CN116963634A

CN116963634A - Article of footwear including reusable waste material and remaining material

Info

Publication number: CN116963634A
Application number: CN202280015787.1A
Authority: CN
Inventors: 弗朗西斯卡·卡波尼; 姜尚熙; 卡拉·尼克雷姆; 埃洛迪·里谢
Original assignee: Nike Innovate CV USA
Current assignee: Nike Innovate CV USA
Priority date: 2021-02-19
Filing date: 2022-02-02
Publication date: 2023-10-27
Also published as: WO2022177738A1; EP4294228A1; US20220264998A1

Abstract

An article of footwear and method of manufacture are provided herein. The article includes an upper fixedly attached to a sole structure. The upper may include a wall, wherein the inner layer is coupled to the outer layer such that the inner layer and the outer layer define a closed bag therebetween. A layer of debris particulate matter is disposed in the closed bag and is at least partially visible through an outer layer formed of a sufficiently transparent material. The sole structure is fabricated from a mixture of discrete pieces of debris particulate matter and virgin polymer material such that the discrete pieces of debris particulate matter are at least partially visible on an outer surface of the sole structure. The sole structure also substantially covers in the plurality of cavities and the plurality of protrusions such that the outsole surface has a dimpled texture.

Description

Article of footwear including reusable waste material and remaining material

Cross Reference to Related Applications

The present application claims priority from U.S. provisional patent application No. 63/151,275, filed on 19, 2, 2021.

Technical Field

The present disclosure relates generally to an article of footwear including reusable waste and remaining material and a method of manufacturing an article of footwear using reusable waste and remaining material.

Background

Footwear generally includes a number of components that have a number of different materials. An article of footwear generally includes an upper operable to receive a foot of a wearer and a sole structure configured to underlie the foot of the wearer to space the foot from the ground. The sole structure generally includes a rubber or foamed elastomeric material that is adapted to attenuate ground impact forces.

It is estimated that more than 3 hundred million shoes are thrown every year worldwide. In the past, waste from these shoes has typically been simply discarded. In addition, the footwear manufacturing process may create residual materials, such as scrap, residues, or chips, that are also typically discarded during the initial formation of the footwear. Recently, techniques have been developed to integrate recycled scrap and form the remainder into new shoes. These techniques typically involve separating the waste and/or excess residual material into small pieces, commonly referred to as "regrind.

Disclosure of Invention

The techniques of this disclosure take a sustainable and environmentally friendly approach to manufacturing footwear that contemplates that waste materials from discarded shoes may be ground or shredded, etc. and recycled to form reusable "green regrind material", and that excess residual materials such as scrap, residue, or scrap material generated during initial shoe formation may be ground or shredded, etc. and recycled to form reusable "natural color regrind material". These reusable "green regrind" and "natural regrind" materials may be further incorporated into new shoes or footwear applications. More particularly, the techniques of this disclosure relate to a manner of constructing an article of footwear that incorporates green and/or natural regrind material into each of the sole structure and outer walls of the upper of the article of footwear.

In general, an article of footwear may include a sole structure and an upper fixedly attached to the sole structure. The upper may include a wall at least partially surrounding an interior volume that is operable to receive a foot of a wearer. The wall may further include an inner layer and an outer layer coupled to the inner layer such that the inner layer and the outer layer define a closed pouch therebetween. At least one of the natural color regrind material, the green regrind material, and/or a combination of the green regrind material and the natural color regrind material may be disposed within a closed pocket between the exterior layer and the interior layer of the upper. The outer layer may be formed from a material that is sufficiently transparent such that the natural color regrind material, the green regrind material, and/or combinations thereof may be at least partially visible through the outer layer, thereby providing a unique visual effect while also improving the cushioning and/or ventilation characteristics of the upper.

In such cases, the upper may be formed via a manufacturing process workflow for forming the upper, wherein reusable material, i.e., recycled material, excess remaining material, such as scrap, residue, or scrap material, may be obtained or received; regrind material, particularly green regrind material or natural regrind material, may be formed by dividing the reusable crumb material into a plurality of discrete pieces of crumb particulate matter via at least one of a grinding process and a shredding process; discrete pieces of crumb particulate matter form a layer of crumb particulate matter; and inserting a layer of debris particulate matter into a closed pocket formed between an inner layer of a wall of an upper of the article of footwear and an outer layer of the wall of the upper.

Additional aspects of the present disclosure relate to a sole structure that includes a first plurality of discrete pieces of reusable debris particulate matter, such as a natural color regrind material, a green regrind material, and/or a combination of a green regrind material and a natural color regrind material, bonded together with a virgin polymeric material. In this manner, the reusable debris particulate matter forms a plurality of distinct shaped, sized, and colored pieces, all of which are irregularly dispersed throughout the sole structure such that more than one of the discrete pieces of reusable debris particulate matter is visible on the outer sole surface. Optionally, in some cases, the outer sole surface of the sole structure may include fifty or more pieces of reusable debris particles of significant shape/color.

In addition, the sole structure may be formed or machined with a plurality of obviously shaped and sized cavities and a plurality of obviously shaped and sized protrusions defined by the outer sole surface. For at least some arrangements, substantially the entire outsole surface of the sole structure is covered with irregularly dispersed cavities and protrusions. Optionally, the sole structure is provided with fifty or more distinctly shaped cavities and fifty or more distinctly shaped protrusions such that the outer sole surface assumes a dimpled appearance. An additional advantage of forming a sole structure with an outer surface defining fifty or more distinct shaped/colored pieces of reusable debris particles, fifty or more distinct shaped cavities, and fifty or more distinct shaped protrusions is that no two sole structures are identical.

In such cases, the sole structure may be formed via a manufacturing process workflow for manufacturing the sole structure of an athletic shoe using natural color regrind material, green regrind material, and/or a combination of green regrind material and natural color regrind material with virgin rubber or elastomeric materials or resins, such as thermoplastic elastomers (TPE) or ethylene-vinyl acetate (EVA) copolymers, and a foaming agent. The mixture may then be subjected to one of compression molding, injection molding, and the like.

In one example, a representative method includes receiving reusable material, i.e., recycled material, excess remaining material, such as scrap, residue, or scrap material; dividing the reusable material into a first plurality of discrete pieces of crumb particulate matter via at least one of a grinding process and a shredding process, thereby forming a regrind material, particularly a green regrind material or a natural regrind material; mixing a mass of discrete crumb particulate matter with virgin polymeric material and a foaming agent to form a sole structure mixture; placing the sole structure mixture in an interior cavity of a final mold shaped like a sole structure; forming a sole structure by heating the treated sole structure mixture above a threshold activation temperature of the foaming agent such that the foaming agent causes the crumb particulate matter to expand and fill the interior cavity of the final mold; and removing the formed sole structure from the mold.

The above summary is not intended to represent each embodiment, or every aspect, of the present disclosure. Rather, the foregoing summary merely provides an exemplification of some of the novel concepts and features set forth herein. The above features and advantages, and other features and attendant advantages of the present disclosure will become apparent from the following detailed description of the illustrated examples and representative modes for carrying out the present disclosure when taken in connection with the accompanying drawings and the appended claims. Furthermore, the present disclosure expressly includes any and all combinations and subcombinations of the elements and features presented above and below.

Drawings

The drawings described herein are for illustration purposes only and are schematic in nature and are intended to be illustrative rather than limiting the scope of the present disclosure.

FIG. 1 is a schematic perspective view of a lateral side of a first example article of footwear.

FIG. 2 is a schematic perspective view of a lateral side of a second example article of footwear.

FIG. 3 is a schematic perspective view of a lateral side of a third example article of footwear.

FIG. 4 is a schematic perspective view of a medial side of a first example article of footwear.

FIG. 5 is a schematic perspective view of a medial side of a second example article of footwear.

FIG. 6 is a schematic perspective view of a medial side of a third example article of footwear.

FIG. 7 is a schematic perspective partially exploded view of a first example article of footwear.

Fig. 8 is a schematic perspective plan view of a first example article of footwear.

Fig. 9 is a bottom view of the representative sole structure of fig. 1-8.

Fig. 10 is a flow chart of an example method of manufacturing the article of footwear of fig. 1-9.

Fig. 11 is a flowchart describing in further detail example step 103 of fig. 10.

Fig. 12 is a flowchart describing in further detail the example step 104 of fig. 10.

Detailed Description

Although the disclosure may be described with respect to a particular application or industry, those skilled in the art will recognize the broader applicability of the disclosure.

The terms "a," "an," "the," "at least one," and "one or more" are used interchangeably to indicate at least one of the items is present. There may be a plurality of such items unless the context clearly indicates otherwise. Unless the context clearly or clearly indicates otherwise, including the claims that follow, all numerical values of parameters (e.g., amounts or conditions) in this specification should be understood to be modified in all instances by the term "about," whether or not "about" actually appears before the numerical value. "about" indicates that the stated value allows some slight imprecision (with values close to being accurate; close or reasonably close to the value; almost). If the imprecision provided by "about" is not otherwise understood in the art with this ordinary meaning, then "about" as used herein at least indicates a change that may be caused by ordinary methods of measuring and using such parameters. Moreover, the disclosure of a range should be understood to specifically disclose all values and further divided ranges within the range.

The terms "comprises," "comprising," "includes," and "including" are inclusive and therefore specify the presence of stated features, steps, operations, elements, or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, or components. The order of steps, processes, and operations may be changed when possible, and additional or alternative steps may be employed. As used in this specification, the term "or" includes any and all combinations of the associated listed items. Any of the terms "… …" should be understood to include any possible combination of the referenced items, including any of the referenced items. Any one of the terms … … should be understood to include any possible combination of the referenced claims in the appended claims, including any one of the referenced claims.

Features shown in one drawing may be combined with, replaced by, or modified by features shown in any of the drawings. Any feature, element, or limitation is not mutually exclusive of any other feature, element, or limitation unless otherwise indicated. Furthermore, there are no absolutely required features, elements or limitations to operation. Any specific configuration shown in the drawings is illustrative only and the specific configuration shown does not limit the claims or the specification.

For consistency and convenience, directional adjectives are employed throughout this detailed description corresponding to the illustrated embodiments. Those of ordinary skill in the art will recognize that terms such as "above," "below," "upward," "downward," "top," "bottom," et cetera, may be used descriptively of the figures, and do not represent limitations on the scope of the invention, as defined by the claims. Any numerical designations such as "first" or "second" are merely illustrative and are not intended to limit the scope of the present disclosure in any way.

As used throughout this detailed description and in the claims, the term "longitudinal" refers to a direction that extends the length of a component. For example, the longitudinal direction of the shoe extends between the forefoot and heel regions of the shoe. The terms "forward" or "anterior" are used to refer to the general direction from the heel region toward the forefoot region, and the terms "posterior" or "posterior" are used to refer to the opposite direction, i.e., the direction from the forefoot region toward the heel region. In some cases, a component may be identified as having a longitudinal axis and a front-to-back longitudinal direction along the axis. The longitudinal direction or axis may also be referred to as a front-to-back direction or axis.

As used throughout this detailed description and in the claims, the term "transverse" refers to a direction that extends the width of the component. For example, the lateral direction of the shoe extends between the lateral side and the medial side of the shoe. The lateral direction or axis may also be referred to as a lateral direction or axis or a medial-lateral direction or axis.

As used throughout this detailed description and in the claims, the term "vertical" refers to a direction that is generally perpendicular to both the lateral and longitudinal directions. For example, in the case of a sole lying on a ground surface, the vertical direction may extend upwardly from the ground surface. It should be understood that each of these directional adjectives may be applied to individual components of the sole. The term "upward" or "upwardly" refers to a vertical direction that points toward the top of the component, which may include the instep, the fastening area, and/or the throat of the upper. The term "downward" or "downwardly" refers to a vertical direction that points toward the bottom of the component opposite the upward direction, and may generally point toward the bottom of the sole structure of the article of footwear.

Furthermore, the term "proximal" refers to a direction that is closer to the center of the footwear component or closer to the foot when the foot is inserted into the article of footwear when the article of footwear is worn by a user. Likewise, the term "distal" refers to a relative position that is farther from the center of the footwear component or farther from the foot when the foot is inserted into the article of footwear when the article of footwear is worn by a user. Thus, the terms proximal and distal may be understood as providing generally opposite terms describing relative spatial locations.

To assist and clarify the ensuing description of the various embodiments, various terms are defined herein. Unless otherwise indicated, the following definitions apply throughout this specification (including the claims). "article of footwear," "article of footwear," and "footwear" may be considered machines and articles of manufacture. The assembled finished article of footwear (e.g., shoe, sandal, boot, etc.) and discrete components of the article of footwear (such as midsole, outsole, upper component, etc.) are considered herein and are alternatively referred to as "article of footwear" in singular or plural form prior to final assembly into the finished article of footwear. Waste from discarded shoes may be ground or shredded, etc. and recycled, which may form a reusable material defined as "green regrind material". Excess residual material, such as scrap, residue, or scrap material, generated during initial shoe formation may be ground or shredded, etc., and recovered to form a reusable material, defined as "natural color regrind material".

The following discussion and accompanying figures disclose various footwear configurations and methods associated with their manufacture. Although article of footwear 10 is depicted in the associated figures as athletic footwear configured for athletic activity, such as a sole-of-gel athletic shoe, concepts associated with the configurations and methods may be applied to various other types of articles of athletic footwear, such as hiking boots and shoes, football shoes, running shoes, cross-training shoes, rugby shoes, basketball shoes, and the like. However, the article of footwear 10 is not limited to rubber sole athletic shoes or other athletic shoes. In some embodiments, the disclosed devices may be configured for use with a variety of non-athletic related footwear including, but not limited to, boots, casual shoes, dress shoes, work shoes, sandals, slippers, or any other type of footwear, which may also incorporate the concepts discussed herein.

In a general sense, the article of footwear 10 of the present disclosure is designed to be manufactured via an environmentally friendly and sustainable process. In this way, scrap material, manufacturing surplus material, or recycled or reclaimed material from discarded or non-sold shoes can be used to form newly formed shoes to reduce material waste. More specifically, recycled and/or reusable material from at least one of the upper and sole structure of another article of footwear or remaining material from the formation of at least one of the upper and sole structure of another article of footwear is separated into a plurality of discrete pieces of reusable debris particulate matter 22, 23, also referred to as "regrind," via one of an abrading process or a shredding process. Regrind material, by definition, is material that has undergone at least one treatment process and subsequent gates, runners, flash, or reject fraction is ground or shredded.

Further, regrind 22, 23 is defined herein as a mixture of cured rubber pellets, elastomer pellets, foam pellets, fabric pieces and at least one of fibers, leather pieces and polymer pieces. Regrind 22, 23 may include ground and/or shredded waste material from used, discarded or non-sold footwear and/or ground or shredded residual material or recycled scrap material from footwear manufacturing. Unless otherwise specified, the term "regrind" shall not imply any particular process, but is intended to generally refer to a sliced piece of post-consumer and/or post-manufacturing waste that has undergone at least one treatment process, and the gate, runner, flash, or reject fraction subsequently produced therefrom.

In one example, the regrind 22, 23 is a "natural color regrind" that is defined as a ground/cut/sliced piece of residual material from the footwear manufacturing, such as ground waste or crumb rubber from the footwear manufacturing, ground waste or crumb foam from the footwear manufacturing, ground or shredded waste from the footwear manufacturing, residue or crumb fabric fibers (e.g., threads, strands, yarns), or combinations thereof. In another example, regrind 22, 23 is recycled or "green regrind" wherein the green regrind consists of recycled, discarded or non-sold pieces of footwear that are ground/shredded/cut/sliced, such as ground cured rubber from footwear, ground foam from footwear, ground or shredded textile fibers from footwear, or combinations thereof. In such examples, the green regrind material is obtained from ground post-consumer waste (e.g., footwear waste), recycled post-consumer shoes, and/or ground portions of non-disposable footwear.

Reusable particulate matter or regrind 22, 23 is then incorporated into one or more of upper 12 and sole structure 14. More specifically, reusable particles 22 may be inserted between inner layer 18 and outer layer 20 of wall 15 of upper 12 of newly formed article of footwear 10. To provide a unique visual effect, the outer layer 20 may be formed of a material that is sufficiently transparent or translucent such that the regrind 22 is at least partially visible through the outer layer 20. Furthermore, reusable particulate matter 23 may be incorporated into sole structure 14, and more specifically, into its impact-attenuating midsole 19 and/or surface-contacting outsole 17, such that reusable particulate matter 23 forms a plurality of distinct shaped, sized, and colored fragments, all of which are irregularly dispersed on outer surface 13 of sole structure 14. In addition, sole structure 14 may be formed or machined with a plurality of cavities 35 of significant shape and size and a plurality of protrusions 37 of significant shape and size. For at least some configurations, substantially the entire outsole surface 13 of the sole structure 14 is covered with irregularly dispersed cavities 35 and protrusions 37 such that the outsole surface 13 assumes a dimpled appearance.

In addition to providing a method of recovering and reusing material from post-consumer footwear and retrieving remaining material from initial shoe formation, the present techniques also provide a more breathable and cushioning structure for upper 12 and improved cushioning for sole structure 14 for the foot. In other words, in contrast to the upper being a solid foam pad alone, the granular natural or green regrind material may allow air and/or evaporated perspiration to pass between the discrete particles, which may improve the comfort of upper 12. Additionally, with respect to upper 12 and sole structure 14, the present technique allows the visual appearance of each shoe in the shoe construction to be unique because the natural and green regrind materials, respectively, may each be derived from different colored materials. This uniqueness may be attributed to the random dispersion of the regrind throughout the closed pocket 33 in the upper 12 and throughout the outer sole surface 13 in the sole structure 14. More specifically, each shoe 10 may present a different appearance based on the available color of the regrind during the manufacturing and dispersion processes. This may increase consumer expectations for obtaining an aesthetically pleasing or unique design or shoe with an creative pattern or color.

Referring to the drawings, wherein like reference numbers refer to like components throughout the several views, an article of footwear 10 is provided. As shown in fig. 1-9, article of footwear 10 includes an upper 12 fixedly attached to a sole structure 14.

Upper 12 is a portion of article of footwear 10 that defines an interior volume or void 16 adapted to receive a foot of a wearer. Upper 12 in the present disclosure also includes a wall 15 that at least partially surrounds an interior volume or void 16. For purposes of uniformity and clarity, the "interior" of article of footwear 10 refers to the space occupied by the foot of the wearer when article of footwear 10 is worn. The "medial side" of wall 15 or other footwear element refers to the face of the panel or element that is (or will be) oriented toward the interior in the finished article of footwear 10. "lateral" or "exterior" of an element refers to a face of the element that is oriented away (or will be oriented away) from the interior in the finished article of footwear 10.

As indicated in fig. 1-6, article of footwear 10 may be divided into a forefoot region 34, a midfoot region 36, and a heel region 38, which are also forefoot region 34, midfoot region 36, and heel region 38 of sole structure 14 and upper 12, respectively. Forefoot region 34 generally includes portions of article of footwear 10 corresponding with the toes and the joints connecting the metatarsals with the phalanges. Midfoot region 36 generally includes portions of article of footwear 10 corresponding with the arch area and instep of the foot. Heel region 38 corresponds with the rear portion of the foot, including the calcaneus bone. Forefoot region 34, midfoot region 36, and heel region 38 are not intended to demarcate precise areas of footwear 10, but are intended to represent general areas of footwear 10 to aid in the following discussion.

The article of footwear 10 also has a lateral portion 24 (fig. 1-3) and a medial portion 26 (fig. 4-6). Lateral portion 24 and medial portion 26 extend through each of forefoot region 34, midfoot region 36, and heel region 38, and correspond to opposite sides of article of footwear 10, each falling on opposite sides of a longitudinal midline LM of article of footwear 10, as indicated in part in fig. 8. Thus, the inner portion 26 is considered to be opposite the outer portion 24.

Sole structure 14 is rigidly secured to upper 12 such that sole structure 14 extends between upper 12 and a support surface, such as a support surface on which a wearer stands. In effect, sole structure 14 functions as a medial support platform that separates the foot of the wearer from the ground. Sole structure 14 may include provisions for attenuating ground reaction forces (i.e., cushioning and stabilizing the foot during vertical and horizontal loads). In addition, sole structure 14 may be configured to provide traction, impart stability, and control or limit various foot motions, such as pronation, supination, or other motions. For example, the disclosed concepts may be applied to footwear configured for use on any of a variety of surfaces, including indoor surfaces or outdoor surfaces. In some embodiments, sole structure 14 may be configured to be on a hard indoor surface (such as hardwood); a soft natural turf surface; or on a hard artificial turf surface to provide traction and stability.

In various embodiments, sole structure 14 may include various components that may individually or collectively provide various attributes to the article, such as support, rigidity, flexibility, stability, cushioning, comfort, reduced weight, or other attributes. For example, sole structure 14 may be manufactured as a single-piece unitary structure with integrally formed insole, midsole, and outsole sections, defined as a single sole. Alternatively, sole structure 14 may include discrete components, such as midsole 19, outsole 17, and a cushioning layer and/or insole. An insole (not shown) may rest on the sole structure 14 in the foot-receiving cavity 16. Midsole 19 attenuates ground reaction forces (e.g., provides cushioning) when compressed between the foot and the ground during walking, running, or other ambulatory activities. Outsole 17 forms a ground-engaging surface 55 of article of footwear 10. In one example, outsole 17 may be one-piece, or may be several outsole components, and may be formed of a wear-resistant material that may be textured to impart traction and/or may include traction elements, such as cleats secured to midsole 19.

The compressible polymer element of sole structure 14, i.e., midsole 19, attenuates ground reaction forces (i.e., provides cushioning) when compressed between the foot and the ground during walking, running, or other ambulatory activities, and may be formed from a compressible polymer element, such as a thermoset or thermoplastic, for example, a crosslinked thermoset plastic, a crosslinked thermoset resin, or a crosslinked thermoset elastomer (e.g., rubber), a polyurethane foam, an Ethylene Vinyl Acetate (EVA) foam, an ionomer polymer foam, or the like. In other configurations, midsole 19 may incorporate fluid-filled chambers, plates, moderators, or other elements that further attenuate forces, enhance stability, or influence the motions of the foot. Midsole 19 may be a single, one-piece midsole or may be multiple components integrated into a single unit.

When the foot is positioned within the foot-receiving interior void 16 of the article of footwear 10, the foot is supported on the foot-facing surface of the midsole 19. Alternatively, the foot-facing surface of midsole 19 may be covered by strobel secured to a lower region of upper 12. Also, alternatively, in embodiments without strobel, the insole may rest on strobel or directly on sole structure 14, in which case the foot is supported by both sole structure 14 and the insole.

However, it is to be understood that sole structure 14 is not limited to incorporation of conventional sole components, and may incorporate various different kinds of elements disposed at the outermost, innermost, and intermediate 'layers' or locations of the sole. Accordingly, sole structure 14 may include an outsole member or element that may or may not be coincident with a conventional 'outsole'. Likewise, sole structure 14 may include an inner sole member or element, which may or may not be an 'insole'. In addition, sole structure 14 may include any number of intermediate and/or centering sole members or elements, which may or may not be a 'midsole'.

In the present disclosure, sole structure 14 may define an outsole surface 13. More specifically, sole structure 14 may include an outsole 17 defining a ground-engaging surface 55, and a midsole 19 disposed between upper 12 and outsole 17, wherein midsole 19 defines a midsole outer surface 57. The ground engaging surface 55 and the midsole outer surface 57 cooperate to define the outsole surface 13.

Sole structure 14, including midsole 19 and outsole 17, may include a first plurality of discrete pieces of debris particulate matter 23. As discussed herein, in a general sense, the article of footwear 10 of the present disclosure is designed to be manufactured in an environmentally friendly and sustainable process that includes techniques for incorporating a first plurality of discrete pieces of debris particulate matter 23 or "regrind" into the sole structure of a new article of footwear 10. In this manner, the scrap material may be subsequently separated into a first plurality of discrete pieces of scrap particulate matter 23 or regrind material. As discussed herein, regrind material, by definition, is material that has undergone at least one treatment process and subsequent gates, runners, flash, or reject fraction is ground or shredded.

Outsole 17 and midsole 19 of sole structure 14 may be manufactured from a mixture of a first plurality of discrete pieces of debris particulate matter 23 and virgin polymer material. Virgin materials herein can be defined as raw materials that neither expand by activation of the mixed blowing agent nor are formed into a final product. For example, the virgin polymer material includes one of an EVA copolymer having 15 to 60 mole% vinyl acetate, a Polyurethane (PU) based material, or a synthetic rubber material.

As described in detail herein, the first plurality of discrete pieces of debris particulate matter 23 or "regrind" material may comprise one of the following materials: "Natural regrind" from ground or shredded excess residual material (such as scrap or scrap material generated during initial shoe formation), "green regrind" from ground or shredded recycled or discarded post-consumer shoes or other non-sales footwear, or a combination of natural regrind and green regrind.

In the case of sole structure 14, the natural color regrind material is a first natural color regrind material that includes the remaining material from the sole structure of another article of footwear formed from at least one of thermoplastic elastomer (TPE) plastic and/or ethylene-vinyl acetate (EVA) copolymer plastic, and the green regrind material may be a first green regrind material that includes recycled material from the sole structure of another article of footwear (used, non-disposable or recycled article of footwear) formed from at least one of thermoplastic elastomer (TPE) plastic and/or ethylene-vinyl acetate (EVA) copolymer plastic.

Sole structure 14 may include a sufficient number of discrete pieces of debris particulate matter 23 such that more than one of discrete pieces of debris particulate matter 23 is at least partially visible on outsole surface 13. More specifically, outsole 17 may include more than fifty (50) discrete pieces of debris particulate matter 23 such that more than one of the discrete pieces of debris particulate matter 23 is visible on ground engaging surface 55, and midsole 19 may include more than fifty (50) discrete pieces of debris particulate matter 23 such that more than one of the discrete pieces of debris particulate matter 23 is visible on midsole outer surface 57. In one example, the first plurality of discrete pieces of debris particulate matter may comprise at least 10% of the volume of sole structure 14. More specifically, the first plurality of discrete pieces of debris particulate matter 23 can comprise from about 12% to about 15% of the outsole 17 and from about 10% to about 15% of the midsole 19. Even more specifically, the discrete pieces of debris particulate matter 23 can comprise more than 10% of the outsole 17 and midsole 19 such that the discrete pieces of debris particulate matter 23 comprise about 13.5% of the outsole 17 and about 13.5% of the midsole 19.

It is also contemplated that these discrete pieces of debris 23 may include a variety of colors and irregular shapes. For example, sole structure 14 is designed to generate a randomly dispersed mixture of discrete pieces of debris particulate matter 23 and virgin polymer material, which is a representative sample designated in the inset of fig. 9, such that the outer sole surface 13 of the illustrated sole structure 14 is distinguished by a unique color scheme provided by the visible nature of the first plurality of discrete pieces of debris particulate matter 23 on the outer sole surface 13.

In another aspect of the present disclosure, and as shown in fig. 1-6 and 9, sole structure 14 may further include a plurality of distinctly shaped cavities 35 and a plurality of distinctly shaped protrusions 37 defined by outsole surface 13 and irregularly dispersed on outsole surface 13. For example, the illustrated outer surface 13 of sole structure 14 is manufactured using a manufacturing process 100 (described below with respect to fig. 10-12), which manufacturing process 100 is designed to produce a randomly dispersed mixture of cavities 35 of significant shape and size and a randomly dispersed mixture of protrusions 37 of significant shape and size, these protrusions 37 being designated in the inset of fig. 9, which protrude in multiple directions from the midsole outer surface 57 and ground-engaging surface 55 of sole structure 14. For at least some configurations, substantially the entire outer sole surface 13 of sole structure 14 is covered with irregularly dispersed cavities 35 and protrusions 37. Optionally, outsole 17 is provided with fifty (50) or more distinctly shaped cavities 35 and fifty (50) or more distinctly shaped protrusions 37 irregularly dispersed on ground-engaging surface 55, and midsole 19 is provided with fifty (50) or more distinctly shaped cavities 35 and fifty (50) or more distinctly shaped protrusions 37 irregularly dispersed on midsole outer surface 57.

In other words, sole structure 14 may be manufactured with atypical (and in some applications unique) surface topologies that may be represented by these distinctly shaped cavities 35 and protrusions 37 (pits and bumps) including irregular shapes, and as such, the combination of cavities 35 and protrusions 37 may exhibit an indeterminate combination of shapes including regular and irregular geometries and dimensions, limited by the total surface area of outsole surface 13, to create a unique visual effect, wherein outsole surface 13 exhibits a pit-like appearance. In general, the surface topology of sole structure 14 may be characterized by the lack of two structurally identical, equally sized surface area segments that are observed by the naked eye. The depressions and protrusions of the outsole surface 13 of the sole structure 14 may be caused by the recovered polymer "sweating" entraining oil during the foaming and forming operations described below.

Sole structure 14 may be permanently and/or fixedly attached to one or more portions of upper 12 (e.g., via adhesive, stitching, welding, or other suitable techniques) and may have a configuration that extends between upper 12 and the ground. For the purposes of this disclosure, the term "permanently attached" refers to two components being joined in a manner such that the components may not be readily separated (e.g., without damaging one or both of the components). Furthermore, the two components may be "permanently attached" by being integrally formed, for example, by a molding process.

In general, upper 12 includes provisions for reducing any tendency of the foot to be pulled away from sole structure 14 during use. In some embodiments, upper 12 may be a conventional upper that defines and at least partially surrounds an interior volume or void 16 for receiving a foot of a wearer. Upper 12 may include a wall 15, with wall 15 at least partially surrounding an interior volume or void 16 and a foot of the wearer. The wall 15 may be formed from a variety of materials, such as leather, fabric, polymer, cotton, foam, composite, and the like. Wall 15 may include an inner layer 18, with inner layer 18 being made of a material having elasticity, breathability, or both, to aid in foot insertion and comfort. For example, the inner layer 18 may be a polymeric or textile material capable of providing elasticity, and may be of a woven, knit (e.g., warp knit) or woven construction.

The wall 15 at least partially defines the lateral side 24 and the medial side 26 of the upper 12 such that the upper 12 may also define an upper 46, the upper 46 extending into the forefoot region 34 and the midfoot region 36 on each of the lateral side 24 and the medial side 26 of the upper 12. Wall 15 of upper 12 may form at least a portion of upper 46.

The wall 15 also defines a throat opening 28 disposed between the lateral portion 24 (fig. 1-3) and the medial portion 26 (fig. 4-6). Throat opening 28 may allow the foot of the wearer to extend into interior void 16 of upper 12. Throat opening 28 may be defined or surrounded by eyelet stiffener 48. Throat opening 28 may also be configured to house a closure system 32, such as a lace 39 or the like, that may selectively couple lateral side 24 and medial side 26 across throat opening 28, while providing the ability to adjust the girth of upper 12. Closure system 32 may generally include an integral closure panel or tongue portion 30 and a plurality of ties 39, each extending between lateral portion 24 and medial portion 26 of wall 15. Tongue portion 30 may be integral with wall 15 or separately secured to wall 15. Tongue portion 30 may extend over the instep area of the foot.

In other embodiments, upper 12 may be configured to provide a 'tension fit' around the foot of the wearer. As used herein, the term "tension fit" refers to a fit that ensures that the upper is pulled against the foot at all times, including on the underside of the sole of the foot that contacts the bottom portion of upper 12. In some cases, the tension fit upper may be configured such that when no foot is present within interior void 16, the volume of interior void 16 is less than the volume of the foot after insertion. In other words, upper 12 may be configured to stretch or expand when the foot is inserted. Such a configuration may provide an upper 12 that remains with the foot, and in particular the plantar's foot, at all times during any activity (e.g., running, jumping, walking, etc.). The tension fit may or may not require stretching in upper 12. In some cases, upper 12 may be configured to stretch substantially when the foot is inserted. In other cases, however, upper 12 may simply fit the foot very snugly without significant expansion.

In the present disclosure, upper 12 may include a wall 15, with wall 15 at least partially surrounding an interior volume or void 16 and a foot of a wearer. Wall 15 may also include an inner layer 18, with inner layer 18 defining an interior cavity 16 adapted to receive a foot of a wearer. In some embodiments, inner layer 18 may include a plurality of discrete layers. Thus, inner layer 18 has an interior surface 21 that contacts the foot of the wearer and an exterior surface 25.

Upper 12 may also include an exterior layer 20 that is formed from a sufficiently transparent or translucent material, such as a transparent or translucent fabric, polymer, mesh, or the like. As used herein, a component is "sufficiently transparent" if it has a light transmittance (i.e., a percentage of incident light transmitted) of at least 80% and a haze (i.e., a percentage of scattered transmitted light) of no more than 56%. Those skilled in the art will readily understand the various methods for determining the light transmittance and haze of an object, such as the outer layer 20.

Exterior layer 20 also defines a surface 31, wherein surface 31 is the outermost surface of upper 12. Outer layer 20 may be coupled to inner layer 18 such that a closed pocket 33 is formed between inner layer 18 and outer layer 20 of wall 15. In the present disclosure, the closed bag 33 is defined as a closed void space between the inner layer 18 and the outer layer 20. The closed pocket 33 is not an open pocket, and inserts may be freely interchanged within the open pocket to alter the appearance of the article of footwear 10. The closed bag 33 is sealed such that, after the final formation of the article of footwear 10 is complete, the inner layer 18 and the outer layer 20 are permanently attached, i.e., joined in a manner such that the components may not be easily separated (e.g., without damaging one or both of the components).

The outer layer 20 may also be coupled to and permanently attached to the inner layer 18 at a plurality of bond area lines 42. The bond area line 42 defines a bag boundary 61 of the closed bag 33 such that the bag boundary 61 defines a closed bag shape. The plurality of bonding area lines 42 may be arranged in a predetermined pattern such that the closed bag 33 is divided into a plurality of closed bags 33a, 33b (fig. 7 to 8).

The plurality of bond area lines 42 may be defined in a variety of ways. In one example, the plurality of bond area lines 42 may be defined as a plurality of pocket boundary sutures. In this manner, inner layer 18 and outer layer 20 may be permanently attached via stitching at bond region lines 42 such that each of the plurality of pockets 33a, 33b is defined by stitching along the entire respective outer boundary 61. In another example, the plurality of bond area lines 42 may be defined as a plurality of bag boundary weld joints. In this manner, the inner layer 18 and the outer layer 20 may be permanently attached via welding, i.e., the inner layer 18 is welded to the outer layer 20 at a plurality of bond area lines 42 such that each of the plurality of pockets 33a, 33b is defined by a weld joint along the entire respective outer boundary 61. In yet another example, the plurality of bond area lines 42 may be defined as a plurality of bag boundary baffle walls. In this manner, the inner layer 18 and the outer layer 20 may be permanently attached via the barrier wall at the plurality of bond area lines 42, with each of the plurality of pockets 33a, 33b being defined along the entire respective outer boundary 61 by the barrier wall extending between the inner layer 18 and the outer layer 20. In such examples, the bag boundary baffle wall may comprise the same material as the outer layer 20.

Upper 12 may also include a plurality of auxiliary stitching 44 that couples or permanently attaches inner layer 18 to outer layer 20. In this manner, each of the auxiliary sutures 44 extends between the inner layer 18 and the outer layer 20. Auxiliary stitching 44 is generally an aesthetic feature of article of footwear 10 and, as such, is disposed in a predetermined pattern on upper 12. In each predetermined pattern, at least one of the auxiliary sutures 44 traverses at least one of the closed pouches 33a, 33 b.

Upper 12 may also include a layer 54 of debris disposed between interior layer 18 and exterior layer 20 and dispersed throughout closed bag 33 (fig. 7). A layer 54 of debris particulate matter is disposed between inner layer 18 and outer layer 20 and dispersed throughout closed bag 33. In this manner, the layer of debris particulate matter 54 is positioned on the upper 12 in the location of the corresponding closed pocket 33.

As shown in fig. 1-6, a closed bag 33 may be disposed in any or each of forefoot region 34, midfoot region 36, heel region 38, and tongue portion 30 of upper 12. In one example, a closed pouch 33 may be disposed in the forefoot region 34 (fig. 1, 4, 7, and 8). In another example, the closed pouch 33 may be disposed in the midfoot region 36 (fig. 2 and 5). In another example, the closed bag 33 may be disposed in the heel region 38 (fig. 3 and 6). In another example, a closed pocket 33 may be provided in the tongue portion 30 (FIG. 8). In one particular example embodiment (fig. 1, 4, 7, and 8), the wall 15 of the upper 12 at least partially defines an upper 46, the upper 46 extending into the forefoot region 34 and midfoot region 36 on each of the lateral side 24 and the medial side 26 of the upper 12. In such examples, the closed bag 33 may be positioned or disposed in the upper 46.

In one example, the layer of debris particulate matter 54 includes a second plurality of discrete pieces of debris particulate matter or regrind 22, which may include: "Natural regrind" from ground or shredded excess residual material (such as scrap or scrap material generated during initial shoe formation), "green regrind" from ground or shredded recycled or discarded post-consumer shoes or other non-sales footwear, or a combination of natural regrind and green regrind.

In a first instance, the second plurality of discrete pieces of debris particulate matter 22 may include a natural color regrind material defined as a first natural color regrind material that includes a remaining material from a sole structure of another article of footwear formed from at least one of thermoplastic elastomer (TPE) plastic and/or ethylene-vinyl acetate (EVA) copolymer plastic. In a second instance, the second plurality of discrete pieces of debris particulate matter 22 may include a natural color regrind material defined as a second natural color regrind material that includes remaining material from an upper of another article of footwear including at least one of leather material, textile material, polymeric material, or foam material, e.g., in one example instance, the second natural color regrind material may be ground or shredded recycled yarn recovered from a production loom. In a third instance, the second plurality of discrete pieces of debris particulate matter 22 may include green regrind material defined as a first green regrind material that includes recycled material from a sole structure of another article of footwear formed from at least one of thermoplastic elastomer (TPE) plastic and/or ethylene-vinyl acetate (EVA) copolymer plastic. In a fourth instance, the second plurality of discrete pieces of debris particulate matter 22 may include green regrind material defined as a second green regrind material that includes recycled material from an upper of another article of footwear formed from at least one of leather material, textile material, polymer material, or foam material.

In one example, the layer of debris particulate matter 54 is defined as a second plurality of discrete pieces of debris particulate matter or regrind 22 that may be sprayed or blown into the bag 33 via a filling machine such that each of the discrete pieces of debris particulate matter 22 or regrind pellets are free floating within the bag 33.

In another example, wherein the second plurality of discrete pieces of debris particulate matter 22 is one of a second natural color regrind material and a second green regrind material, the discrete pieces of debris particulate matter 22 are woven together in a mesh configuration to include the layer of debris particulate matter 54.

In yet another example, as shown in FIG. 7, the crumb particulate matter layer 54 comprises a second plurality of discrete crumb particulate matter pieces or regrind 22 and a resin binder, which may comprise virgin polymer. In this manner, the second plurality of discrete pieces of crumb particulate matter or regrind 22 may be bonded together with a resin binder and then inserted into the closed bag 33 in the form of a layer as shown in fig. 7. More specifically, the second plurality of discrete pieces of crumb particulate matter 22 may be mixed with a resin binder to form a mixture. The second plurality of discrete pieces of crumb particulate matter 22 may comprise from about 3% to about 15% of the mixture so that they are readily visible within the mixture. The mixture of the resin binder and the second plurality of discrete pieces of crumb particulate matter 22 may be placed in a mixing vessel, which is then placed in a mixer and thoroughly mixed to coat all of the outer surfaces of the discrete pieces of crumb particulate matter 22 with the resin binder. The mixture may then be removed from the mixer and formed into a sheet-like structure having a thickness 52. In some embodiments, the thickness 52 may be from about 0.07 millimeters to about 1.3 millimeters, and more particularly about 1.0 millimeters. In this manner, the layer of crumb particulate matter 54 may be a die cut layer defining a layer boundary 59, wherein the layer boundary 59 defines a layer shape such that the layer shape is substantially the same as the closed pocket shape. In this manner, as shown in the example of fig. 7, the layer 54 of debris particulate matter is seamlessly mated into the closed pocket 33 defined between the inner layer 18 and the outer layer 20.

Due to the transparent and/or translucent nature of exterior layer 20, regardless of where closed bag 33 is positioned on upper 12, and regardless of the composition of debris layer 54, once positioned between interior layer 18 and exterior layer 20, is at least partially visible through exterior layer 20. In other words, the outer layer 20 is formed of a material that is sufficiently transparent such that the layer 54 of debris particulate matter is at least partially visible through the outer layer 20.

In this manner, the debris particulate matter 22, 23, such as natural regrind material, green regrind material, or a combination thereof, may be readily seen by an observer or wearer of the article of footwear 10 to not only exhibit a desired and unique aesthetic design, but also to exhibit a sustainable and environmentally friendly manufacturing process 100 in which the debris material, manufacturing remaining material, or recycled or reclaimed material from waste or non-sold footwear applications is used to form newly formed footwear to reduce material waste.

Such a method of manufacture 100 includes techniques for incorporating a first plurality of discrete pieces of debris particulate matter 23 or "regrind" into the sole structure 14 of the new article of footwear 10 and incorporating a second plurality of discrete pieces of debris particulate matter 22 or "regrind" into the upper 12 of the new article of footwear 10. Thus, as disclosed herein and described in detail by the manufacturing method 100 illustrated by example in fig. 1-12, scrap or residual material from footwear manufacturing and/or recycled scrap from recycled or discarded post-consumer or non-sold footwear may be used to form the newly formed article of footwear 10.

The method 100 of fig. 10 may be initiated, for example, in response to receipt of an activation command signal received from a human-machine interface (HMI) of the central control terminal. The initial stages of the manufacturing process may include receiving, supplying, retrieving, and/or utilizing (collectively, "providing") various materials, tools, and machines required to manufacture the article of footwear 10. For example, at step 101, a batch of scrap material is obtained from an available repository of scrap material. More specifically, at step 101, scrap material is obtained or harvested from remaining material, such as scrap or scrap material generated during initial shoe formation and/or from recycled or waste scrap material from post-consumer shoes or non-disposable footwear.

Once the scrap material is received and any attached sorting, cleaning or other pre-treatment is completed, the scrap material may then be separated into a plurality of discrete pieces of scrap particulate matter 22, 23 or regrind material at step 102. More specifically, the crumb material may be divided into a first plurality of discrete crumb particulate matter pieces 23 and a second plurality of discrete crumb particulate matter pieces 22.

As discussed herein, regrind material, by definition, is material that has undergone at least one treatment process and subsequent gates, runners, flash, or reject fraction is ground or shredded. As such, in one example, the separation of the crumb material into the discrete crumb particulate matter blocks 22, 23 may be accomplished via a grinding process, i.e., inserting the crumb material into a grinder to produce a first plurality of discrete crumb particulate matter blocks 23 and a second plurality of discrete crumb particulate matter blocks 22. In another example, dividing the debris material into a plurality of discrete pieces of debris particulate matter 22, 23 may be accomplished via a shredding process, i.e., inserting the debris material into a shredder to create a first plurality of pieces of discrete debris particulate matter 23 and a second plurality of pieces of discrete debris particulate matter 22.

Whereas the discrete pieces of crumb particulate matter 22, 23 or regrind are formed via a grinding process or shredding process in step 102, the shredding or grinding nature of the regrind may result in each of the discrete pieces of crumb particulate matter 22 or regrind pellets having a different shape. In other words, the discrete pieces of crumb particulate matter 22, 23 or regrind pellets do not have a regular or standardized shape, as it is possible to obtain a wide range of pellet sizes including, but not limited to, fine, small dust-like particles up to 0.25 inch or larger pieces of material as the crumb material passes through a grinder or chopper. In other words, the discrete pieces of crumb particulate matter 22, 23 or regrind pellets do not have a regular or standardized shape, and each piece of discrete pieces of crumb particulate matter 22, 23 or regrind pellets may have a unique and different shape. Alternative ways of producing the discrete pieces of crumb particulate matter 22, 23 or regrind material include the techniques described in U.S. patent No. 9,132,430, which is incorporated herein by reference in its entirety.

As indicated herein, the scrap material is obtained or harvested from remaining material such as scrap or scrap material generated upon initial shoe formation and/or recycled or discarded post-consumer shoes or other non-marketable footwear. In one example, the scrap material is obtained or harvested from a remaining material, such as scrap or scrap material generated during initial shoe formation of another article of footwear, such that the regrind material 22, 23 generated at step 102 is defined as "natural color regrind material". The natural color regrind material may include at least one of leather material, textile material, polymeric material, foam material, or elastomeric material in the form of ground or chopped pieces of remaining material, such as scrap or other debris from at least one of the upper and sole structure of another article of footwear. In one example, the natural color regrind material is a first natural color regrind material that includes a remaining mass of material from the sole structure of another article of footwear, which may include at least one of a foamed thermoplastic material or a thermoset material. In another example, the natural color regrind material is a second natural color regrind material that includes a remaining piece of material from the upper of another article of footwear, such as yarn, thread, label, fabric, upper foam, leather or polymer trim, etc., which may include at least one of leather material, fabric material, and foam material. In yet another example, the natural color regrind material may include a mixture of a first natural color regrind material and a second natural color regrind material such that the natural color regrind material includes remaining material from each of the upper and sole structures of another article of footwear.

In another example, scrap material is obtained or harvested from recycled or discarded post-consumer or non-sold footwear such that the regrind material 22, 23 produced at step 102 is defined as "green regrind material". The green regrind material may comprise at least one of leather material, textile material, polymeric material, foam material, or elastomeric material in the form of ground or shredded pieces of recycled or discarded post-consumer or non-sell footwear. In one example, the green regrind material is a first green regrind material that includes pieces of a sole structure of recycled or discarded post-consumer or non-disposable footwear, which may include at least one of a foamed thermoplastic material or a thermoset material. Suitable examples of foamed thermoplastic materials may include polyurethane foams, ethylene-vinyl acetate (EVA) foams, ionomer foams, and the like. Examples of thermoset polymeric materials can include crosslinked thermoset plastics, crosslinked thermoset resins, or crosslinked thermoset elastomers, such as rubber. In another example, the green regrind material is a second green regrind material that includes pieces from the uppers of recycled or discarded post-consumer or non-disposable footwear, such as yarns, threads, labels, fabrics, upper foam, leather or polymer pieces, etc., and the green regrind material may include at least one of leather material, fabric material, and foam material. In yet another example, the green regrind material may include a mixture of a first green regrind material and a second green regrind material such that the green regrind material includes pieces from each of the upper and sole structure of recycled or discarded post-consumer shoes or non-disposable footwear. The crumb particulate matter 22, 23 or regrind material may also be formed from a combination of green regrind material and natural regrind material.

At step 103, a sole structure 14 of the article of footwear is formed wherein the first plurality of discrete pieces of debris particulate matter 23 are incorporated into the sole structure 14 such that the first plurality of discrete pieces of debris particulate matter 23 occupy a sufficient amount of the sole structure 14 such that more than one of the first plurality of discrete pieces of debris particulate matter 23 is visible on the formed outer sole surface 13 of the sole structure 14. Step 103 is described in further detail in fig. 11 via sub-steps 201 to 204.

In fig. 11, at step 201, a first plurality of discrete pieces of crumb particulate matter 23 are mixed with a resin binder and a foaming agent to collectively form a sole structure mixture. The discrete pieces of crumb particulate matter 23 may comprise from about 10% to about 15% of the mixture so that they are readily visible within the mixture. The resin binder may be a composition of virgin polymeric materials that are raw materials that neither expand by activation of the mixed blowing agent nor are formed into a final product. For example, the virgin polymer material includes one of an EVA copolymer having 15 to 60 mole% vinyl acetate, a Polyurethane (PU) based material, or a synthetic rubber material. The sole structure mixture of the resin binder and the discrete pieces of crumb particulate matter 23 may be placed in a mixing vessel, which is then placed in a mixer and thoroughly mixed to coat all of the outer surfaces of the discrete pieces of crumb particulate matter 23 with the resin binder.

In at least some embodiments, a blowing agent is incorporated as a separate component into the mixture of recycled and virgin polymeric materials for causing expansion of the mixture during molding. The foaming agent may be thermally decomposable and may be selected from organic and inorganic chemical foaming agents. The blowing agent may comprise any substance capable of creating a cell structure in the plastic, alone or in combination with other substances. The blowing agent may include compressed gas that expands when pressure is released, soluble solids that leave behind pores when filtered out, liquids that form cells when turned into gas, and chemical agents that decompose or react under the influence of heat to form gas. For example, chemical blowing agents can range from simple salts such as ammonium bicarbonate or sodium bicarbonate to complex denitrification agents. For at least some applications, the blowing agent includes azohexahydrobenzonitrile, diazourea, azodicarbonamide, diazodiaminobenzene, benzenesulfonyl hydrazide, terephthaloyl azide, sulfonyl hydrazide compounds, sodium bicarbonate, ammonium bicarbonate, or any combination thereof. The decomposition temperature of the blowing agent may be from about 120 ℃ to about 200 ℃.

A variety of other additives may be incorporated into the sole structure mixture prior to introduction into the final mold used to form sole structure 14. For example, chemical foaming aids may be added to reduce the decomposition temperature of the foaming agent. Conversely, a chemical foaming inhibitor may be appropriately added to raise the decomposition temperature of the thermally decomposable foaming agent. Another option may include adding a metered amount of chemical cross-linking agent to link the polymer chains of the crumb particulate matter to the polymer chains of the virgin material. Under the temperature conditions of the reaction, the peroxide-based reagent may be activated to initiate the crosslinking process by removing hydrogen atoms from the polymer backbone to provide crosslinking sites. The nature and level of the cross-linking agent may be selected to provide suitable foaming and cross-linking together with the foaming agent.

Other components may be added to the polymer composition including fillers, activators, leveling agents, pigments, flame retardants, lubricants, and other suitable additives. Non-limiting examples of filler materials include talc, mica silicate, tape sulfate, magnesium hydroxide, magnesium carbonate, magnesium silicate, calcium carbonate, and other commercially available fillers. In addition to EVA or TPE-based materials, the polymer composition may also contain rubber fillers such as Ethylene Propylene Rubber (EPR), styrene-isoprene-styrene (SIS) copolymer rubber, styrene-butadiene rubber, and other polyolefin resins. In other examples, polyethylene wax may be used as a processing aid, stearic acid may be used as a lubricant, dicumyl peroxide may be used as a polymerization initiator, zinc oxide may be used as an activator for the blowing agent, and titanium dioxide may be used as a white pigment.

Once the sole structure mixture is complete and ready for molding, the sole structure mixture is placed in the interior cavity of the final mold, which is shaped like the desired sole structure 14, as indicated at process block 202. Optionally, a release agent may be applied to the exposed surface of each complementary recess of the final mold prior to placing the sole structure mixture in the interior cavity of the final mold to facilitate separation of sole structure 14 from the final mold assembly after formation.

At step 203, sole structure 14 may be formed via compression molding, injection molding, two-shot molding, insert molding, co-injection molding, or any other technique for forming the desired sole structure 14, including heating the sole structure mixture above a threshold activation temperature of the foaming agent such that the foaming agent causes the sole structure mixture to expand and fill the interior cavity of the final mold.

At step 204, the formed sole structure 14 may then be removed from the final mold.

Referring back to fig. 10, at step 104, forming upper 12 of article of footwear 10 includes inserting a second plurality of discrete pieces of debris particulate matter 22, such as natural regrind material, green regrind material, or a combination thereof, between inner layer 18 of wall 15 of upper 12 and outer layer 20 of wall 15 of upper 12 and further dispersing it throughout closed pocket 33 formed between inner layer 18 and outer layer 20. Step 104 is described in further detail in fig. 12 via sub-steps 301 to 306.

In the example where the closed bag 33 is a plurality of closed bags 33a, 33b, the discrete pieces of debris particulate matter 22 are dispersed throughout each of the closed bags 33a, 33 b. Discrete pieces of crumb particulate matter 22 may be interposed between the inner layer 18 and the outer layer 20 and further dispersed throughout the closed bag 33 via various processes.

In one example, the regrind 22 may be sprayed or blown or otherwise positioned within the bag 33 via a filling machine such that each of the discrete pieces of crumb particulate matter 22 or regrind pellets are free floating within the bag 33.

In another example, the crumb particulate matter 22 may be bonded together and then inserted into the closed bag 33 in layers. More specifically, at step 301, the discrete pieces of crumb particulate matter 22 may be mixed with a resin binder to form an upper mixture. The discrete pieces of crumb particulate matter 22 may comprise from about 3% to about 15% of the upper mixture so that they are readily visible within the mixture. The mixture of the resin binder and the discrete pieces of crumb particulate matter 22 may be placed in a mixing vessel, which is then placed in a mixer and thoroughly mixed to coat all of the outer surfaces of the discrete pieces of crumb particulate matter 22 with the resin binder. The upper mixture may then be removed from the mixer and formed into a sheet-like structure 54 having a thickness 52.

At step 302, the sheet structure 54 or upper mixture layer may be placed in a dryer at, for example, 80 degrees celsius for 30 minutes. Once dried, the sheet structure may be compression molded or thermoformed to produce a layer 54 of crumb particulate matter having a thickness 52, as shown in FIG. 7. The thickness 52 may be from about 0.7 millimeters to about 1.3 millimeters, and more specifically about 1.0 millimeters.

At step 303, the layer of crumb particulate matter 54 may be die cut into a predetermined layer shape, wherein the layer shape is defined by the layer boundary 59 and is substantially the same as the closed bag shape defined by the bag boundary 61. In this manner, the layer 54 of debris particulate matter is seamlessly mated into the closed pocket 33 defined between the inner layer 18 and the outer layer 20.

At step 304, a layer shape may be placed on the outer layer 20 and in contact with the outer layer 20. At step 305, inner layer 18 may be positioned over layer shape and outer layer 20 such that inner layer 18 and outer layer 20 form closed pocket 33 about perimeter or outer layer boundary 59 of debris layer 54 such that debris layer 54 is disposed within closed pocket 33.

Outer layer 20 may also be coupled to and permanently attached to inner layer 18 at a plurality of bond area lines 42 at step 306. The plurality of bond area lines 42 may be arranged in a predetermined pattern such that the closed pouch 33 and the layer shape are surrounded by the bond area lines 42.

The plurality of bond area lines 42 may be defined in a variety of ways. In one example, the plurality of bond area lines 42 may be defined as a plurality of pocket boundary sutures such that coupling the inner layer 18 of the wall 15 of the upper 12 to the outer layer 20 of the wall 15 of the upper includes sewing the inner layer 18 to the outer layer 20 at each of the plurality of bond area lines 42 such that each of the bond area lines is defined as a suture and each of the plurality of pockets 33a, 33b is defined by a suture along the entire respective outer boundary.

In another example, the plurality of bond area lines 42 may be defined as a plurality of pocket boundary adhesive nodes such that coupling the inner layer 18 of the wall 15 of the upper 12 to the outer layer 20 of the wall 15 of the upper 12 includes applying an adhesive to one of the inner layer 18 and the outer layer 20 at the bond area lines 42 and joining the inner layer 18 and the outer layer 20 at the bond area lines 42.

In another example, the plurality of bond area lines 42 may be defined as a plurality of bag boundary weld joints. In this manner, inner layer 18 and outer layer 20 may be permanently attached via welding, i.e., inner layer 18 is welded to outer layer 20 at a plurality of bond area lines 42 such that each of the plurality of pockets 33 is defined by a weld joint along the entire respective outer boundary. As used herein, the term "welding" or variants thereof (such as "thermal bonding") is defined as a technique for securing two elements to one another that involves softening or melting a polymeric material within at least one of the elements such that the materials of the elements are secured to one another upon cooling. Similarly, the term "weld" or variants thereof (e.g., "thermal bonding") is defined as a bond, link, or structure that joins two elements through a process that involves softening or melting polymeric material within at least one of the elements such that the materials of the elements are fixed to each other upon cooling.

Welding generally creates a heat affected zone in which the materials of the two joined components intermix. The heat affected zone may be considered a "weld" or a "hot bond". Further, welding may involve (a) melting or softening two layers comprising polymeric material such that the polymeric materials from each layer intermix with each other (e.g., diffuse across a boundary layer between the polymeric materials) and fix together upon cooling, and (b) melting or softening the polymeric materials in the first layer such that the polymeric materials extend into or infiltrate into the structure of the second layer (e.g., infiltrate into cracks or cavities formed in the second layer, or extend around or bond with filaments or fibers in the second layer to secure the layers together upon cooling).

In one embodiment, to complete the weld, a resin adhesive is applied to the inner layer 18 at each of the bond area lines 42, the resin adhesive is heated to a tacky state such that the resin adhesive penetrates into the inner layer 18 and the outer layer 20 at each of the plurality of bond area lines 42, and the resin adhesive is cooled to a solid state.

In another embodiment, wherein one of the inner layer 18 and the outer layer 20 is formed of a thermoplastic material, to complete the weld, each layer 18, 20 formed of the thermoplastic material is heated to a tacky state such that the thermoplastic layer penetrates the other of the inner layer 18 and the outer layer 20 at the plurality of bond area lines 42 and cools the thermoplastic layer to a solid state.

Referring back to fig. 10, at step 106, the formed upper 12 and the formed sole structure 14 may be fixedly attached to each other via adhesive, stitching, welding, or other suitable techniques to form the finished article of footwear 10.

The detailed description and drawings are supporting and describing the teachings of the present disclosure, but the scope of the teachings of the present disclosure is limited only by the claims. While some of the best modes and other embodiments for carrying out the teachings of the present disclosure have been described in detail, various alternative designs and embodiments exist for practicing the teachings of the present disclosure as defined in the appended claims.

While various embodiments have been described, the description is intended to be exemplary, rather than limiting, and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible within the scope of these embodiments. Any feature of any embodiment may be used in combination with or in place of any other feature or element in any other embodiment unless explicitly limited. Accordingly, these embodiments are not limited except as by the appended claims and their equivalents. Further, various modifications and changes may be made within the scope of the appended claims.

However, the benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature or element of any or all the claims unless such benefits, advantages, solutions or elements are explicitly stated in such claims. Additional embodiments of the present disclosure are provided in the following enumerated clauses:

clause 1: an article of footwear, comprising: an upper and a sole structure, the upper including a wall at least partially surrounding an interior volume operable to receive a foot of a wearer, wherein the wall includes: an inner layer; an outer layer coupled to the inner layer such that the inner layer and the outer layer define a closed pouch therebetween; a layer of debris particulate matter disposed between the inner layer and the outer layer and dispersed throughout the closed bag, and wherein the outer layer is formed of an at least partially transparent material such that the layer of debris particulate matter is at least partially visible through the outer layer; the sole structure configured to support the foot of the wearer thereon and fixedly attached to the upper, the sole structure including a first plurality of discrete pieces of debris particulate matter and defining an outer sole surface such that more than one of the discrete pieces of debris particulate matter of the first plurality of pieces of debris particulate matter is at least partially visible on the outer sole surface; and wherein the sole structure includes a plurality of distinctly shaped cavities and a plurality of distinctly shaped protrusions defined by and irregularly dispersed on the outsole surface; and wherein the layer of crumb particulate matter in the upper comprises leather material, textile material, polymeric material or foam material, and the plurality of discrete crumb particulate matter blocks in the sole structure comprises rubber, thermoplastic elastomer (TPE) and/or Ethylene Vinyl Acetate (EVA) copolymer.

Clause 2: the article of footwear of clause 1, wherein the layer of debris particulate matter comprises at least one of a green regrind material or a natural regrind material.

Clause 3: the article of footwear of clause 2, wherein the first plurality of discrete pieces of debris particulate matter comprises at least 10% of the sole structure.

Clause 4: the article of footwear of clause 2, wherein the sole structure further comprises an outsole defining a ground-engaging surface, wherein the outsole is manufactured from a mixture of the first plurality of discrete pieces of crumb particulate matter and virgin polymer material.

Clause 5: the article of footwear of clause 4, wherein the first plurality of discrete pieces of crumb particulate matter comprises at least one of green regrind material or natural regrind material.

Clause 6: the article of footwear of clause 5, wherein the outsole includes more than 50 of the discrete pieces of debris particulate matter in the first plurality of discrete pieces of debris particulate matter such that more than one of the discrete pieces of debris particulate matter is visible on the ground engaging surface.

Clause 7: the article of footwear of clause 6, wherein the first plurality of discrete pieces of debris particulate matter comprises from about 12% to about 15% of the outsole.

Clause 8: the article of footwear of clause 6, wherein the sole structure further comprises a midsole disposed between the upper and the outsole, the midsole defining a midsole outer surface, wherein the ground-engaging surface and the midsole outer surface cooperate to collectively define the outsole surface; and wherein the midsole is fabricated from a mixture of the first plurality of discrete pieces of crumb particulate matter and virgin polymer material.

Clause 9: the article of footwear of clause 8, wherein the midsole includes more than 50 of the discrete pieces of debris particulate matter in the first plurality of discrete pieces of debris particulate matter such that more than one of the discrete pieces of debris particulate matter is visible on the midsole outer surface.

Clause 10: the article of footwear of clause 9, wherein the first plurality of discrete pieces of crumb particulate matter comprises from about 12% to about 15% of the midsole.

Clause 11: the article of footwear according to clause 9, wherein: the ground engaging surface defining at least 50 of the distinctly shaped cavities and at least 50 of the distinctly shaped protrusions irregularly dispersed thereon; and said midsole outer surface defines at least 50 of said distinctly shaped cavities and at least 50 of said distinctly shaped protrusions irregularly dispersed thereon.

Clause 12: the article of footwear of clause 11, wherein the ground-engaging surface and the midsole outer surface cooperate to collectively define the outsole surface such that the outsole surface is substantially covered with irregularly dispersed, distinctly-shaped cavities and distinctly-shaped protrusions.

Clause 13: the article of footwear according to clause 12, wherein: the outer layer is coupled to the inner layer at a plurality of bond area lines, and wherein the plurality of bond area lines are defined as at least one of a plurality of pouch boundary sutures, a plurality of pouch boundary weld joints, or a plurality of pouch boundary baffle walls extending between the inner layer and the outer layer; the plurality of bond area lines defining a bag boundary of the closed bag; and the bag boundary of the closed bag defines a closed bag shape.

Clause 14: the article of footwear according to clause 13, wherein: the upper has a lateral side and a medial side and further defines a forefoot region, a midfoot region, and a heel region; each of the lateral side and the medial side extends into the forefoot region, the midfoot region, and the heel region; the upper further defines an upper that extends into the forefoot region and the midfoot region on each of the lateral side and the medial side; the wall forming at least a portion of the upper; and wherein the closed bag is disposed in one of the upper, the midfoot region, or the heel region.

Clause 15: the article of footwear of clause 14, wherein the layer of debris particulate matter is defined as a second plurality of discrete pieces of debris particulate matter such that each of the second plurality of pieces of debris particulate matter is free-floating within the pocket.

Clause 16: the article of footwear of clause 14, wherein the crumb particulate matter layer further comprises a second plurality of discrete crumb particulate matter blocks fixed to each other via a resin binder, such that the crumb particulate matter layer is a die cut crumb particulate matter layer defining layer boundaries and a thickness of from about 0.07 millimeters to about 1.3 millimeters; and wherein the layer boundary defines a layer shape, wherein the layer shape is substantially the same as the closed pocket shape.

Clause 17: the article of footwear according to clause 12, wherein: the first plurality of discrete pieces of crumb particulate matter are further defined as an abrasive block of at least one of the natural color regrind material or the green regrind material or at least one of a chopped piece of the natural color regrind material or the green regrind material; and the layer of crumb particulate matter comprises a second plurality of discrete pieces of crumb particulate matter, wherein the second plurality of pieces of discrete crumb particulate matter are defined as at least one of abrasive pieces of at least one of the natural color regrind material or the green regrind material or cut pieces of the natural color regrind material or the green regrind material.

Clause 18: the article of footwear according to clause 17, wherein: the first plurality of discrete pieces of crumb particulate matter is a plurality of discrete pieces of a first natural color regrind material, wherein the first natural color regrind material comprises a remaining material from a sole structure of another article of footwear; and the second plurality of discrete pieces of crumb particulate matter is a plurality of discrete pieces of a second natural color regrind material, wherein the second natural color regrind material comprises a remaining material from an upper of another article of footwear.

Clause 19: the article of footwear according to clause 17, wherein: the first plurality of discrete pieces of crumb particulate matter is a plurality of discrete pieces of a first green regrind material comprising recycled material from a sole structure of another article of footwear; and the second plurality of discrete pieces of crumb particulate matter is a plurality of discrete pieces of a second green regrind material comprising recycled material from an upper of another article of footwear.

Clause 20: the article of footwear according to clause 17, wherein: the first plurality of discrete pieces of crumb particulate matter is a plurality of discrete pieces of a first natural color regrind material, wherein the first natural color regrind material comprises a remaining material from a sole structure of another article of footwear; and the second plurality of discrete pieces of crumb particulate matter is a plurality of discrete pieces of a second green regrind material, wherein the second green regrind material comprises recycled material from an upper of another article of footwear.

Clause 21: the article of footwear according to clause 17, wherein: the first plurality of discrete pieces of crumb particulate matter is a plurality of discrete first pieces of green regrind material, wherein the first green regrind material comprises recycled material from a sole structure of another article of footwear; and the second plurality of discrete pieces of crumb particulate matter is a plurality of discrete pieces of a second natural color regrind material, wherein the second natural color regrind material comprises a remaining material from an upper of another article of footwear.

Claims

1. An article of footwear, comprising:

an upper comprising a wall at least partially surrounding an interior volume operable to receive a foot of a wearer, wherein the wall comprises:

an inner layer;

an outer layer coupled to the inner layer such that the inner layer and the outer layer define a closed pouch therebetween;

a layer of debris particulate matter disposed between the inner layer and the outer layer and dispersed throughout the closed bag, and wherein the outer layer is formed of an at least partially transparent material such that the layer of debris particulate matter is at least partially visible through the outer layer;

A sole structure configured to support the foot of the wearer thereon and fixedly attached to the upper, the sole structure including a first plurality of discrete pieces of debris particulate matter and defining an outer sole surface such that more than one of the discrete pieces of debris particulate matter of the first plurality of pieces of debris particulate matter is at least partially visible on the outer sole surface; and is also provided with

Wherein the sole structure includes a plurality of distinctly shaped cavities and a plurality of distinctly shaped protrusions defined by and irregularly dispersed on the outsole surface; and is also provided with

Wherein the layer of crumb particulate matter in the upper comprises leather material, textile material, polymeric material or foam material and the plurality of discrete crumb particulate matter blocks in the sole structure comprises rubber, thermoplastic elastomer (TPE) and/or Ethylene Vinyl Acetate (EVA) copolymer.

2. The article of footwear of claim 1, wherein the layer of crumb particulate matter comprises at least one of a green regrind material or a natural regrind material.

3. The article of footwear of claim 2, wherein the first plurality of discrete pieces of debris particulate matter comprises at least 10% of the sole structure.

4. The article of footwear of claim 2, wherein the sole structure further includes an outsole defining a ground-engaging surface, wherein the outsole is manufactured from a mixture of the first plurality of discrete pieces of debris particulate matter and virgin polymer material.

5. The article of footwear of claim 4, wherein the first plurality of discrete pieces of debris particulate matter includes at least one of green regrind material or natural regrind material.

6. The article of footwear of claim 5, wherein the outsole includes more than 50 of the discrete pieces of debris particulate matter in the first plurality of discrete pieces of debris particulate matter such that more than one of the discrete pieces of debris particulate matter is visible on the ground engaging surface.

7. The article of footwear of claim 6, wherein the first plurality of discrete pieces of debris particulate matter comprises from about 12% to about 15% of the outsole.

8. The article of footwear of claim 6, wherein the sole structure further includes a midsole disposed between the upper and the outsole, the midsole defining a midsole outer surface, wherein the ground-engaging surface and the midsole outer surface cooperate to collectively define the outsole surface; and is also provided with

Wherein the midsole is fabricated from a mixture of the first plurality of discrete pieces of crumb particulate matter and virgin polymer material.

9. The article of footwear of claim 8, wherein the midsole includes more than 50 of the discrete pieces of debris particulate matter in the first plurality of discrete pieces of debris particulate matter such that more than one of the discrete pieces of debris particulate matter is visible on the midsole outer surface.

10. The article of footwear of claim 9, wherein the first plurality of discrete pieces of debris particulate matter comprises from about 12% to about 15% of the midsole.

11. The article of footwear of claim 9, wherein:

the ground engaging surface defining at least 50 of the distinctly shaped cavities and at least 50 of the distinctly shaped protrusions irregularly dispersed thereon; and is also provided with

The midsole outer surface defines at least 50 of the distinctly shaped cavities and at least 50 of the distinctly shaped protrusions irregularly dispersed thereon.

12. The article of footwear of claim 11, wherein the ground engaging surface and the midsole outer surface cooperate to collectively define the outsole surface such that the outsole surface is substantially covered with irregularly dispersed distinctly-shaped cavities and distinctly-shaped protrusions.

13. The article of footwear of claim 12, wherein:

the outer layer is coupled to the inner layer at a plurality of bond area lines, and wherein the plurality of bond area lines are defined as at least one of a plurality of pouch boundary sutures, a plurality of pouch boundary weld joints, or a plurality of pouch boundary baffle walls extending between the inner layer and the outer layer;

the plurality of bond area lines defining a bag boundary of the closed bag; and is also provided with

The bag boundary of the closed bag defines a closed bag shape.

14. The article of footwear of claim 13, wherein:

the upper has a lateral side and a medial side and further defines a forefoot region, a midfoot region, and a heel region;

each of the lateral side and the medial side extends into the forefoot region, the midfoot region, and the heel region;

the upper further defines an upper that extends into the forefoot region and the midfoot region on each of the lateral side and the medial side;

the wall forming at least a portion of the upper; and is also provided with

Wherein the closed bag is disposed in one of the upper, the midfoot region, or the heel region.

15. The article of footwear of claim 14, wherein the layer of debris particulate matter is defined as a second plurality of discrete pieces of debris particulate matter such that each of the second plurality of pieces of debris particulate matter is free-floating within the pocket.

16. The article of footwear of claim 14, wherein the crumb particulate matter layer further comprises a second plurality of discrete crumb particulate matter blocks secured to each other via a resin binder such that the crumb particulate matter layer is a die cut crumb particulate matter layer defining layer boundaries and a thickness of from about 0.07 millimeters to about 1.3 millimeters; and is also provided with

Wherein the layer boundary defines a layer shape, wherein the layer shape is substantially the same as the closed pocket shape.

17. The article of footwear of claim 12, wherein:

the first plurality of discrete pieces of crumb particulate matter are further defined as an abrasive block of at least one of the natural color regrind material or the green regrind material or at least one of a chopped piece of the natural color regrind material or the green regrind material; and is also provided with

The layer of crumb particulate matter comprises a second plurality of discrete pieces of crumb particulate matter, wherein the second plurality of pieces of discrete crumb particulate matter are defined as at least one of abrasive pieces of the natural color regrind material or the green regrind material or cut pieces of the natural color regrind material or the green regrind material.

18. The article of footwear of claim 17, wherein:

the first plurality of discrete pieces of crumb particulate matter is a plurality of discrete pieces of a first natural color regrind material, wherein the first natural color regrind material comprises a remaining material from a sole structure of another article of footwear; and is also provided with

The second plurality of discrete pieces of crumb particulate matter is a plurality of discrete pieces of a second natural color regrind material, wherein the second natural color regrind material comprises a remaining material from an upper of another article of footwear.

19. The article of footwear of claim 17, wherein:

the first plurality of discrete pieces of crumb particulate matter is a plurality of discrete pieces of a first green regrind material comprising recycled material from a sole structure of another article of footwear; and is also provided with

The second plurality of discrete pieces of crumb particulate matter is a plurality of discrete pieces of a second green regrind material comprising recycled material from an upper of another article of footwear.

20. The article of footwear of claim 17, wherein:

The second plurality of discrete pieces of crumb particulate matter is a plurality of discrete pieces of a second green regrind material, wherein the second green regrind material comprises recycled material from an upper of another article of footwear.

21. The article of footwear of claim 17, wherein:

the first plurality of discrete pieces of crumb particulate matter is a plurality of discrete first pieces of green regrind material, wherein the first green regrind material comprises recycled material from a sole structure of another article of footwear; and is also provided with