possibility a user can design an individual decoration or other pattern on the surface of the component to be produced. The user may also design a shape, for example a specific individual cut and/or three dimensional decoration on e.g. an upper component. Various decorative patterns and/or shapes may also be selected from a menu. Information of the desired decoration, pattern, shape and so on can be communicated from the user terminal 87 to the server apparatus 80 for generation of appropriate control data. For example, a user can take a picture of something he/she wants to be produced, e.g. printed, on the uppers and use this as an input. The server apparatus can then use conversion tools to generate appropriate control data. The user may also e.g. draw a pattern or shape using computer aided drawing tools and send the generated information to the server for generation of the control data.

Figure 9 is a flowchart for manufacturing a first component for an article of footwear comprising at least one fastening member for interlocking with a second component of the article of footwear. The method comprises sending at 90, from a local controller of a manufacturing device, a request for control data for use in manufacture of the first component to a remote control data management apparatus. The request comprises information for identifying the article of footwear so that the remote management apparatus can map the request to a correct article of footwear and generate appropriate control data for the particular article of footwear. Information e.g. of the size, colours and so on may also be included in the request. At 92 the requested control data is received from the remote control data management apparatus. The manufacturing device can then be controlled at 94 based on the received control data to produce at least the at least one fastening member of the first component. For example, correctly sized and shaped fastening tabs and apertures thereof can be produced accurately based on the control data to replacement uppers. A user can produce just one upper, or a pair of uppers on demand.

The print head 71 can be operated such that material is layered in appropriate angles. The print head can be arranged to operate in e.g. a 5-axis or 7-axis control system.

According to an aspect 3D printed material may be printed on a base material or substrate, for example leather or fabric, such that it forms at least one 3D printed tab member extending from the base material for fastening the component to other component. The partially sectioned side view of Figure 10 shows an example where a portion 110 of an upper component 100 can be produced to comprise 3D printed material fastened to a base portion 102 of the component by the 3D printing process. The 3D printed material provides appropriate tab members 112 for the component 100. According to a possibility a user can cut a piece of base material of a predefined size and shape and then 3D print the tabs, and possible other elements onto the material. During the printing process the 3D printed material merges and bonds with the base material that provides a substrate. The 3D printed materia! can provide a rim 1 10 around the edge of the base materia! 102, as is also shown in the example of Figure 10. The rim 1 10 can be printed around the entire periphery of the base material 102 and the tabs 1 12 can printed at the same time so that they extend from the rim.

By means of this an integrated component structure can be provided that fits accurately with the slots and attachment members of the sole component. In Figure 10 example the tabs 1 12 first inserted unfolded into the slots and then folded so that the ends thereof are sandwiched between the insole 120 and outsole 130.

According to a possibility the base material on which the 3D printed material is applied to, provides at least a part of a tab for fastening the upper and sole components together, the 3D printed material being applied to strengthen the tab structure and/or provide accurate and correctly shaped holes or other fastening members.

The piece of material 102 on which material can be added to can comprise, e.g., a sheet of fabric, leather, synthetic leather, felt, plastic, rubber and/or foam material, or any combination of materials as appropriate.

The control data can be for controlling operation of other devices than a 3D printer, for example a device implementing another additive manufacturing technology, a decorating machine and/or a cutting or milling machine.

Easy recycling of the article of footwear, by allowing for disassembly of the article of footwear without requiring the use of specialised equipment or solvents may be provided. Alternatively, an adhesive or cement, heating, and/or stitching may be used to fix together two or more of the upper, first sole part and second sole part. Mechanical connections formed in accordance with the present invention may be useful for location and holding together components while an adhesive or cement cures. The use of mechanical connections formed in accordance with the present invention in combination with fixing means such as adhesive, cement, heating or stitching may provide a strong bond between the components of the article of footwear. It may be made possible to use less adhesive, cement or stitching than would otherwise be required.

While certain aspects of the invention may be illustrated and described as block diagrams, flow charts, or using some other schematic pictorial representation, it is well understood that these blocks, apparatus, systems, techniques and control methods described herein may be implemented in, as non-limiting examples, hardware, software, firmware, special purpose circuits or logic, general purpose hardware or controller or other computing devices, or some combination thereof. Also, certain aspect such as the control data downloading and use of the downloaded control data can also be implemented independently from manufacture of upper components with fastening members.

The foregoing description provides by way of exemplary and non-limiting examples a full and informative description of exemplary embodiments of the invention. However, various modifications and adaptations may become apparent to those skilled in the relevant arts in view of the foregoing description, when read in conjunction with the accompanying drawings and the appended claims. All such and similar modifications of the teachings of this invention will still fall within the spirit and scope of this invention.