WO2011082275A1

WO2011082275A1 - Lastless, molded footwear and methods of construction

Info

Publication number: WO2011082275A1
Application number: PCT/US2010/062447
Authority: WO
Inventors: Alan Hardy; Mark Mcmillan; Brian Krezel; Mark Thompson
Original assignee: Li Ning Sports Usa, Inc.
Priority date: 2009-12-30
Filing date: 2010-12-29
Publication date: 2011-07-07

Abstract

In certain embodiments the inventive subject matter is directed to a module for a shoe, particularly athletic shoes, such as running or court shoes, comprising, a contoured three dimensional covering for at least one of a lateral or medial forefoot, midfoot, or rearfoot area of a foot, the covering comprising a plurality of subzones, each subzone formed having different structural, functional, or material property attributes, the module being formed in a single forming process that generally creates and defines the subzones. The inventive subject matter is also directed to a shoe comprising one module or a plurality of modules assembled together. The module or modules are preconfigured with complementary shapes and dimensions so that they may be directly or indirectly connected together without a last. In some embodiments, the modules and other parts are configured so that they may be joined without stitching.

Description

LASTLESS, MOLDED FOOTWEAR AND METHODS OF CONSTRUCTION

Inventors: Alan Hardy; Mark McMillan; Brian Krezel; and Mark Thompson CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to and the benefit of U.S. Provisional Patent Application No. 61/291,316, filed December 30, 2009, to Alan Hardy, Mark McMillan, Brian Krezel and Mark Thompson, entitled LASTLESS, MOLDED FOOTWEAR AND METHODS OF CONSTRUCTION, the contents of which are hereby incorporated by reference herein as if listed in its entirety for all purposes.

BACKGROUND

The inventive subject matter is generally directed to footwear constructions and methods of constructions. It is particularly directed to athletic footwear for use in sports, recreation or artistic (e.g., jazz dance) activities.

Referring to Fig. 1, athletic footwear 1 is generally made by cutting flat materials for the shoe upper 10 into complex shapes and stitching them together to make an enclosure that tries to emulate a complex three-dimensional foot shape. The individual pieces are assembled around a three dimensional representation of the foot, which is called a last 20. With such a configuration, a sole unit 12 (e.g., sockliner 14, midsole 16, and/or outsole 18) must also be attached to the materials on the last 20 via a lasting board 22. To reflect different foot sizes and morphologies, a library of lasts with a range of differing size and shape attributes is needed in a production operation. And each last and the footwear parts to be assembled must be manually handled. Because of the use of flat materials and traditional construction methods, making the parts conform and align to the last is challenging and voids 3 may result, causing a sloppy fit against a wearer' s foot (not shown). Also, a substantial amount of waste material is generated in the process of trimming and stitching or otherwise securing together two dimensional materials into a three dimensional shape. Further, because there may be overlapping layers of material in the construction of a shoe, there is a multiplication of the waste.

A last 20 is a stylized representation of the human foot. A conventional last shape is based primarily on traditional shoe shapes rather than ergonomics of the human foot. Many last shapes in use today are still based on ones developed in the 1800s. Among the specific problems with such last shapes are the following: (1) the shapes were stylized to facilitate manufacturing using flat materials; (2) last shapes were also predicated by fashion, not actual foot morphologies and biomechanics; and (3) the shapes may not be suitable for different kinds of footwear categories, e.g., low top shoes versus high top shoes, necessitating additional libraries of lasts for specific categories.

While some have attempted to create ergonomically correct lasts, all such attempts have been limited by traditional stitch-and-glue-based manufacturing methods or traditional assembly methods using flat materials.

To date, conventional footwear construction methods do not adequately allow engineered performance materials, e.g., thermoplastic laminates, injection molded polymers, extruded polymers, and synthetic leathers and textiles to be fabricated into volumetric, three-dimensional shapes to achieve more optimal fit, biomechanical shape requirements, and critical biomechanical performance needs or characteristics (e.g., targeted areas of flex, breathability, softness, and rigidity).

To date, conventional footwear construction methods do not adequately allow for three-dimensional parts for the shoe sole 12 and/or upper 10 to be formed or assembled to provide the foot with adequate fit, support, flexibility, durability, articulation, and/or breathability. Accordingly, there is a need for improved internal, volumetric shoe shapes, which better match the shape and/or functions of the human foot.

Further, there is a need for more efficient manufacturing using modern polymer materials. Still further, there is a need for improved manufacturing methods that reduce or eliminate the usual expensive and labor-intensive assembly steps used in the current art.

There is also a need to eliminate the excessive waste inherent in the existing manufacturing methods.

SUMMARY

The inventive subject matter allows for the combination of highly engineered performance materials which can be located and fabricated precisely in order to maximize, or at least better meet biomechanical requirements, critical biomechanical performance needs, i.e., flex where it needs to flex, breathe where it needs to breathe, be soft and comfortable, and be stiff and rigid where it needs to be rigid.

The inventive subject matter also allows for construction of shoes without the need for a last or the associated labor-intensive steps in the assembly process.

The inventive subject matter also allows for the construction of shoes that are stitchless, thereby simplifying the construction process and thereby reducing costs.

The inventive subject matter can also allow for the construction of shoes with minimal waste.

The inventive subject matter allows for use of complex, compound and accurately positioned three-dimensional shapes, which mimic foot anatomy or reflect other design parameters, in a simple and efficient construction process.

The inventive subject matter allows for footwear and footwear components that more closely match the shapes of the human foot. The inventive subject matter also allows for a monocoque construction that has customized or engineered reaction to forces during use of a shoe.

By eliminating the need to manually align an upper to a midsole via a last, the inventive subject matter, allows for more accurate biomechanical alignment of the sole of the foot with the upper anatomy of the foot and ankle.

In certain embodiments, the inventive subject matter is directed to a module for a shoe, particularly athletic shoes, such as, for example, running or court shoes. The module can be a contoured three-dimensional covering for at least one of a lateral or a medial forefoot, a midfoot, or a rearfoot area of a foot. The covering can comprise a plurality of subzones, with each subzone having one or more corresponding structural, functional, and material property attributes. The module can be formed using a single forming process that generally creates and defines each of the subzones. The module, which can be a monolithic structure, can have a homogenous or heterogeneous composition. In some instances, the inventive subject matter is also directed to a shoe comprising one module. In other instances, the inventive subject matter is directed to a shoe comprising a plurality of modules assembled together. The module or modules are preconfigured with complementary shapes and dimensions so that they may be directly or indirectly connected together (e.g., assembled together to form a shoe) without using a last. In some embodiments, the modules and other parts are configured so that they may be joined together without stitching.

In certain embodiments, to avoid the need for part-by-part assembly, the inventive subject matter contemplates a single mold or forming process adapted to provide a shoe with contoured sections and subzones having unique, corresponding attributes.

These and other embodiments are described in more detail in the following detailed descriptions and the figures. The foregoing is not intended to be an exhaustive list of embodiments and features of the inventive subject matter. Persons skilled in the art are capable of appreciating other embodiments and features from the following detailed description in conjunction with the drawings. BRIEF DESCRIPTION OF THE DRAWINGS

The following figures show embodiments according to the inventive subject matter, unless noted as showing prior art.

Fig. 1 is a representation of a shoe according to the prior art; more particularly, it is a cross-section taken through a forefoot portion of an item of athletic footwear.

Fig. 2 shows one example of a lateral module that extends from a toe to an ankle of a foot.

Fig. 3 shows a midfoot-lateral heel module with a plurality of materials across different subzones.

Fig. 4 shows a compression mold for use in forming a contoured module.

Fig. 5 shows a rear elevation view of a rearfoot or heel contoured module.

Fig. 6 is a front, lateral-side perspective view of a completely assembled left shoe that includes a lateral module and a medial module, each formed from a mold such as that shown in Fig. 4.

Fig. 7 shows outsole and midsole contoured modules formed using a mold of the type shown in Fig. 4.

Fig. 8 shows a sole unit assembly of the midsole portion module and outsole portion modules shown in Fig. 7.

Fig. 9 shows another view of a complete assembly of the shoe shown in Fig. 6 along with the contoured module shown in Fig. 3. Fig. 10 shows a medial side view of a complete assembly of the shoe shown in Fig. 6 including the rigid or semi-rigid structural frame or cage shown in Fig. 12.

Fig. 11 shows a rear elevation view of a complete assembly of the shoe shown in

Fig. 6.

Fig. 12 shows a rigid or semi-rigid structural frame or cage for use in an assembly according to the inventive subject matter.

Fig. 13 shows a medial side, elevation view of another possible embodiment of a shoe (e.g., a left shoe).

Fig. 14 shows an exploded assembly view of the medial side of the shoe shown in Fig. 13.

Fig. 15 shows a top plan view of the shoe shown in Fig. 13.

Fig. 16 shows a lateral side, elevational view of the shoe of Fig. 13.

Fig. 17 shows a cross section of the shoe shown in Figs. 13-16 through lines A-A' in Fig. 13.

Fig. 18 shows a cross section of the shoe in Figs. 13-16 through lines B-B' in Fig.

13.

Fig. 19 shows a cross section of the shoe in Figs. 13-16 through lines C-C in Fig.

13.

Fig. 20 shows a cross section of the shoe in Figs. 13-16 through lines D-D' in Fig. 13.

DETAILED DESCRIPTION

The inventive subject matter is directed novel methods of construction of footwear parts and finished footwear items, and the innovative products formed using such methods. Representative embodiments according to the inventive subject matter are shown in Figs. 2 through 20. In the illustrated examples, the shoe is shown as a high-top shoe suitable for a court sport like basketball. Nonetheless, myriad other innovative shoe configurations can be achieved using the innovative techniques disclosed herein.

The inventive subject matter uses one or more pre-formed, contoured (i.e., three- dimensional) modules that form or are assembled together to form a complete, volumetric upper which may be attached to a sole unit. In addition, the pre-formed modules may include one or more sole unit portions in a monolithic molded structure. The modules, for example, may represent lateral and medial three-dimensional modules that wrap over the side portions, top portions and/or sole portions of a foot. The modules are formed to have a plurality of sections providing different functionalities or properties. As used herein, the term "uni-body upper," refers to a single contoured hollow shape that accepts a substantial portion of the foot. A "substantial portion of the foot" used in this context means the upper area or sole area of a forefoot, midfoot and/or rearfoot; thus, a shape that "accepts a substantial portion of the foot" in this context means an enclosure for at least covering or containing a substantial portion of the foot. Also, the term "covering" is not limited to an intact layer of material. It also may be achieved by a set of straps or mesh material, for example, which generally define a covered area, but have voids over that area.

Innovative techniques used to form the modules can use one or more of the following: cold molding, extrusion molding, vulcanization, thermoforming, compression molding, and injection molding processes, as well as other known techniques used for molding of plastics and/or thermoformable materials, to form non-planar, volumetric shapes. Some innovative approaches disclosed herein can allow use of one or more thermoplastic laminates, natural leathers, synthetic leathers, natural textiles, and synthetic textiles in a formed, non-planar volumetric shape. Fig. 2 shows one example of a lateral module 110.1 for an upper 110 (Fig. 6). The module 110.1 extends from about a toe to about an ankle of a foot (e.g., between subzone 130.1 to subzone 130.6, in the illustrated example). That module is like the one used in the shoe 100 of Fig. 6. A generally complementary medial module 110.2, shown in Fig. 10, can be assembled directly or indirectly to the module 110.1 shown in Fig. 2. The shoe 100 (Fig. 6) can include various subzones in the upper 110 and/or sole unit 112 (e.g., Figs. 7 and 8) that each correspond to one or more specific functions or effects. For instance, the module 110.1 shown in Fig. 2 is a monolithic part (or construct) that provides upper 110 with a plurality of subzones 130.1, 130.2, 130.3, 130.4, 130.5, 130.6, 130.7, 130.8 that each has a respective combination of attributes (some which may differ from an attribute of the other subzones). A variation in attributes between selected adjacent or spaced apart zones may be achieved in module 110.1, or any other module for a shoe by, for example, using or otherwise integrating into a given zone a selected material having one or more desired properties, e.g., a selected or desired durometer, modulus of elasticity or visco-elasticity, tensile strength, water or vapor permeability, thermal conductivity, abrasion resistance, tractionability, electrical conductivity, and/or light reflectance or other responsiveness to electromagnetic radiation. Selected characteristics, variations of selected characteristics, may also be achieved by integrally molding into a subzone or otherwise integrating to a subzone one or more discrete components, such as, for example, a structural component, e.g., a rigid or a semi-rigid bar, a cage or a frame structure, a textile sheet, a mesh material, strapping, webbing, cable, or lacing. For example, a frame (or a cage) 111 (see Figs. 6 & 12 can be molded of a rigid TPU, or like material, to provide stability, protection and/or support to a wearer' s foot at the rearfoot area. Another example of a discrete component that can be integrated into a subzone includes a component in the nature of an electronics device, e.g., wireless transceiver, a GPS unit, a microcomputer including a processor and data memory, a lighting device, an accelerometer based device, an energy source (e.g, a battery, solar cell, or fuel cell), etc. Desired or selected variations in performance characteristics may also be achieved in some instances by using the same material between or among adjacent subzones, with each subzone having a lesser or greater thickness (e.g., compared to another subzone), or by forming a mechanically more rigid structure, e.g., one subzone may include a perforated layer (such as to allow relatively more flexibility or

breathability) and an adjacent subzone may be a solid layer (such as to provide relatively more flexibility). Other examples of moldable elements that can be used to achieve a desired performance characteristic include, for example, gussets, beams, stiffeners, webs, struts and the like, configured to stiffen a portion of a subzone. Also, a module defining a subzone can also define a coupler (e.g., elements 34A through 34D) configured to fixedly engage a respective other module and thereby form a stiff shell-like structure. Such a structure can provide structural support to a shoe and a wearer's foot, ankle and portions thereof. Selected variations may also include layers or panels having distinct colors, patterns, symbols or branding, such as for cosmetic effect.

Looking at Fig. 2, subzone 130.1 is generally disposed over a toe area of a shoe. In Fig. 2, a lateral half module 110.1 is shown. The module 110.1 can be a monolithically molded portion of an upper (e.g., upper 110, in FIG. 9) that has a volumetric shape to help define a toe cap for receiving the toes of a wearer's foot. Since it is desirable to reinforce the toe area of a court shoe, the module 110.1 may use a relatively firmer (or stiffer) material in that subzone. The firmness (or stiffness) may be achieved by integrating a different material having a higher durometer or rigidity, or a stiffening structure, or both, in the toe area, or in other ways, as indicated above. For example, subzone 130.1 may be formed using a lightweight, cellular foam, such as ethylvinyl acetate (EVA) or polyurethane (PU) in any desired durometer from soft to hard.

In some instances, the subzone 130.1 can include a laminate construction configured to provide increased stiffness compared to the stiffness of another subzone. Subzone 130.2 is adjacent subzone 130.1 on the lateral side of the forefoot portion of the module 110.1. Subzone 130.2 may be a monolithically molded portion of the upper that has a three dimensional volumetric shape configured to provide for lateral step stability or support along the lateral side of the forefoot. Subzone 130.2 may be made, for instance, of a rigid material relative to one or more adjacent zones. The subzone 130.1 can also include a formed stiffening element or an integral stiffening element, as described above, for example. The medial side of the shoe may include a similar stability or support subzone (not shown) defined by the medial-side module 110.2.

Subzone 130.3 is a subzone that is adjacent subzone 130.2 at its distal end, and subzone 130.5 at its proximal end. The subzone 130.3 is positioned near or at a lateral midfoot side of the upper. Subzone 130.3 has roughly a diamond-like shaped periphery portion 130.3a formed of a molded material framing a central portion 130.3b formed of a flexible textile material, such as a mesh. A mesh material may be inset into the frame to provide breathability, flexibility or lighter weight to the shoe, and particularly to the subzone 130.3, as compared to, for example, the subzone 130.2, which lacks such a mesh material.

Subzone 130.4 is a reinforced portion formed of a relatively rigid moldable polymer in which lacing holes 130.4a (or other means for securing a lace) may be disposed. Subzone 130.5 is positioned in an area near the lower, lateral side of the rearfoot area. Subzone 130.5 can be made using a relatively rigid moldable polymer. Subzone 130.6 may have a construction similar to subzone 130.3, such as with a framed aperture 130.6a of moldable materials defining an opening 130.6b for a material or a perforated moldable material that is positioned to generally correspond to the ankle zone of a high top shoe. The module 110.1 (and thus the shoe incorporating such a module) may also define one or more flexural zones 130.7 and 130.8 (e.g., fluted regions) that facilitate flex of the foot and shoe along natural lines of the foot's flexion. For example, subzone 130.7 is a notched region in the monolithic module 110.1. When worn, the notched region runs generally along some or all the metatarsal heads of the wearer's foot and may wrap partly down the lateral side of the shoe. (A generally complementary, but not necessarily identical, construction would be found in the complementary module 110.2.) A similar notch 130.8 can be located at the area where the ankle hinges. A textile material or other thin flexible material may be used to infill the notched area.

Alternatively, instead of a notch, the flexural line may be defined by a moldable plastic that is more flexible than adjacent areas.

As indicated above, a module may also include lower portions that wrap under the foot and serve as a lower enclosure portion. Such lower portions can share a unitary (or monolithic) construction with one or more modules defining the upper, or may be affixable to one or more such upper modules. A lower enclosing portion may provide midsole and/or outsole functionality. For example, a lateral or medial module like one or more of the modules 110.1, 110.2 and 110.3 can be made substantially of a material such as EVA and/or include an EVA portion that wraps under the foot to provide some or all of a sole unit 112 (e.g., Fig. 6). The sole unit portion can be of a different (e.g., a relatively higher or lower) durometer or stiffness compared to the upper to provide, e.g., higher durability, stability, cushioning, or traction.

A given contoured module for an upper portion or a uni-body upper module may be efficiently formed in a single forming process, such as, for example, injection or compression molding. Such a single-forming process can efficiently provide a module having a plurality of subzones. In other embodiments, multiple molding steps may be used to produce a monolithic structure, e.g., through multi-shot molding, co-molding or over-molding processes. Co-molded or over-molded subzones can be spatially independent, laminate, or loosely layered.

Although the example of full-length lateral and medial modules 110.1, 110.2 described above represents a two-module construction for entirely or almost entirely enclosing the foot, one, two, or three or more modules may also be used in other embodiments to define an enclosure over some or all of the foot. For example, Fig. 3 shows another possible embodiment of a lateral module 110.3 for a shoe that is not a full length module (described in more detail below.) This module 110.3 is suitable for use in a shoe such as shoe 100 of Fig. 6.

The module 110.3 comprises a plurality of materials among different subzones. For example, subzone 130.9 corresponds to the ankle of a wearer and is formed of a textile material, for example, a woven fabric framed by a stiffer periphery 130.9a. Such a subzone configuration can allow ventilation and may also have elasticity or softness for comfort, fit and/or flexibility. Subzone 130.10 corresponds to a side portion of a midfoot and includes a woven material similar to Subzone 130.9 to provide the same kinds of functions. Subzones such as 130.9 and 130.10 may be pertures, through-holes, cut-outs, voids, recesses, channels, etc., formed in a flexible, structural material. For example, such a structural material may be open- or closed-cell foamed polymers or a combination of solid polymer or composite materials. Example materials for the foam polymers include ethylvinylacetate (EVA), polyurethane (PU), but generally any foamable or solid polymer, either thermoplastic, thermoforming, cured or natural material, or combinations thereof, may be used. Fig. 4 shows a compression mold 30 for use in forming a contoured, complex module, as described according to the inventive subject matter. In this embodiment, the mold 30 defines four cavities 30A (left top), 30B (left bottom), 30C (right top), and 30D (right bottom). Such cavities can comprise a recessed feature, a feature extending from a surface, or a combination thereof. Cavities 30A and 30B close together to define the three-dimensional, volumetric shape of a medial module like module 110.1 or 110.3. For example, the cavity 30A comprises a raised feature and the cavity 30B defines a corresponding recessed feature. When closed together, the raised feature of cavity 30A can extend inwardly of the recessed feature of cavity 30B. The materials (e.g., laminate materials) can be placed in compression between the respective surfaces of the raised and recessed features of the cavities 30A and 30B, respectively. Cavities 30B and 30C can close together in a similar fashion to form a complementary medial module 110.2. The cavities can also have features that correspond to features in the molded article. For example, feature 130.9' is a raised mold feature in cavity 30B that is shaped to correspond to subzone 130.9. Similarly, feature 130.10' is a raised feature that corresponds to subzone 130.10. In this example, the cavity 30B for a medial module has placed therein a sheet of flat moldable polymer, such as EVA material, cut to a profile of the mold having medial subzones 130.9, 130.10 and 130.11, which may be the same or different from the arrangement of subzones discussed above for the lateral module 110.1 and 110.3, above. (Lateral mold cavity 30D is shown empty but in production would have a sheet of similar material before the clamshell mold 30 is closed.)

In one possible embodiment, an innovative forming process provides a laminate of structural and/or woven materials wherein the woven materials cover some or all of the outside of the shoe to provide structural integrity to a soft material, such as EVA, and/or an aesthetic similar to conventional shoes having a woven, non- woven, leather, or other textile or fabric-like material. For example, cavities 30A and 30C are shown with a fabric material. The fabric laminates to the inside (foot facing side) of the moldable polymer materials (not shown but positioned beneath the fabric) in cavities 30B and 30D.

Typically, a molding process includes heating and/or applying pressure to the materials between respective cavities, thereby causing one or both layers of materials to melt and fuse with the other. Although not shown in this example, more than two layers of materials may be inserted in the mold cavities to form a laminate of three or more layers. For example, for comfort, durability and/or aesthetics, a woven, non- woven, leather, or other textile or fabric-like material can be laminated on both sides of a moldable polymer layer to provide an upper with inside and outside surface of such material or materials supported by the polymer layer. The material could be coextensive with the moldable polymer or located in just selected subzones.

In another possible embodiment, a woven, non-woven, leather, or other textile or fabric-like material is sandwiched between opposed layers of moldable polymer, which may have surfaces that are uninterrupted by or defining openings to provide desired functions, such as structural reinforcement, selected flexibility, or ventilation.

Looking more closely at the molding process, opposed mold halves (e.g., defining cavities 30A and 30B) can be clamped together under pressure and heat using known direct compression molding techniques to form a single, contoured, complexly-shaped module having multiple subzones similar to one or more of the modules discussed above. Nonetheless, the inventive subject matter is not limited to use of direct compression molding. Other molding techniques, such as direct injection molding, co-molding, and insert molding may be used. In addition, automated and custom molding techniques may be used, such as taking foot measurement data and inputting it into a moldless forming process, such as a stereo lithographic process. In other embodiments, discrete structures or devices formed of one or more materials are placed in the mold with one or more other materials and processed to form a monolithic, heterogeneous structure.

In view of the foregoing disclosure, the inventive subject matter contemplates a single forming process that can output a monolithically (i.e., a unitary structure) molded, three-dimensional volumetric structure with one or more subzones that is homogeneous in terms of use of only moldable polymers of the same or different materials, or that is heterogeneous in terms of integrating materials other than moldable polymers (e.g., a woven material forming a laminted module) into the monolithic structure that is output from the molding step. By "single forming process" it is meant that after placing a moldable material into a mold cavity (e.g., with or without one or more other materials), the mold need only be opened or released one time to output a completed, monolithic part having a three-dimensional, volumetric shape corresponding to the mold cavity. Such a part can have a homogeneous or a heterogeneous bulk composition. Notably, however, the inventive subject matter is not limited to single molding processes. Novel structures and parts for footwear, and related methods, are disclosed herein that may involve multi- step molding processes.

Fig. 5 shows a rearfoot or heel contoured module 110.4 that may be integrated into an upper. The module 110.4 has a subzone 130.12 for cushioning the malleolus and a subzone 130.13 that is relatively more rigid for support at an upper portion of the

Achilles tendon, and a lower subzone 130.14 for flex at a lower portion of the Achilles tendon. Lateral and/or medial modules like modules 110.1 and 110.2 may have openings for receiving one or more subzones (not shown) of a rearfoot module like module 110.4. For example, Figs. 10 and 11 show a shoe with such an integrated module. Fig. 6 shows a complete assembly of a shoe 100 that includes assembled lateral and medial modules formed from the mold shown in Fig. 4. These modules may be indirectly joined by a coupling member (e.g., a coupler, a stitch, interlocking features) or may be joined directly together, as by fusing or with an adhesive. In the example shown, a coupling member 32 is disposed between the modules and along the inside and/or outside surfaces of the modules. In the example shown in Fig. 6, a coupling member also serves as a tongue/vamp for the shoe. The modules and members may be interconnected to each other by, for example, adhesives, fasteners, or mechanical interconnects (e.g., male/female snap-fitting parts), chemical bonding, vulcanization, heat fusion, or combination of these techniques. The modules may be connected to the sole unit 112 (Fig. 7) by similar techniques. As can be appreciated, these techniques advantageously may allow for stitchless manufacturing. Further, because these parts can be contoured to precise dimensions and shapes, they may be assembled or molded together without the need for a last, providing an improved fit of a wearer's foot.

Fig. 8 shows a sole unit 112 assembly of a midsole portion 116 and an outsole portion 118. An assembled upper unit or the modularized parts of the upper may be assembled onto the sole or portions thereof.

One feature of the inventive subject matter is the use of a set of assembly elements 34, e.g., assembly elements 34A, 34B, 34C, 34D (Fig. 2), positioned along edges or surfaces of parts to be coupled to each other. In Fig. 2, the assembly elements 34A, 34B, 34C, 34D can provide inwardly wrapping surfaces configured to oppose a corresponding region of a sole unit 112. Such elements can be glued, fused or otherwise joined to the region of the sole unit. Such assembly elements facilitate assembly of modules to each other or to other parts. For example, assembly elements may be arranged on

complementary parts in corresponding, set positions to facilitate alignment of the parts. The assembly elements may be any set of spaced indicators that may be perceived by a human or machine vision assembler and used to align parts. In some embodiments, the assembly elements may serve as interconnects for connecting parts. For example, the interconnects may be male/female snap fit interconnects. The interconnects may serve as the sole means for securing the parts or they may be used in combination with other joining techniques described above.

In another possible embodiment the assembly elements are in the nature of channels, recesses, or pockets formed along a surface or adjacent an edge of a module that is to be joined with another part. Such features define an area for application of an adhesive or other bonding means. In the case of adhesive, the use of such features allows parts to be joined without overflow of the adhesive, providing for efficient and clean use of adhesives.

Examples of specific athlete-specific performance benefits will now be described with regard to basketball (although other benefits can be attained in basketball and other sports).

An athlete, player, consumer, or other user can have their foot scanned or tuned into a digital cloud map. This digitized representation of the foot can be analyzed and mathematically converted into a performance 3D shape (e.g., a rendered three- dimensional CAD model). This shape can define the three-dimensional volumetric shape for the void in a shoe in which a wearer's foot will be inserted, allowing the shoe to cover the foot with a user-specific fit (sometimes referred to as a "perfect" fit).

In some instances, the user can complete a questionnaire (oral or written) about performance factors, such as position played, injury history, and/or additional performance requirements. If required, additional injury or performance requirements may be provided by an athletic trainer, coach, and/or physician. This information can be input into a computer program of a general or special purpose computer with a processor and memory that is programmed to evaluate the input data relating to three-dimensional volumetric foot shape and/or questions relating to performance factors. The program assesses the data and outputs to a manufacturer, seller, or user data or information about characteristics of a custom shoe and foot shape to provide the user with an appropriate and tuned piece of footwear to meet the user's need or desire.

The shoe can be built or tuned to the needs of the user based on the input data. For example, the output data can be fed into a machine configured for manufacturing a shoe or parts of the shoe (e.g., modules as described above). In another example, the shoe can be sold as a kit of parts that can be assembled by a seller or a user. Information output from the program can indicate a desired or optimal selection or arrangement of parts in the kit for the user.

As indicated above, in some embodiments, a machine can use data based on the output of a customization or tuning program to make a shoe according to the inventive subject matter that meets the performance and fit requirement of a given user. By way of example and not limitation, custom manufacturing may be directed as follows:

a. From input data, a computer program may also instruct a machine to

construct a shoe providing an articulating ankle in the planter, dorsal, and/or pronation directions while being rigid in the supinated direction to help assist in the decrease of standard ankle sprain and extension injury. b. From input data, a computer program may also instruct a machine to

construct a shoe providing additional support areas or structures to the shoe based upon a user's need or desire.

c. From input data, a computer program may also instruct a machine to

construct a compressed, poured, and/or injected midsole unit, outsole unit, or complete sole unit with varying midsole and outsole hardness and surface patterns to provide the user with an appropriate ride, lateral support, protection, flexibility, traction, sock attenuation, etc. d. From input data, a computer program may also instruct a machine to

construct a shoe providing unique and athlete specific performance features, such as anti-inversion bar or lateral sole unit support features, which can be built into the footwear.

Such processes as just described can be applied to all footwear related activities such as but not limited to running, jumping, and lateral load based activity sports.

As used herein a "sole unit" generally means the structural material of a shoe that is disposed between the bottom of a wearer's foot and the ground. In general, a sole unit has one or more integral units (e.g., modules 116, 118 in Fig. 7) that correspond to the full length and width of the foot. However, a sole unit can correspond to just a portion of the foot such as the rearfoot, midfoot, forefoot, or combinations of those areas. A sole unit may include a full or partial midsole and/or discrete reaction elements in combination with an outsole, which provides an outer surface for ground contact, abrasion resistance and/or traction. A sole unit can be a single unit that provides such midsole or outsole functions across some or all the length of a foot. For example, some shoes have a monolithic, single layer of a foamed polymer, such as EVA that provides both midsole and outsole functions.

Contemplated fabrication methods for the sole unit components include molding, injection molding, blow molding, direct-injection molding, one-time molding, composite molding, insert molding, co-molding separate materials, or other techniques known in the art, alone or in combination. Contemplated fabrication or assembly methods include adhesives, bonding agents, welding, mechanical bonding, or interlocking shapes, alone or in combination.

Dampening elements, which are a form of cushioning element, may also be incorporated into the sole units disclosed herein. "Dampening" generally refers to the ability of certain materials to dissipate mechanical energy and thereby reduce the amplitude of oscillations, vibrations, or waves. In footwear, shock from impact may generate compression waves or other vibrations within the sole system. Contemplated dampening materials include visco-elastomers. In some instances, plain elastomer materials may be used as dampers; however, they may not provide as desirable dampening qualities on the spring unit as a visco-elastomer. Example materials for a visco-elastic damper include any number of polymers, including polyurethanes and polyethylenes in foam or gel form, fabricated by conventional molding practices or by film. Other suitable visco-elastomers are known to persons skilled in the art.

Contemplated fabrication methods for visco-elastomers include molding, injection molding, blow molding, direct- injection molding, one-time molding, composite molding, insert molding, co-molding separate materials, or other techniques known in the art, alone or in combination. Contemplated fabrication or assembly methods include adhesives, bonding agents, welding, mechanical bonding, or other mechanical or chemical fastening means know to persons in the art, alone or in combination.

The outsole or traction surface for a sole assembly may include natural and synthetic rubbers, leather, cleats, spikes, felts, ethylvinyl acetate (EVA) foam, polyurethane (PU) foams, and other known or discovered sole unit materials, and combinations of the foregoing.

Figs. 13-20 show another possible embodiment of a left shoe 201 having a plurality of subzones formed of monolithically molded pieces that are assembled together. In this embodiment, the shoe is assembled from a set of components that include an upper 210 molded to sole unit 212 having (and in some instances, consisting) of a midsole 216 and outsole 218, and internal bootie 214 (Fig. 14). The upper 210 includes a medial module 210.1 and a lateral module 210.2 (Figs. 15 and 16), each of which may be molded as a three-dimensional piece that is generally complementary to the other and helps define some or all of the three-dimensional volumetric shape of the shoe, i.e., the void in the shoe for receiving a foot. As with modules described above, the modules 210.1, 210.2 may be made of a flexible, moldable material, for example foamed EVA or PU. In some applications, the modules have a relatively soft Durometer, such as a durometer ranging from about 25 to about 50, with a Durometer of 35 serving well for some applications. The modules may also serve to define subzones 230.1 and 230.2, which may be tuned to provide performance or fit attributes, for example, as described above for other module embodiments. The module 230.2 further includes a void 214.1 around the ankle area for enhancing flexibility of the ankle, breathability, and/or lightweightness.

The shoe shown in Fig. 13 also includes a toe cap module 236 made of a monolithically molded structure and having three-dimensional shape that assembles with the medial and lateral modules, 210.1 and 210.2, and sole unit 212 to define entirely or substantially the three dimensional volumetric shape of the shoe. In this embodiment, the shape is adapted to receive bootie 214 (Fig. 14), which may be made, for example, of stretchable mesh or other textile, fabric, natural or synthetic materials based construction. Such booties may be removable or permanently affixed to one or more of the modules forming the upper 210 and/or sole unit 212.

The shoe in Fig. 13 may also include a rear heel module 238 made of a relatively inflexible material to impart reinforcement and stability of the rear foot and ankle. For example, module 238 may be made of TPU and have a substantially higher Durometer or modulus of elasticity relative to either or both of the medial and lateral modules 210.1 and 210.2.

Persons skilled in the art will recognize that many modifications and variations are possible in the details, materials, and arrangements of the parts and actions which have been described and illustrated in order to explain the nature of the inventive subject matter, and that such modifications and variations do not depart from the spirit and scope of the teachings and claims contained therein.

All patent and non-patent literature cited herein, if any, is hereby incorporated by references in its entirety for all purposes.

Claims

CURRENTLY CLAIMED INVENTIONS:

1. A module for a shoe, comprising,

a three-dimensional module for covering at least one of a lateral or medial forefoot, midfoot, or rearfoot area of a foot, the covering comprising a plurality of subzones, each subzone formed having different structural, functional, or material property attributes, the module being formed in a single forming process that generally creates and defines the subzones, the module having a homogenous or heterogeneous monolithic structure.

2. The module of claim 1 wherein at least one first subzone comprises a ventilation subzone comprising a breathable woven or non-woven material and a second subzone comprises a structural material.

3. The module of claim 2 wherein the second subzone further includes a fabric or other textile disposed on the outer surface of the structural material.

4. The module of claim 3 wherein the fabric and structural material are co-molded together in the single forming process and joined via a fusion bond.

5. A shoe comprising an upper assembly of a plurality of modules as described in claim 1, wherein the modules are preconfigured to form a predefined void for receiving a foot and the parts are generally complementary for assembly directly together, or indirectly using connectors, so as to not require a last.

6. The shoe of claim 5 wherein the modules of the shoe are connected together

without stitches.

7. The shoe of claim 1 further comprising a sole unit, the sole unit comprising a polymer for shock dissipation and /or energy return, for example, EVA, PU, or other midsole material used in construction of athletic footwear.

8. The shoe of claim 7 wherein the upper assembly comprises:

an enclosure for substantially covering all of a forefoot, midfoot and rearfoot, and the modules provide a plurality subzones comprising voids in a flexible structural material and a breathable textile disposed across the voids; and

a substantial or major portion of the structural material where there are no voids has a textile material co-molded or otherwise adhered to its outer surface.

9. The shoe of claim 5 wherein at least one of the modules comprises a foamed or non-foamed moldable polymer having an inner or outer layer of textile disposed thereon, the materials being joined via a fusion bond.

10. The shoe of claim 5 wherein the modules include a plurality of distinct subzones each directed to support, protection, cushioning, flexibility, and/or

breathability.

11. The shoe of claim 1 wherein at least one module includes at least a portion of a sole unit.

12. The shoe of claim 5 wherein at least one module includes a subzone comprising a frame or cage having a substantially higher rigidity relative to an adjacent subzone of the same or a different module.

13. A method of making a module, comprising:

inserting a moldable polymer into a mold cavity having the shape of a three- dimensional module for covering at least one of a lateral or medial forefoot, midfoot, or rearfoot area of a foot, the mold cavity including features for defining a plurality of subzones, each subzone formed having different structural, functional, or material property attributes; inserting a textile material into the same mold cavity; and

molding the materials together into a monolithic structure in a single forming process that generally creates and defines the subzones.

14. The module of claim 1 wherein the module has at least one subzone comprising a laminate of a textile material and a moldable plastic, the materials being joined by a fusion bond. shoe comprising:

a plurality of modules each having a non-planar, three dimensional shape defining at least an upper portion of a shoe comprising lateral and medial portions side portions of the shoe that extend over the lateral and medial sides of a foot, two or more modules comprising a laminate of inner and outer textile materials laminated to a middle layer of a moldable plastic, the materials being joined by a fusion bond; and a sole unit joined to the modules.

16. The module of claim 1 wherein the module comprises a moldable polymer

structural material having an outer layer of textile disposed thereon, the outer textile and structural materials being co-molded together in the single forming process.

17. The module of claim 16 wherein the moldable polymer structural layer further includes an inner layer of textile material disposed thereon, the inner textile material and structural materials being co-molded together in the single forming process.

18. A shoe comprising an upper assembly of a plurality of modules as described in claim 16, wherein the modules are preconfigured to form a predefined void for receiving a foot and the parts are generally complementary for assembly directly together, or indirectly using connectors.

19. The shoe of claim 18 further comprising a sole unit assembled to the upper

assembly.

20. The shoe of claim 19 wherein the upper assembly comprises:

21. A shoe comprising an upper assembly of a plurality of modules each having a non-planar, three dimensional shape defining at least an upper portion of a shoe comprising lateral and medial portions side portions of the shoe that extend over the lateral and medial sides of a foot, wherein the modules are preconfigured to form a predefined void for receiving a foot and the parts are generally complementary for assembly directly together, or indirectly using connectors, and wherein at least two modules comprise a moldable polymer structural material.

22. The shoe of claim 21 further comprising a sole unit assembled to the upper

assembly.

23. The shoe of claim 22 wherein the upper assembly comprises: