US20250072548A1

US20250072548A1 - Footwear with textured skin

Info

Publication number: US20250072548A1
Application number: US18/460,166
Authority: US
Inventors: Kyle Christopher JOHNSON
Original assignee: Adidas AG
Current assignee: Adidas AG
Priority date: 2023-09-01
Filing date: 2023-09-01
Publication date: 2025-03-06
Also published as: CN119547955A; EP4516148A3; EP4516148A2

Abstract

An article of footwear includes a porous body comprising a lattice of interconnected unit cells and a first porosity. The article of footwear also includes skin layer integrally formed on an exterior of the porous body. The skin layer has a second porosity and defines ribs that extend outward from the porous body. The second porosity is less than the first porosity.

Description

FIELD

The described embodiments generally relate to soles for articles of footwear. More particularly, described embodiments relate to soles for articles of footwear including porous bodies formed by a lattice structure and a skin located on an exterior of the porous body to provide desired mechanical and/or aesthetic characteristics to the articles.

BACKGROUND

The human foot is a complex and remarkable piece of machinery, capable of withstanding and dissipating many impact forces. The natural padding of fat at the heel and forefoot, as well as the flexibility of the arch, help to cushion the foot. Although the human foot possesses natural cushioning and rebounding characteristics, the foot alone is incapable of effectively overcoming many of the forces encountered during every day activity. Unless an individual is wearing shoes that provide proper cushioning and support, the soreness and fatigue associated with every day activity is more acute, and its onset may be accelerated. This discomfort for the wearer may diminish the incentive for further activity. Equally important, inadequately cushioned footwear can lead to injuries such as blisters; muscle, tendon, and ligament damage; and bone stress fractures. Improper footwear can also lead to other ailments, including back pain.
Individuals are often concerned with the amount of cushioning an article of footwear provides. This is true for articles of footwear worn for non-performance activities, such as a leisurely stroll, and for performance activities, such as running, because throughout the course of an average day, the feet and legs of an individual are subjected to substantial impact forces. When an article of footwear contacts a surface, considerable forces may act on the article of footwear and, correspondingly, the wearer's foot. The sole of an article of footwear functions, in part, to provide cushioning to the wearer's foot and to protect it from these forces.
Proper footwear should be durable, comfortable, and provide other beneficial characteristics for an individual. Therefore, a continuing need exists for innovations in footwear.

BRIEF SUMMARY

A first embodiment (1) of the present application is directed to an article of footwear. The article of footwear can comprise a porous body comprising a lattice of interconnected unit cells and a first porosity. The article of footwear can also comprise a skin layer integrally formed on an exterior of the porous body. The skin layer can comprise a second porosity and defining ribs that extend outward from the porous body, wherein the second porosity can be less than the first porosity.
In a second embodiment (2) further to embodiment (1), the skin layer can be a solid layer lacking through pores.
In a third embodiment (3) further to embodiment (2), the porous body can be a lattice of interconnected unit cells. The unit cells can each comprise a base geometry. The skin layer does not comprise a lattice of interconnected unit cells comprising the base geometry.
In a fourth embodiment (4) further to any of embodiments (1)-(3), the ribs can have a height distribution within a range from 0.5 mm through 10 mm.
In a fifth embodiment (5) further to any of embodiments (1)-(4), the ribs can have a width distribution within a range from 0.5 mm through 10 mm.
In a sixth embodiment (6) further to any of embodiments (1)-(5), the ribs can be separated by channels. Each channel can have a constant width for a length of at least a majority of a length of the rib.
In a seventh embodiment (7) further to embodiment (6), the ribs can be parallel to each other.
In an eighth embodiment (8) further to any of embodiments (1)-(7), at least a portion of an outsole of the article can lack the skin layer such that the porous body provides part of a ground facing side of the outsole.
In a ninth embodiment (9) further to any of embodiments (1)-(8), an area occupied by the skin layer can cover at least 50% of the exterior of the porous body.
In a tenth embodiment (10) further to any of embodiments (1)-(9), the porous body can define at least a portion of a sole and at least a portion of an upper for the article of footwear.
In an eleventh embodiment (11) further to any of embodiments (1)-(10), the article of footwear can be a sandal comprising an upper that comprises at least part of the porous body. The skin layer can extend across at least a portion of the upper.
In a twelfth embodiment (12) further to embodiment (11), the ribs can be separated by channels including respective portions of the skin layer. An area occupied by the skin layer can cover at least 50% of the exterior of the porous body.
In a thirteenth embodiment (13) further to embodiment (12), the upper can comprise an outer side and an inner side. The skin layer can extend across at least a portion of the outer side and at least a portion of the inner side.
In a fourteenth embodiment (14) further to embodiment (13), the article can comprise a sole attached to the upper. The sole can comprise a second portion of the porous body. The skin layer can extend onto the sole.
In a fifteenth embodiment (15) further to any of embodiments (1)-(14), the article can comprise a sole comprising at least a portion of the porous body and comprising an insole side. The skin layer can extend across at least a portion of the insole side.
A sixteenth embodiment (16) of the present application is directed to a sandal. The sandal can comprise a porous body comprising a lattice of interconnected unit cells. The sandal can also comprise a sole comprising a first portion of the porous body. The sandal can also comprise an upper comprising a second portion of the porous body and connected to the sole. The sandal can also comprise a first plurality of ribs extending across a portion of an exterior of the sole. The first plurality of ribs can define a first plurality of channels between neighboring ribs among the first plurality of ribs. The channels among the first plurality of channels can be equal in width along at least a portion of their length. The sandal can also comprise a second plurality of ribs extending across a portion of an exterior of the upper. The second plurality of ribs can define a second plurality of channels between neighboring ribs among the second plurality of ribs, and the channels among the second plurality of channels can be equal in width along at least a portion of their length.
In a seventeenth embodiment (17) further to embodiment (16), the sandal can comprise a skin layer that has a lower porosity than the porous body. The sole can comprise an insole side configured to face a bottom of a wearer's foot when the sandal is worn. The skin layer can extend onto the insole side of the sole.
In an eighteenth embodiment (18) further to embodiment (17), the first plurality of ribs, the second plurality of ribs, or both, can be defined by the skin layer.
In a nineteenth embodiment (19) further to embodiment (17) or embodiment (18), the insole side of the sole can comprise a recessed portion and a raised perimeter. The first plurality of ribs can extend across the recessed portion.
In a twentieth embodiment (20) further to embodiment (19), the ribs among the first plurality of ribs can have a first height defined relative to the first plurality of channels. The raised perimeter can have a second height defined relative to the first plurality of channels. The second height can be greater than the first height.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a side elevation view of an article of footwear according to some embodiments.

FIG. 1B is a top plan view of the article of FIG. 1A.

FIG. 1C is a bottom plan view of the article of FIG. 1A

FIG. 1D is a cross-section of the article of footwear of FIG. 1A on the sagittal plane 1D-1D′ shown in FIGS. 1B and 1C.

FIG. 1E is an enlarged portion of the cross-section of FIG. 1A.

FIG. 1F is a plan view of a portion of an exterior of the article of FIG. 1A.

FIG. 2A is a perspective view of an article of footwear according to some embodiments.

FIG. 2B is a side elevation view of the article of FIG. 2A.

FIG. 2C is a top plan view of the article of FIG. 2A.

FIG. 2D is a bottom plan view of the article of FIG. 2A.

FIG. 2E is a cross-section of the article of FIG. 2A on the sagittal plane 2E-2E′ shown in FIGS. 2C and 2D.

FIG. 2F is an enlarged portion of the cross-section of FIG. 2E.

FIG. 3A is a perspective view of an article of footwear according to some embodiments.

FIG. 3B is a side elevation view of the article of FIG. 3A.

FIG. 3C is a top plan view of the article of FIG. 3A.

FIG. 3D is a bottom plan view of the article of FIG. 3A.

FIG. 3E is a cross-section of the article of FIG. 3A on the sagittal plane 3E-3E′ shown in FIGS. 3C and 3D.

FIG. 3F is an enlarged portion of the cross-section of FIG. 3E.

FIG. 4A is a perspective view of an article of footwear according to some embodiments.

FIG. 4B is a side elevation view of the article of FIG. 4A.

FIG. 4C is a top plan view of the article of FIG. 4A.

FIG. 4D is a bottom plan view of the article of FIG. 4A.

FIG. 4E is a cross-section of the article of FIG. 4A on the sagittal plane 4E-4E′ shown in FIGS. 4C and 4D.

FIG. 4F is an enlarged portion of the cross-section of FIG. 4E.

FIG. 4G is another enlarged portion of the cross-section of FIG. 4E.

FIG. 5A is a perspective view of an article of footwear according to some embodiments.

FIG. 5B is a side elevation view of the article of FIG. 5A.

FIG. 5C is a top plan view of the article of FIG. 5A.

FIG. 5D is a bottom plan view of the article of FIG. 5A.

FIG. 5E is a cross-section of the article of FIG. 5A on the sagittal plane 5E-5E′ shown in FIGS. 5C and 5D.

FIG. 5F is an enlarged portion of the cross-section of FIG. 5E.

FIG. 5G is another enlarged portion of the cross-section of FIG. 5E.

DETAILED DESCRIPTION

The present invention(s) will now be described in detail with reference to embodiments thereof as illustrated in the accompanying drawings. References to “one embodiment”, “an embodiment”, “an exemplary embodiment”, etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.
Articles of footwear according to the present disclosure can comprise a porous body. In some embodiments, the porous body can comprise a three dimensional mesh. As used herein, the term “three-dimensional mesh” means a three-dimensional structure comprising interconnected structural members defining a plurality of unit cells. The structural members, and thus the unit cells, can be connected at nodes. The unit cells can be arranged in a lattice configuration. For example, the interconnected structural members can be struts that are connected at nodes and that define unit cells arranged in a lattice configuration. Exemplary lattice configurations include, but are not limited to modified basic cubic lattices, modified body-centered cubic lattices, and modified face-centered cubic lattices.
In some embodiments, a portion or entirety of an article of footwear discussed herein can be monolithically formed, for example using an additive manufacturing method. In some embodiments, the porous body and skin of an article of footwear discussed herein can be monolithically formed. In some embodiments, the sole and upper of an article of footwear discussed herein can be monolithically formed.
A portion or an entirety of an article of footwear comprising a porous body (for example, a three-dimensional mesh) as discussed herein can be manufactured using one or more additive manufacturing methods. Additive manufacturing methods can allow for fabrication of three-dimensional objects without the need for a mold. By reducing or eliminating the need for molds, additive manufacturing methods can reduce costs for a manufacturer, and in turn a consumer, of a product (e.g., a shoe). Integral manufacturing of an article of footwear using additive manufacturing can make the assembly of separate elements of the article of footwear unnecessary. Similarly, an additively manufactured article of footwear can be fabricated from single material, which can facilitate easy recycling of the article of footwear.
Further, since molds may not be required, additive manufacturing methods facilitate customization of products. Additive manufacturing methods can be leveraged to provide customized and affordable footwear for individuals. Exemplary additive manufacturing techniques include for example, selective laser sintering, selective laser melting, selective heat sintering, stereo lithography, fused deposition modeling, or 3-D printing in general. Various additive manufacturing techniques related to articles of footwear are described for example in US 2009/0126225, WO 2010/126708, US 2014/0300676, US 2014/0300675, US 2014/0299009, US 2014/0026773, US 2014/0029030, WO 2014/008331, WO 2014/015037, US 2014/0020191, EP 2564719, EP 2424398, and US 2012/0117825. In some embodiments, the additive manufacturing process can include a continuous liquid interface production process. For example, the additive manufacturing process can include a continuous liquid interface production process as described in U.S. Pat. No. 9,453,142, issued on Sep. 27, 2016, which is hereby incorporated in its entirety by reference thereto.
In some embodiments, 3-D printing a porous body can comprise 3-D printing the body in an intermediate green state, shaping the body in the green state, and curing the green body in its final shape.
Techniques for producing an intermediate object from resins by additive manufacturing are known. Suitable techniques include bottom-up and top-down additive manufacturing, generally known as stereolithography. Such methods are known and described in, for example, U.S. Pat. No. 5,236,637 to Hull, U.S. Pat. Nos. 5,391,072 and 5,529,473 to Lawton, U.S. Pat. No. 7,438,846 to John, U.S. Pat. No. 7,892,474 to Shkolnik, U.S. Pat. No. 8,110,135 to El-Siblani, U.S. Patent Application Publication No. 2013/0292862 to Joyce, and US Patent Application Publication No. 2013/0295212 to Chen et al. The disclosures of these patents and applications are incorporated by reference herein in their entirety.
In some embodiments, the additive manufacturing step can be carried out by one of the family of methods sometimes referred to as continuous liquid interface production (CLIP). CLIP is known and described in, for example, U.S. Pat. Nos. 9,211,678; 9,205,601; 9,216,546; and others; in J. Tumbleston et al., Continuous liquid interface production of 3D Objects, Science 347, 1349-1352 (2015); and in R. Janusziewcz et al., Layerless fabrication with continuous liquid interface production, Proc. Natl. Acad. Sci. USA 113, 11703-11708 (Oct. 18, 2016). Other examples of methods and apparatus for carrying out particular embodiments of CLIP include, but are not limited to: Batchelder et al., US Patent Application Pub. No. US 2017/0129169 (May 11, 2017); Sun and Lichkus, US Patent Application Pub. No. US 2016/0288376 (Oct. 6, 2016); Willis et al., US Patent Application Pub. No. US 2015/0360419 (Dec. 17, 2015); Lin et al., US Patent Application Pub. No. US 2015/0331402 (Nov. 19, 2015); D. Castanon, US Patent Application Pub. No. US 2017/0129167 (May 11, 2017). B. Feller, US Pat App. Pub. No. US 2018/0243976 (published Aug. 30, 2018); M. Panzer and J. Tumbleston, US Pat App Pub. No. US 2018/0126630 (published May 10, 2018); K. Willis and B. Adzima, US Pat App Pub. No. US 2018/0290374 (Oct. 11, 2018) L. Robeson et al., PCT Patent Pub. No. WO 2015/164234 (see also U.S. Pat. Nos. 10,259,171 and 10,434,706); and C. Mirkin et al., PCT Patent Pub. No. WO 2017/210298 (see also US Pat. App. US 2019/0160733). The disclosures of these patents and applications are incorporated by reference herein in their entirety.
While stereolithography techniques such as CLIP can be preferred, it will be appreciated that other additive manufacturing techniques, such as jet printing (see, e.g., U.S. Pat. No. 6,259,962 to Gothait and US Patent App. Ser. No. US 2020/0156308 to Ramos et al.) can also be used.
In some embodiments, an article of footwear can comprise a porous body and a skin layer on the porous body. The skin layer can define, in whole or in part, one or more textures (e.g., ribs or studs) on the article of footwear. The skin layer can have a lesser porosity than the porous body. The skin layer can be a solid layer. In some embodiments, the skin layer can define ribs that extend outward from the porous body. In some embodiments, the porous body can comprise a three dimensional mesh. In such embodiments, the three dimensional mesh can comprise interconnected structural members defining a plurality of unit cells. The structural members, and thus the unit cells, can be connected at nodes. The unit cells can be arranged in a lattice configuration. For example, the interconnected structural members can be struts that are connected at nodes and that define unit cells arranged in a lattice configuration.
In some embodiments, the article of footwear can comprise an upper and a sole. The upper and the sole can each comprise a respective portion of the porous body. In some embodiments, ribs can be defined on the upper. In some embodiments, ribs can be defined on the sole. In some embodiments, ribs can be defined on the upper and on the sole. In some embodiments, the porous body and the skin layer can define an entirety of the upper. In some embodiments, the porous body and the skin layer can define an entirety of the sole. In some embodiments, the porous body can extend continuously from the sole to the upper. In some embodiments, the skin layer can extend continuously from the sole to the upper.
In some embodiments, the sole can comprise an insole side configured to face a bottom of the wearer's foot. In some embodiments, ribs can be defined on the insole side. In some embodiments, the insole side can comprise a recessed portion and a raised perimeter extending around the recessed portion. In such embodiments, the ribs can extend across the recessed portion.
Channels can be defined between the ribs on articles of footwear discussed herein. In some embodiments, each widthwise cross section of a channel can comprise a minimum defined at a local lowest point of the channel. In some embodiments, at each location along a longitudinal axis on which toe and heel directions are defined relative to the article of footwear, a raised perimeter for an insole side can be higher than any channel minimum in a recessed portion at the same location along the longitudinal axis. In some embodiments, at each location along the longitudinal axis, the raised perimeter can be higher than any rib at the same location along the longitudinal axis.
FIGS. 1A-1C are, respectively, side top and bottom view of an article of footwear 110 according to some embodiments, and FIG. 1D is a cross section of the article of footwear 110. In the illustrated embodiment, the article of footwear 110 is a “slide” style sandal, though the concepts of the present disclosure can be applied to types of footwear other than slides, such as other types of sandals or footwear other than sandals.
Turning to FIGS. 1E and 1F, with continued reference to FIGS. 1A-1D, article 110 comprises a porous body 146 and a skin layer 162 on the porous body. Skin layer 162 can have a lesser porosity than porous body 146. In some embodiments, skin layer 162 can be a solid layer. In such embodiments, skin layer 162 can optionally lack any through pores (i.e., pores that extend from outside article 110 through skin layer 162 to porous body 145). In further embodiments, skin layer 162 can be a layer of material lacking any pores.
In some embodiments, porous body 146 can comprise a first porosity and the skin layer 162 can comprise a second porosity less than the first porosity. In some embodiments, the second porosity can be at least 5% less than the first porosity. In further embodiments, the second porosity can be at least 10% less than the first porosity. In further embodiments, the second porosity can be at least 25% less than the first porosity. In further embodiments, the second porosity can be at least 50% less than the first porosity. In further embodiments, the second porosity can be at least 75% less than the first porosity. In further embodiments, the second porosity can be at least 90% less than the first porosity. In further embodiments, the second porosity can be at least 95% less than the first porosity. In further embodiments, the second porosity can be at least 99% less than the first porosity. In further embodiments, the second porosity can be 100% less than the first porosity, in which case the second porosity can be zero, and the skin layer 162 can be free of pores 144. For example, in embodiments wherein the porous body 146 is a lattice of interconnected unit cells comprising a base geometry that defines the pores and the porosity of the skin layer 162 is 100% less than the porosity of the porous body 146, the skin layer 162 does not comprise any lattice of interconnected unit cells comprising the base geometry.
“Porosity” as used herein refers to a void fraction for a component, which refers to a volumetric amount of void space compared to a total volume of a component being considered. Thus, for example, the porosity of a unit cell is a volume of void space in the unit cell's geometry divided by the total volume of the unit cell. Similarly, as another example, a porosity of a skin layer is an amount of void in a representative portion of the skin layer divided by the total volume of the representative portion. As a non-limiting example, a component having 1 cubic centimeter (cc) of void space for a 2 cubic centimeter (cc) portion of the component has a porosity of 50%. A higher porosity means that a component has a greater void faction.
Zero is a possible value of “porosity” as used herein and means that the component has zero void space for the portion of the component being considered. Thus, where a first component is said to have a greater porosity than a second component, the second component can have zero void space unless stated otherwise
In some embodiments, porous body 146 can be a three dimensional mesh. In such embodiments, the three dimensional mesh can comprise interconnected structural members 150 defining a plurality of unit cells. The structural members 150, and thus the unit cells, can be connected at nodes 154. In some embodiments, the unit cells can be unit cells comprising a base geometry arranged in a lattice configuration. For example, interconnected structural members 150 can be struts 150 that are connected at nodes 154 and that define unit cells arranged in a lattice configuration. As used herein “base geometry” means the base three dimensional shape of a unit cell. A base geometry is the three dimensional shape of a unit cell in an unwarped and unmodified state (e.g., when the unit cell is not deformed by loading, conformed to a specific shape, or modified as described herein). The base geometry of a unit cell can be, but is not limited to, a dodecahedron (e.g., rhombic), a tetrahedron, an icosahedron, a cube, a cuboid, a prism, or a parallelepiped. In further examples, a base geometry can be struts and nodes forming, for example, but not limited to, a dodecahedron (e.g., rhombic), a tetrahedron, an icosahedron, a cube, a cuboid, a prism, or a parallelepiped.
In some embodiments, pores 144 of porous body 146 can be cavities defined by the lattice of unit cells. A size of a pore 144 can be defined as a diameter of a largest sphere that could fit in the pore 144. Average pore size can be defined as an average diameter of sizes of all pores 144 defined by an object. A maximum pore size can be defined as a diameter of a largest sphere that could fit in any pore defined by an object. In some embodiments, skin layer 162 can have a smaller maximum pore size than porous body 146. In some embodiments, skin layer 162 can have a maximum pore size smaller than an average pore size of porous body 146.
In some embodiments, skin layer 162 can cover a majority of an exterior of porous body 146. As used herein, the exterior of porous body 146 refers to a boundary of a volume that contains porous body 146 without extending into any pores 144 in porous body 146. In embodiments wherein porous body 146 comprises a three dimensional mesh of unit cells, the boundary that defines the exterior of porous body 146 does not extend into any voids defined within the base geometry of the unit cells. In some embodiments, one or more of the unit cells can be truncated at the exterior of porous body 146, thereby forming an incomplete instance of the base geometry that adjoins the boundary. In such embodiments, the area of the exterior of the porous body is the surface area of a shape that extends across the surfaces formed at the truncations of the incomplete base geometries without extending into any voids defined within the existing portions of the incomplete base geometries.
In some embodiments, skin layer 162 can cover at least 50% of the exterior of porous body 146, at least 60% of the exterior of porous body 146, at least 75% of the exterior of porous body 146, at least 90% of the exterior of porous body 146, at least 95% of the exterior of porous body 146, at least 99% of the exterior of porous body 146, or an entirety of the exterior of porous body 146. Skin layer 162 can extend onto any one or any combination of an outsole side 122 of sole 114, an insole side 124 of sole 114, an outer side 130 of upper 118, and an inner side 132 of upper 118. For example, skin layer 162 can extend across at least a portion of upper 118. In some such embodiments, skin layer 162 can extend across at least a portion of outer side 130 of upper 118. In further such embodiments, skin layer 162 can extend across at least a portion of inner side 132 of upper 118. Similarly, skin layer 162 can extend across at least a portion of sole 114. In some such embodiments, skin layer 162 can extend across a portion of outsole side 122 of sole 114. In further such embodiments, skin layer 162 can extend across at least a portion of insole side 124 of sole 114.
Article 110 can comprise ribs 134 extending outward from porous body 146. Ribs 134 can run along an exterior of article 110. Ribs 134 can include part of skin layer 162. In some embodiments, ribs 134 can be defined entirely by skin layer 162 such that skin layer 162 comprises ribs 134. In other embodiments, ribs 134 can be defined partially by skin layer 162 and partially by porous body 146 such that ribs 134 comprise part of skin layer 162 and part of porous body 146.
Ribs 134 can comprise various shapes and characteristics as described herein. In some embodiments, ribs 134 can comprise features of ribs 234 described herein. In some embodiments, ribs 134 can comprise features of ribs 334 described herein. In some embodiments, ribs 134 can comprise features of ribs 434 described herein.
Some ribs 134 can extend across multiple surfaces by wrapping around contours of the exterior of article 110. For example, some ribs 134 can extend onto both sole 114 and upper 118. Some such ribs 134, as shown in FIG. 1A in particular, can extend from outsole side 122 of sole 114 to outer side 130 of upper 118. Other such ribs 134, as shown in FIG. 1E in particular, can extend from insole side 124 of sole 114 to inner side 132 of upper 118. Some ribs 134 extending from insole side 124 of sole 114 to inner side 132 of upper 118 can encircle a portion of inner space 126. Other ribs 134 can extend from outsole side 122 to insole side 124 and thereby wrap around sole 114 as shown in FIGS. 1B and 1C. The ribs 134 that wrap around sole 114 can extend across raised perimeter 178 of insole side 124.
In some embodiments, a first plurality of ribs 134 can extend across a portion of an exterior of sole 114, wherein the first plurality of ribs 134 defines a first plurality of channels 158 between neighboring ribs 134 among the first plurality of ribs 134. Channels 158 among the first plurality of channels 158 can be equal in width along at least a portion of their length. In some embodiments, a second plurality of ribs 134 can extend across a portion of an exterior of upper 118, wherein the second plurality of ribs 134 defines a second plurality of channels 158 between neighboring ribs 134 among the second plurality of ribs 134. Channels 158 among the second plurality of channels 158 can be equal in width along at least a portion of their length.
Channels 158 are defined between ribs 134. Whereas ribs 134 are local raised portions of an exterior of article 110, channels 158 are local recesses in the exterior of article 110 between adjacent ribs. Thus, on any surface of article 110 across which ribs 134 extend, an alternating pattern of ribs 134 and channels 158 can be defined. A depth of channels 158 is the same as height 166 of ribs 134 adjoining those channels 158. Height 166 can vary at different locations across article 110, but can remain within a range of, for example, from 0.5 mm through 10 mm.
As shown in FIGS. 1E and 1F specifically, a width 168 of a channel 158 at a given location is a distance between peaks of the two ribs 134 between which the channel is defined, measured perpendicular to a tangent line 160 to a center line 172 of channel 158 at that location. A width of a rib 134 is similarly the distance between the center lines 172 of the two adjacent channels 158 measured perpendicularly to a line tangent to a center line of the rib 134 at that location. Widths of channels 158 and ribs 134 can vary at different locations on article 110. In some embodiment, widths of ribs 134 and channels 158 across article 110 can fall within a range from 0.5 mm through 10 mm. In further embodiments, some or all channels 158 can have a constant width 168 along at least a majority of their respective lengths.
In some embodiments, skin layer 162 can be absent from some portions of the exterior of porous body 146 such that porous body 146 provides part of an exterior of article 110. In some such embodiments, skin layer 162 can define openings that extend through skin layer 162 to expose porous body 146. In some embodiments wherein skin layer 162 defines openings, the openings may be defined in channels 158. In some embodiments wherein skin layer 162 is absent from some portions of the exterior of porous body 146, porous body 146 may define part of a ground-facing side of sole 114.
Each rib 134 has an inner volume 164 defined outward from the lowest points of the adjoining channels 158. In the illustrated embodiment, the inner volume 164 of each rib 134 is filled with the material that makes up skin layer 162 such that skin layer 162 includes the ribs 134 (as shown for example in FIG. 3F). In other embodiments, porous body 146 can extend into inner volume 164 such that each rib 134 includes a portion of skin layer 162 and a portion of porous body 146 (as shown for example in FIG. 2F).
With specific reference again to FIGS. 1A-D, article 110 comprises a sole 114 and an upper 118. An interior space 126 of article 110 is defined between sole 114 and upper for receiving a wearer's foot 170. Sole 114 can be defined by porous body 146 and skin layer 162. Upper 118 can be defined by porous body 146 and skin layer 162. In some embodiments, sole 114 and upper 118 can be defined by different portions of the same porous body 146 and skin layer 162 such that sole 114 and upper 118 are monolithic. In such embodiments, sole 114 and upper 118 each comprise a respective portion of porous body 146. That is, sole 114 can comprise a first portion of porous body 146 and upper can comprise a second portion of porous body 146. Further, porous body 146 can define a portion of sole 114. Similarly, porous body 146 can define a portion of upper 118.
Sole 114 comprises an outsole side 122 and an insole side 124. Outsole side 122 faces away from upper 118. Outsole side 122 also faces toward the ground when article 110 is worn, as shown for example in FIG. 1D. In the illustrated embodiment, outsole side 122 can be configured to engage the ground when article 110 is worn as shown in FIG. 1D, though in other embodiments article 110 can be provided with an additional sole element for attaching to outsole side 122 and engaging the ground. In some embodiments, ribs 134 can extend across outsole side 122 and thereby act to facilitate traction between sole 114 and the ground.
Insole side 124 faces toward upper 118 and therefore defines a boundary of interior space 126. Insole side 124 of the illustrated embodiment can contact the bottom or sole of wearer's foot 170 when article 110 is worn, as shown for example, in FIG. 1D, though in other embodiment article 110 can be provided with an insole insert to be disposed between insole side 124 and the wearer's foot 170.
In some embodiments, ribs 134 can extend across insole side 124. In such embodiments, the ribs 134 can create an uneven distribution of pressure across the bottom or sole of wearer's foot 170. In particular, the wearer's foot 170 experiences a greatest pressure where it contacts ribs 134. Within the area of contact between most individual ribs 134 and wearer's foot 170, the greatest pressure on the wearer's foot 170 will be at a peak of the rib 134, meaning a highest point of the rib 134 and the furthest from the bottoms of the adjacent channels 158. Conversely, the wearer's foot 170 can experience relatively little or no pressure from sole 114 where foot 170 extends across channels 158.
The above described uneven distribution of pressure between insole side 124 of sole 114 and the wearer's foot 170 created by ribs 134 extending across insole side 124 can have a therapeutic effect on the wearer's foot 170. In particular, the uneven pressure distribution created by ribs 134 can have a massaging effect on the sole of wearer's foot 170. The areas of relatively high pressure between ribs 134 and the wearer's foot 170 can act as pressure points and thereby relieve any one or any combination of tension, soreness, and fatigue in the muscles of foot 170, particularly the plantar muscles but without limitation thereto. Such massaging effect can also stimulate blood flow to the foot, particularly to the plantar muscles but without limitation thereto, which can facilitate the wearer's recovery from activities that tax foot muscles, such as athletic activities.
In some embodiments, a raised perimeter 178 can defined on insole side 124 of sole 114. In such embodiments, raised perimeter 178 can define a recessed portion (for example, recess portion 180 as shown in FIG. 1B) of insole side 124 that is surrounded by the raised perimeter. A height 174 of raised perimeter 178 at each longitudinal location along sole 114 is defined relative to a theoretical planar surface defined across a bottom of outsole side 122. The theoretical planar surface 106 is defined such that it would align with a planar surface upon which article 110 can rest with outsole side 122 facing downward. The longitudinal axis 108 includes a forward direction and a backward direction defined relative to article 110 such that a toe end 112 is a forward-most point of article 110 and a heel end 116 is a backward-most point of article 110.
In some embodiments, the height of raised perimeter 178 can range from 5 mm to 10 mm, from 10 mm to 15 mm, from 15 mm to 20 mm, or from 20 mm to 25 mm.
Each widthwise cross section of a channel 158 can include a minimum defined at a local lowest point 182 of the channel 158, which can be aligned with the center line 172. In some embodiments, at each location along longitudinal axis 108, raised perimeter 178 can be higher than any channel minimum in the recessed portion at the same location along longitudinal axis 108. In such embodiments, the recessed portion of insole side 124 can be an area bounded by raised perimeter 178 that includes channels 158 that extend below raised perimeter 178 as well as ribs 134 between which those channels 158 are defined. In some embodiments, at each location along longitudinal axis 108, raised perimeter 178 can be higher than any part of any rib 134 at the same location along longitudinal axis 108. In such embodiments, the recessed portion of insole side 124 can be an area bounded by raised perimeter 178 that does not extend to a height of raised perimeter 178. In embodiments wherein raised perimeter 178 is higher than ribs 134, ribs 134 can have a first height defined relative to channels 158 while raised perimeter 178 has a second height defined relative to channels 158, the second height being greater than the first height.
In some embodiments, ribs 134 on both outsole side 122 and insole side 124 of sole 114 can extend transverse to longitudinal axis 108. The orientation of ribs 134 on outsole side 122 and insole side 124 of sole 114 transverse to longitudinal axis 108 can facilitate bending of sole 114 in a manner that cooperates with the rolling of the wearer's foot 170 through a stride (i.e., bending about horizontal axes perpendicular to longitudinal axis 108).
In some embodiments, a majority or all ribs 134 on both outsole side 122 and insole side 124 of sole 114 extend on respective trajectories defining angles less than or equal to 15° away from perpendicular to longitudinal axis 108, with the respective trajectory of a rib 134 for this purpose being defined by a straight line extending from a lateral-most end of the rib 134 to a medial-most end of the rib 134. In some embodiments, a majority or all ribs 134 on both outsole side 122 and insole side 124 of sole 114 extend less than or equal to 15° away from perpendicular to longitudinal axis 108 along a majority of their length, with the direction of extension of each rib 134 at a given position along its length being defined by a line tangent to the rib 134 at that position. In some embodiments, a majority or all ribs 134 on both outsole side 122 and insole side 124 of sole 114 extend less than or equal to 15° away from perpendicular to longitudinal axis 108 along an entirety of their length, with the direction of extension of each rib 134 at a given position along its length being defined by a line tangent to the rib 134 at that position. Generally, the closer ribs 134 on outsole side 122 and insole side 124 are to perpendicular to longitudinal axis 108, the less sole 114 overall will resist bending in a manner complementary to a wearer's stride as described above, and the more sole 114 will resist bending about longitudinal axis 108. Thus, ribs 134 on outsole side 122 and insole side 124 extending perpendicular or nearly perpendicular to longitudinal axis 108 can facilitate flexibility in sole 114 that lends itself to a comfortable walking experience while providing lateral-medial support.
Upper 118 comprises an outer side 130 and an inner side 132. Inner side 132 is a lower side of upper 118 that faces toward sole 114 and interior space 126. In the illustrated embodiment, ribs 134 extend across inner side 132 and can therefore contact the wearer's foot 170 when article 110 is worn. Ribs 134 on inner side 132 can therefore act to massage a top side of wearer's foot 170 when article 110 is worn. In some embodiments, ribs 134 can be absent from inner side 132 of upper 118.
Outer side 130 is an upper side of upper 118 that faces away from sole 114 and interior space 126. In the illustrated embodiment, ribs 134 extend across outer side 130. In some embodiments, ribs 134 can be absent from outer side 130.
FIGS. 2A-4G illustrate articles of footwear within embodiments generally according to the concepts described above with regard to FIGS. 1A-1F. Thus, all details described above with regard to FIGS. 1A-1F are equally true for the embodiments of FIGS. 2A-4G except where specifically stated or shown otherwise. Additionally, all variations upon the embodiments described above with regard to FIGS. 1A-1F can also be applied to the embodiments of FIGS. 2A-4G. Similarly, features and potential variations illustrated or described below can be applied to the embodiments of FIGS. 1A-1F individually or in any combination. Further, features and potential variations illustrated or described below can be applied to other embodiments described below. Moreover, in the embodiments of FIGS. 1A-4G, like numerals refer to like elements, with differences in the first digit of each numeral indicating which illustrated embodiment the numeral refers to, e.g., numerals 110, 210, 310, and 410 refer to articles of footwear in FIGS. 1A-1F. 2A-2F, 3A-3F, and 4A-4G, respectively. In another example, numerals 126, 226, 326, and 426 all indicate an interior space in which a wearer's foot can be received.
FIGS. 2A-2F illustrate an article 210 having ribs 234 with varying degrees of curvature. Similarly to what was described with regard to the foregoing embodiments, a longitudinal axis 208 including a forward direction and a backward direction is defined relative to article 210 such that a toe end 212 is a forward-most point of article 210 and a heel end 216 is a backward-most point of article 210, as shown in FIG. 2E. Though ribs 234 of the illustrated embodiment are curved, in some embodiments a majority of ribs on outsole side 222 and insole side 224 can extend in a direction that is at least 45° away from longitudinal axis 208 for a majority of the rib's 234 length. In further embodiments, each rib 234 on outsole side 222 and insole side 224 can extend in a direction that is at least 45° away from longitudinal axis 208 for a majority of the rib's 234 length.
Ribs 234 can extend across both sole 214 and upper 218. Moreover, ribs 234 can extend across both outsole side 222 and insole side 224 of sole 214. Similarly, ribs 234 can extend across both outer side 230 and inner side 232 of upper 218.
Some ribs 234 can extend across multiple surfaces by wrapping around contours of the exterior of article 210. For example, some ribs 234 extend onto both sole 214 and upper 218. Some such ribs 234, as shown in FIGS. 2A and 2B in particular, can extend from outsole side 222 of sole 214 to outer side 230 of upper 218. Other such ribs 234, as shown in FIG. 2E in particular, extend from insole side 224 of sole 214 to inner side 232 of upper 218. Some ribs 234 extending from insole side 224 of sole 214 to inner side 232 of upper 218 can encircle a portion of inner space 226. Other ribs 234 can extend from outsole side 222 to insole side 224 and thereby wrap around sole 214 as shown in FIGS. 2B and 2C. The ribs 234 that wrap around sole 214 can extend across raised perimeter 278 of insole side 224.
As shown in FIG. 2D, in some embodiments, openings 238 can be defined through skin layer 262 at some locations. In such embodiments, openings 238 enable air to flow into and out of porous body 246. In some embodiments, openings 238 can make article 218 less resistant to compression and enable portions of article 210 to be compressed without compensatory expansion of other portions of article 210. In embodiments wherein article 210 is produced by a method involving the use of a flowable substrate, openings 238 can enable the substrate to be drained from porous body 246. Examples of such methods include additive manufacturing processes wherein article 210 is constructed in a bath of the flowable substrate, such as in CLIP wherein the flowable substrate is a liquid. In other examples, the flowable substrate could be a powder.
In the illustrated embodiment, openings 238 are defined on outsole side 222 of sole 214. In other embodiments, openings 238 can be located elsewhere on article 210 instead of or in addition to outsole side 222 of sole 214. In some embodiments, openings 238 can be omitted altogether. Further, in the illustrated embodiment openings 238 can be defined in channels 258, though in other embodiments openings 238 can additionally or alternatively be defined elsewhere, such as on ribs 234.
As shown in FIG. 2F, porous body 246 can extend into the inner volume 264 of ribs 234. As a result, ribs 234 of the illustrated embodiment each comprise a portion of porous body 246 and a portion of skin layer 262. Porous body 246 extends into inner volume 264 because height 266 of ribs 234 exceeds a thickness of skin layer 262 at least at ribs 234. In some embodiments, height 266 of some ribs 234 can be greater than a thickness of skin layer 262 at any point.
As also shown in FIG. 2F, ribs 234 of the illustrated embodiment can have arcuate cross-sectional shapes. The arcuate cross-sectional shapes can define smooth, round profiles on the external surface of article 210. In some embodiments, ribs 234 at different locations on article 210 can have different cross-sectional shapes. Channels 258 of the illustrated embodiment also have arcuate cross-sectional shapes. Likewise, channels 258 can have different cross-sectional shapes at different locations on article 210.
As further shown in FIG. 2F, porous body 246 can be a mesh formed by a lattice of unit cells. The unit cells can each have a base geometry of struts 250 such that the lattice is a structure of struts 250 and nodes 254, the nodes 254 being defined where struts 250 intersect. The lattice of unit cells defines pores 244.
FIGS. 3A-3F illustrate an article 310 having ribs 334 and channels 358 defining flat, parallel walls 356. As shown in FIG. 3F, for example, ribs 334 comprises two of the walls 356 and each channel 358 exists between two of the walls 356. The walls 356 contribute to a box shaped cross-section of ribs 334. Compared to some other embodiments presented herein, the box shaped cross-section of ribs 334 provides a relatively large contact area between each rib 334 and the surface on which a wearer of article 310 walks. The larger contact area can improve traction between the outsole side 322 of sole 314 and the surface.
Some ribs 334 can extend across multiple surfaces by wrapping around contours of the exterior of article 310. For example, some ribs 334 can extend onto both sole 314 and upper 318. Some such ribs 334, as shown in FIGS. 3A and 3B in particular, can extend from outsole side 322 of sole 314 to outer side 330 of upper 318. Other such ribs 334, as shown in FIG. 3E in particular, can extend from insole side 324 of sole 314 to inner side 332 of upper 318. Some ribs 334 extending from insole side 324 of sole 314 to inner side 332 of upper 318 can encircle a portion of inner space 326. Other ribs 334 can extend from outsole side 322 to insole side 324 and thereby wrap around sole 314 as shown in FIGS. 3B and 3C. The ribs 334 that wrap around sole 314 can extend across raised perimeter 378 of insole side 324.
As shown in FIGS. 3C and 3D, ribs 334 on sole 314 can extend in a herringbone pattern. In particular, FIG. 3C shows that ribs 334 on insole side 324 have a herringbone pattern across a majority of their lateral-medial extent. Specifically, a majority of ribs 334 on insole side 324 can have a herringbone pattern across a majority of their lateral-medial extent. Further, the herringbone shape of ribs 334 on insole side 324 can be defined within the recessed portion bounded by raised perimeter 376. Some ribs 334 having a herringbone pattern in the recessed portion can lack the herringbone pattern where they extend across raised perimeter 376. Similarly, FIG. 3D shows that ribs 334 extending across outsole side 322 can have a herringbone pattern across a majority of their lateral-medial extent. In some embodiments, a majority of ribs 334 on outsole side 322 can have a herringbone pattern across a majority of their lateral-medial extent.
An overall trajectory for a portion of a rib 334 having the herringbone pattern can be measured from one end of the portion of the rib 334 having the herringbone pattern to another end of the portion of the rib 334 having the herringbone pattern. For example, in the illustrated embodiment, ribs 334 can lack the herringbone pattern where they cross raised perimeter 376. A trajectory of the portion of ribs 334 having the herringbone pattern in the recessed portion of insole side 324 can therefore be measured from points on the ribs 334 at the edges of the recessed portion. The overall trajectory of each portion of a rib 334 having the herringbone pattern can be less than or equal to 15° away from perpendicular to longitudinal axis 308. Similarly to what was described with regard to the foregoing embodiments, longitudinal axis 308 includes a forward direction and a backward direction and is defined relative to article 310 such that a toe end 312 is a forward-most point of article 310 and a heel end 316 is a backward-most point of article 310, as shown in FIG. 3E.
In some embodiments, the herringbone pattern of ribs 334 on sole 314 can improve traction between sole 314 and certain surfaces. For example, the teeth defined by the herringbone pattern of ribs 334 on outsole side 322 can dig into a surface a wearer walks on and thereby provide traction between the surface and outsole side 322. The herringbone pattern of ribs on insole side 324 can similarly engage a wearer's foot. Engaging the wearer's foot in this manner can prevent the sole 314 from slipping unexpectedly, which can reduce the likelihood of the wearer tripping or stepping out of the article 310. The traction provided by the herringbone pattern on either side 322, 324 can be of particular use when article 310 is worn in a wet environment, such as at a pool. Openings 438 can ventilate porous body 346 when article 310 is worn in such environments.
As shown in FIGS. 3B and 3C, in some embodiments, ribs 334 can lack the herringbone pattern on upper 318. For example, ribs 334 can lack the herringbone pattern on an outer side 330 of upper 318, which reduces the visibility of the herringbone shape to observers of article 310. In some embodiments, ribs 334 can also lack the herringbone shape on inner side 332 of upper 318.
As shown in FIG. 3F, porous body 346 may not extend into inner volumes 364 of ribs 334. Instead, inner volumes 364 of ribs 334 can be occupied by the material of skin layer 362. In such embodiments, skin layer 362 includes ribs 334. In particular, a thickness of skin layer 362 varies to be greater at ribs 334 and lesser at channels 358. Ribs 334 are therefore relatively rigid because of the locally greater thickness of skin layer 362, which can contribute to the above-described traction promoting effects of the ribs and resist bending about longitudinal axis 308. Meanwhile, channels 358 can remain relatively flexible because of the locally decreased thickness of skin layer 362, which can allow for bending about medial-lateral axes and thereby facilitate a comfortable walking experience.
As further shown in FIG. 3F, porous body 346 can be a mesh formed by a lattice of unit cells. The unit cells can each have a base geometry of struts 350 such that the lattice is a structure of struts 350 and nodes 354, the nodes 354 being defined where struts 350 intersect. The lattice of unit cells defines pores 344.
FIGS. 4A-4G illustrate an article 410 having ribs 434 of differing cross-sectional shape at different portions of article 410. Similarly to what was described with regard to the foregoing embodiments, a longitudinal axis 408 including a forward direction and a backward direction is defined relative to article 410 such that a toe end 412 is a forward-most point of article 410 and a heel end 416 is a backward-most point of article 410, as shown in FIG. 4E. Though ribs 434 of the illustrated embodiment are curved, ribs 434 on outsole side 422 and insole side 424 can extend in a direction that is less than or equal to 15° away from perpendicular to longitudinal axis 408 for a majority of the rib's 434 length.
Some ribs 434 can extend across multiple surfaces by wrapping around contours of the exterior of article 410. For example, some ribs 434 can extend onto both sole 414 and upper 418. Some such ribs 434, as shown in FIGS. 4A and 4B in particular, can extend from outsole side 422 of sole 414 to outer side 430 of upper 418. Other such ribs 434, as shown in FIG. 4E in particular, can extend from insole side 424 of sole 414 to inner side 432 of upper 418. Some ribs 434 extending from insole side 424 of sole 414 to inner side 432 of upper 418 can encircle a portion of inner space 426. Other ribs 434 can extend from outsole side 422 to insole side 424 and thereby wrap around sole 414 as shown in FIGS. 4B and 4C. The ribs 434 that wrap around sole 414 can extend across raised perimeter 478 of insole side 424.
As shown in FIGS. 4C and 4D, ribs 434 can be parallel to each other. Ribs 434 can follow straight medial-lateral paths on sole 414 and upper 418. Ribs 434 on outer side 430 of upper 418 can be parallel to ribs 434 on inner side 432 of upper 418. Similarly, ribs 434 on insole side 424 of sole 414 can be parallel to ribs 434 on outsole side 422 of sole 414. Moreover, some ribs 434 on upper 418 can be parallel to some ribs 434 on sole 414. As in other embodiments, openings 438 can be defined, for example, on outsole side 422 of sole 414.
Turning to FIGS. 4F and 4G, porous body 446 can be a mesh formed by a lattice of unit cells. The unit cells can each have a base geometry of struts 450 such that the lattice is a structure of struts 450 and nodes 454, the nodes 454 being defined where struts 450 intersect. The lattice of unit cells defines pores 444.
Porous body 446 can extend into inner volumes 464 of ribs 434. Ribs 434 can therefore have a height 466 relative to channels 458 that is greater than a thickness of skin layer 462 at ribs 434. Moreover, ribs 434 can comprise a portion of porous body 446 and a portion of skin layer 462.
FIG. 4G specifically depicts a cross-section of ribs 434 on outsole side 422 of sole 414, whereas FIG. 4F depicts a cross-section of ribs elsewhere on article 410. Whereas ribs 434 shown in FIG. 4F each have a triangular cross-sectional shape, ribs 434 on outsole side 422 of sole 414 have a flat peak 435 as shown in FIG. 4G. In some embodiments, a majority of ribs 434 on outsole side 422 of sole 414 have a flat peak 435. In further embodiments, all ribs 434 on outsole side 422 have a flat peak 435. The flat peak 435 can increase a contact area between ribs 434 of outsole side 422 and a surface being walked on, thereby promoting traction between outsole side 422 and the surface.
In various embodiments, ribs 434 can have the triangular cross-sectional shape of FIG. 4F in contrast to the flat peaked cross-sectional shape shown in FIG. 4G at various locations or combinations of locations on article 410. In some embodiments, ribs 434 at least on insole side 424 of sole 414 have the triangular cross-sectional shape. In further embodiments, ribs 434 at least on upper 418 have the triangular cross-sectional shape. In further embodiments, only ribs 434 on outsole side 422 of sole 414 have flat peaks 435.
FIGS. 5A-5F illustrate an article 510 of footwear generally according to the concepts described above with regard to FIGS. 1A-4G except that article 510 has studs 534 instead of ribs. Thus, all details described above with regard to FIGS. 1A-4G are equally true for the embodiment of FIGS. 5A-5F except where specifically stated or shown otherwise. Additionally, all variations upon the embodiments described above with regard to FIGS. 1A-4G can also be applied to the embodiments of FIGS. 5A-5F. Moreover, in the embodiment of FIGS. 5A-5F, numerals continue to refer to like elements indicated by like numerals in FIGS. 1A-4G, with differences in the first digit of each numeral indicating which illustrated embodiment the numeral refers to, e.g., numeral 510 refers to an article of footwear in FIGS. 5A-5F in the same way that numerals 110, 210, 310, and 410 refer to articles of footwear in FIGS. 1A-1F, 2A-2F. 3A-3F, and 4A-4G, respectively. In another example, 526 indicates an interior space in which a wearer's foot can be received similar to the interior spaces 126, 226, 326, 426 of the foregoing embodiments.
Similarly to what was described with regard to the foregoing embodiments, a longitudinal axis 508 including a forward direction and a backward direction is defined relative to article 510 such that a toe end 512 is a forward-most point of article 510 and a heel end 516 is a backward-most point of article 510, as shown in FIGS. 5B and 5E.
Studs 534 can be placed along any of the paths along which ribs 134, 234, 334, 434 of any of the above-described embodiments extend. Studs 534 can thus be distributed across upper 518 and sole 514. Studs 534 can be located on both outsole side 522 and insole side 524 of sole 514. Similarly, studs 534 can be located on both outer side 530 and inner side 532 of upper 518. Channels 558 are defined between studs 534. Openings 538 can be defined in channels 558 as shown in the illustrated embodiment or elsewhere in other embodiments.
In some embodiments, studs 534 on an outsole side 522 of sole 514 can have flatter peaks than studs 534 elsewhere on article 510. In such embodiments, at least partially flat peaks 535 of studs 534 on the outsole side 522 of sole 514 can promote traction between article 510 and the ground.
Turning to FIGS. 5F and 5G, porous body 546 can be a mesh formed by a lattice of unit cells. The unit cells can each have a base geometry of struts 550 such that the lattice is a structure of struts 550 and nodes 554, the nodes 554 being defined where struts 550 intersect. The lattice of unit cells defines pores 544.
In some embodiments, porous body 546 does not extend into inner volumes 564 of studs 534. In such embodiments, inner volumes 564 of studs 534 are occupied by the material of skin layer 562, and skin layer 562 includes studs 534. In such embodiments, a thickness of skin layer 562 varies to be greater at studs 534 and lesser at channels 558 defined between studs 534. In such embodiments, studs 534 are therefore relatively rigid because of the locally greater thickness of skin layer 562, which can contribute to traction promoting and therapeutic effects of studs 534. Meanwhile, channels 558 defined between studs 534 remain relatively flexible because of the locally lesser thickness of skin layer 562, which can allow for bending with the wearer's foot and thereby facilitate a comfortable walking experience. In some embodiments, porous body 546 can extend into inner volumes of studs 534 as described herein for ribs. In such embodiments, studs 534 can have a height 566 relative to channels 558 that is greater than a thickness of skin layer 562 at studs 534.
FIG. 5G depicts a cross-section of studs 534 on outsole side 522 of sole 514, whereas FIG. 5F depicts a cross-section of studs 534 elsewhere on article 510. Whereas studs 534 shown in FIG. 5F each have a round cross-sectional shape, studs 534 on outsole side 522 of sole 514 can have a flat peak 535 as shown in FIG. 5G. In some embodiments, a majority of studs 534 on outsole side 522 of sole 514 have a flat peak 535. In further embodiments, all studs 534 on outsole side 522 have a flat peak 535. The flat peak 535 can increase a contact area between studs 534 of outsole side 522 and a surface being walked on, thereby promoting traction between outsole side 522 and the surface.
In various embodiments, studs 534 can have the round cross-sectional shape of FIG. 5F in contrast to the flat peaked cross-sectional shape shown in FIG. 5G at various locations or combinations of locations on article 510. In some embodiments, studs 534 at least on insole side 524 of sole 514 have the triangular cross-sectional shape. In further embodiments, studs 534 at least on upper 518 have the triangular cross-sectional shape. In further embodiments, only studs 534 on outsole side 522 of sole 514 have flat peaks 535.
Where a range of numerical values comprising upper and lower values is recited herein, unless otherwise stated in specific circumstances, the range is intended to include the endpoints thereof, and all integers and fractions within the range. It is not intended that the disclosure or claims be limited to the specific values recited when defining a range. Further, when an amount, concentration, or other value or parameter is given as a range, one or more ranges, or as list of upper values and lower values, this is to be understood as specifically disclosing all ranges formed from any pair of any upper range limit or value and any lower range limit or value, regardless of whether such pairs are separately disclosed. Finally, when the term “about” is used in describing a value or an end-point of a range, the disclosure should be understood to include the specific value or end-point referred to. Whether or not a numerical value or end-point of a range recites “about,” the numerical value or end-point of a range is intended to include two embodiments: one modified by “about,” and one not modified by “about.”
As used herein, the term “about” refers to a value that is within ±10% of the value stated. For example, about 10% can include any percentage between 9% and 11%. The terms “comprising,” “comprises,” “including,” and “includes” are open-ended transitional phrases. A list of elements following the transitional phrase “comprising,” “comprises,” “including,” and “includes” is a non-exclusive list, such that elements in addition to those specifically recited in the list can also be present.
It is to be appreciated that the Detailed Description section, and not the Summary and Abstract sections, is intended to be used to interpret the claims. The Summary and Abstract sections may set forth one or more but not all exemplary embodiments of the present invention as contemplated by the inventor(s), and thus, are not intended to limit the present invention and the appended claims in any way.
The foregoing description of the specific embodiments will so fully reveal the general nature of the invention(s) that others can, by applying knowledge within the skill of the art, readily modify and/or adapt for various applications such specific embodiments, without undue experimentation, without departing from the general concept of the present invention(s). Therefore, such adaptations and modifications are intended to be within the meaning and range of equivalents of the disclosed embodiments, based on the teaching and guidance presented herein. It is to be understood that the phraseology or terminology herein is for the purpose of description and not of limitation, such that the terminology or phraseology of the present specification is to be interpreted by the skilled artisan in light of the teachings and guidance.
The breadth and scope of the present invention(s) should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents.

Claims

What is claimed is:

1. An article of footwear, comprising:

a porous body comprising a lattice of interconnected unit cells and a first porosity; and

a skin layer integrally formed on an exterior of the porous body, the skin layer comprising a second porosity and defining ribs that extend outward from the porous body,

wherein the second porosity is less than the first porosity.

2. The article of claim 1, wherein the skin layer is a solid layer lacking through pores.

3. The article of claim 2, wherein:

the porous body is a lattice of interconnected unit cells, wherein the unit cells each comprise a base geometry; and

the skin layer does not comprise a lattice of interconnected unit cells comprising the base geometry.

4. The article of claim 1, wherein the ribs have a height distribution within a range from 0.5 mm through 10 mm.

5. The article of claim 1, wherein the ribs have a width distribution within a range from 0.5 mm through 10 mm.

6. The article of claim 1, wherein the ribs are separated by channels, and each channel has a constant width for a length of at least a majority of a length of the rib.

7. The article of claim 6, wherein the ribs are parallel to each other.

8. The article of claim 1, wherein at least a portion of an outsole of the article lacks the skin layer such that the porous body provides part of a ground facing side of the outsole.

9. The article of claim 1, wherein an area occupied by the skin layer covers at least 50% of the exterior of the porous body.

10. The article of claim 1, wherein the porous body defines at least a portion of a sole and at least a portion of an upper for the article of footwear.

11. The article of claim 1, wherein the article of footwear is a sandal comprising an upper that comprises at least part of the porous body, wherein the skin layer extends across at least a portion of the upper.

12. The article of claim 11, wherein the ribs are separated by channels including respective portions of the skin layer, and an area occupied by the skin layer covers at least 50% of the exterior of the porous body.

13. The article of claim 12, wherein the upper comprises an outer side and an inner side, and the skin layer extends across at least a portion of the outer side and at least a portion of the inner side.

14. The article of claim 13, comprising a sole attached to the upper, wherein:

the sole comprises a second portion of the porous body; and

the skin layer extends onto the sole.

15. The article of claim 1, comprising a sole comprising at least a portion of the porous body and comprising an insole side, wherein the skin layer extends across at least a portion of the insole side.

16. A sandal, comprising:

a porous body comprising a lattice of interconnected unit cells;

a sole comprising a first portion of the porous body;

an upper comprising a second portion of the porous body and connected to the sole;

a first plurality of ribs extending across a portion of an exterior of the sole, wherein the first plurality of ribs defines a first plurality of channels between neighboring ribs among the first plurality of ribs, and the channels among the first plurality of channels are equal in width along at least a portion of their length; and

a second plurality of ribs extending across a portion of an exterior of the upper, wherein the second plurality of ribs defines a second plurality of channels between neighboring ribs among the second plurality of ribs, and the channels among the second plurality of channels are equal in width along at least a portion of their length.

17. The sandal of claim 16, comprising a skin layer that has a lower porosity than the porous body, the sole comprises an insole side configured to face a bottom of a wearer's foot when the sandal is worn, and the skin layer extends onto the insole side of the sole.

18. The sandal of claim 17, wherein the first plurality of ribs, the second plurality of ribs, or both, is defined by the skin layer.

19. The sandal of claim 17, wherein:

the insole side of the sole comprises a recessed portion and a raised perimeter; and

the first plurality of ribs extends across the recessed portion.

20. The sandal of claim 19, wherein the ribs among the first plurality of ribs have a first height defined relative to the first plurality of channels, the raised perimeter has a second height defined relative to the first plurality of channels, and the second height is greater than the first height.