WO2021201842A1 - Footwear midsoles with a support piece and a customized orthopedic piece - Google Patents

Footwear midsoles with a support piece and a customized orthopedic piece Download PDF

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Publication number
WO2021201842A1
WO2021201842A1 PCT/US2020/025951 US2020025951W WO2021201842A1 WO 2021201842 A1 WO2021201842 A1 WO 2021201842A1 US 2020025951 W US2020025951 W US 2020025951W WO 2021201842 A1 WO2021201842 A1 WO 2021201842A1
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WO
WIPO (PCT)
Prior art keywords
piece
customized orthopedic
support piece
customized
article
Prior art date
Application number
PCT/US2020/025951
Other languages
French (fr)
Inventor
Stephan Walter EMMENEGGER
Edward PONOMAREV
Original Assignee
Hewlett-Packard Development Company, L.P.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Hewlett-Packard Development Company, L.P. filed Critical Hewlett-Packard Development Company, L.P.
Priority to PCT/US2020/025951 priority Critical patent/WO2021201842A1/en
Publication of WO2021201842A1 publication Critical patent/WO2021201842A1/en

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Classifications

    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B13/00—Soles; Sole-and-heel integral units
    • A43B13/02—Soles; Sole-and-heel integral units characterised by the material
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B13/00—Soles; Sole-and-heel integral units
    • A43B13/14—Soles; Sole-and-heel integral units characterised by the constructive form
    • A43B13/16—Pieced soles
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B17/00—Insoles for insertion, e.g. footbeds or inlays, for attachment to the shoe after the upper has been joined
    • A43B17/003—Insoles for insertion, e.g. footbeds or inlays, for attachment to the shoe after the upper has been joined characterised by the material
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F5/00—Orthopaedic methods or devices for non-surgical treatment of bones or joints; Nursing devices; Anti-rape devices
    • A61F5/01—Orthopaedic devices, e.g. splints, casts or braces
    • A61F5/14—Special medical insertions for shoes for flat-feet, club-feet or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D35/00—Producing footwear
    • B29D35/02—Producing footwear made in one piece using a moulding technique, e.g. by injection moulding or casting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00—Products made by additive manufacturing

Definitions

  • Footwear tends to be mass produced with variance among a specific style or type of footwear typically being limited to size. Mass production of footwear is facilitated by industrial processes, such as injection molding, that are effective in keeping costs down when many of the same item are made.
  • FIG. 1 is a perspective view of an example apparatus to injection mold a midsole of a footwear article with an article that includes a support piece inserted into a mold cavity to isolate materials of different properties injected into different sub-cavities of the mold, the support piece having customized orthopedic pieces attached thereto.
  • FIG. 2 is a top perspective view of the article of FIG. 1 that includes the support piece having the customized orthopedic pieces attached thereto.
  • FIG. 3 is a cross-sectional view of the example apparatus of FIG. 1 with material injected onto the support piece.
  • FIG. 4 is a cross-sectional view of a footwear article with an injection molded midsole and integrated support piece with customized orthopedic pieces as produced by the apparatus of FIG. 1 .
  • FIG. 5 is a top perspective view of another example support piece having customized orthopedic pieces attached thereto.
  • FIG. 6 is a top perspective view of another example support piece having customized orthopedic pieces attached thereto, with upper and lower stiffeners.
  • FIG. 7 is a top perspective view of another example support piece with ax upper or lower stiffener. 2
  • FIG. 8 is a top perspective view of another example support piece with stiffeners.
  • FIG. 9 is a flowchart of an example method of molding a midsole of a footwear article using an article that includes a support piece and a customized orthopedic piece attached thereto.
  • Footwear often lacks customizable features or features specific to an individual wearer or small group of wearers.
  • the mass production technologies that keep costs low also tend to inhibit wearer-specific features.
  • a midsole may be injection molded with one shot of polyurethane (PU) foam or similar material. Such midsoles therefore tend to have homogenous material properties. If not homogenous, then the material properties are often unpredictable due to chaotic flow of injected material.
  • PU polyurethane
  • a midsole when molding a footwear article, such as a shoe, a midsole may be customized by inserting a support piece with a customized orthopedic piece and/or orthopedic pieces attached thereto into a midsole mold cavity.
  • a customized orthopedic piece may be generated using biometric data of a particular wearer, for example to customize the customized orthopedic piece, and the midsole, according to a particular orthopedic configuration of the wearer and/or to provide a particular orthopedic function and/or provide particular performance to the wearer.
  • the biometric data may indicate that the wearer has corns at a first location at a bottom of a foot, and needs particular support at a second location at the bottom of the foot; while such support pieces may allow for a certain level of customization, it may not be sufficient to address particular types of orthopedic issues.
  • customized orthopedic pieces may be generated, for example using three-dimensional (3D) printing, and/or any suitable technique, from the biometric data to provide orthopedic relief and/or support for locations of the foot, and/or to provide any other suitable orthopedic function using the midsole.
  • a support piece may be provided with one customized orthopedic piece, or more than one customized orthopedic piece, depending on the orthopedic function and/or functions of the midsole.
  • the term “orthopedic function” generally includes functionality which may improve athletic performance, and the like, for a wearer of a footwear article with a customized orthopedic piece incorporated therein.
  • the term “orthopedic function” may alternatively be referred to as a “performance function” and/or “performance enhancing function”; similarly the term “customized orthopedic piece” may alternatively be referred to as a “customized performance piece” and/or “customized performance-enhancing piece”.
  • a customized orthopedic piece may be attached to the support piece at a location based on the biometric data such that the customized orthopedic piece is positioned to provide orthopedic relief and/or support and/or any other suitable orthopedic function for a corresponding location of the foot.
  • the support piece comprises a stiffener, and/or stiffeners, that may be about the length and width of the midsole.
  • the support piece may be to support a first material (e.g. a polyurethane injected material) received during injection molding of the midsole, and the customized orthopedic piece may be of a second material, with the first and second materials having differing material properties including, but not limited to, different durometer hardnesses, and the like, to provide respective orthopedic functions to the midsole.
  • a customized orthopedic piece may be attached to the support piece in any suitable manner, including, but not limited to: 3D printing the customized orthopedic piece and the support piece together (e.g. of different materials) such that the customized orthopedic piece is integrated with the support piece; gluing the customized orthopedic piece to the support piece; thermally attaching the customized orthopedic piece to the support piece; and/or using any other suitable technique. 4
  • the support piece may be provided in the form of a baffle to divide the mold cavity into sub-cavities, which may be injected with materials having different properties, which may be selected to provide further orthopedic function to the midsole.
  • the support piece in the form of the baffle, isolates the sub-cavities so that the different materials may be precisely injected into the desired locations.
  • the support piece and the customized orthopedic piece remains in place and becomes part of the midsole.
  • a support piece with a customized orthopedic piece attached thereto allows for orthopedic function(s) to be provided by the material(s) supported by the support piece and by the customized orthopedic piece(s), and furthermore the orthopedic function(s) may be customized for a specific individual wearer or a small group of wearers with similar orthopedic conditions.
  • An aspect of the present specification provides an article comprising: a support piece comprising a customized orthopedic piece, wherein the support piece is to support a first material, and the customized orthopedic piece is of a second material having a differing material property to the first material.
  • a footwear article comprising: a midsole including: polyurethane injected material of a first durometer hardness; a customized orthopedic piece comprising a three- dimensionally printed lattice structure having a second durometer hardness different from the first durometer hardness; and a support piece that supports the polyurethane injected material, the customized orthopedic piece attached to the support piece.
  • Another aspect of the present specification provides a method comprising: inserting a support piece into a midsole mold cavity, the support piece comprising a customized orthopedic piece at a location based on biometric data; positioning an injection needle at the midsole mold cavity; and 5 injecting, using the injection needle, a first material into the midsole mold cavity; the first material having a first durometer hardness; and a second material of the customized orthopedic piece having a second durometer hardness different from the first durometer hardness
  • FIG. 1 shows an example system 100 to injection mold a midsole of a footwear article, such as a shoe.
  • the system 100 may be used with an injection molding machine, such as a carousel-type machine that rotates a plurality of molds to different stations.
  • the example system 100 may be a mold or part of a mold of such an injection molding machine.
  • the apparatus includes a mold frame 102.
  • the mold frame 102 defines a mold cavity 108.
  • the mold frame 102 may include opposing side frames 110, 112 and a bottom frame 114.
  • the mold frame 102 receives a last 116 that carries an upper 118 of a footwear article that is under manufacture to enable the molding of a midsole onto the upper 118.
  • the side frames 110, 112, bottom frame 114, and the last 116 may be movable with respect to each other to open and close the mold cavity 108.
  • the opposing side frames 110, 112, bottom frame 114, and upper 118, as carried by the last 116, may be brought into mutual engagement to close the mold cavity 108.
  • Material such as polyurethane (PU), thermoplastic polyurethane (TPU), rubber, or the like, may be injected into the closed mold cavity 108 to form a midsole.
  • the article 103 generally includes a support piece 104 and customized orthopedic pieces 105-1, 105-2 attached thereto.
  • the support piece 104 is generally to receive at least a first material compatible with injection molding and support the customized orthopedic pieces 105-1, 105-2.
  • the support piece 104 has two customized orthopedic pieces 105-1, 105-2, attached thereto including: a first customized orthopedic piece 105-1 attached to a forefoot region of the support piece 104, and a second customized orthopedic piece 105-2 attached to a heel region of the support piece 104.
  • the customized orthopedic pieces 105-1, 105-2 are 6 interchangeably referred to hereafter, collectively, as the customized orthopedic pieces 105 and, generically, as a customized orthopedic piece 105.
  • the article 103 may include as few as one customized orthopedic piece 105, or more than two customized orthopedic pieces 105.
  • the support piece 104 comprises a customized orthopedic piece 105 and/or more than one customized orthopedic pieces 105.
  • a customized orthopedic piece 105 is generally of a second material having differing material properties to the first material (e.g. an injection mold material) supported the support piece 104. Examples of material properties which differ may include, but are not limited to, durometer hardness, density, material composition (e.g., PU vs. TPU), color, stiffness, and the like.
  • the support piece 104 is provided in the form of a baffle which divides the mold cavity 108 into a first sub-cavity 120 and a second subcavity 122.
  • the support piece 104 includes a separating wall 130 that divides the mold cavity 108 into a first sub-cavity 120 and a second sub-cavity 122.
  • the support piece 104 hence isolates a first material injected into the first sub-cavity 120 from a second material injected into the second sub-cavity 122.
  • the second material may have a differing material property to the first material. Examples of material properties which differ include, but are not limited to, durometer hardness, density, material composition (e.g., PU vs. TPU), color, stiffness, and the like.
  • the support piece 104 divides the mold cavity into two sub-cavities 120, 122, in other examples, the support piece 104 may be adapted to not divide the mold cavity 108 into sub-cavities, or, in other examples, the support piece 104 may be adapted to divide the mold cavity 108 into more than two sub-cavities. 7
  • the customized orthopedic pieces 105 may also have differing materials properties which may both differ from the materials properties of the materials injected into the two sub-cavities 120, 122.
  • a type of the support piece 104 by selecting a type of the support piece 104, one, or more than injection molded materials (e.g. depending on the type of the support piece 104), and materials properties thereof, may be customized, and by selecting one, or more than one, customized orthopedic piece 105, and materials properties thereof, may be customized.
  • a midsole produced using the system 100 and the article 103 may be highly customizable.
  • the support piece 104 may be made of a suitable material such as plastic or metal. Furthermore, the materials properties of the support piece 104 may be selected to provide a given stiffness which may provide yet more customizability to the midsole produced by the system 100. Hence, portions of the support piece 104, other than the separating wall 130, may be referred to as “stiffeners”, described in more detail below. For example, the position, geometry, thickness, or material of the support piece 104 may be selected to provide a customized stiffness (and/or more than one customized stiffness) characteristic to the midsole.
  • the separating wall 130 is generally sufficiently strong and rigid to avoid significant deformation under pressure of injected material. While some deformation is tolerable, it should be understood that larger deformation may translate into less accuracy in the finished midsole.
  • the separating wall 130 may include an injection opening 107 to receive an injection molding needle to inject a first material into the first subcavity 120. After injection of the first material into the first sub-cavity 120, the different second material may be injected into the second sub-cavity 122. The first and second materials bond to the upper 118 and outsole as well as to the support piece 104, which ultimately forms part of the finished footwear article. 8
  • the support piece 104 as depicted hence allows a sequence of materials of different properties to be injected to make a customized midsole.
  • a property such as material composition, density, color, stiffness, and similar, may be varied at different locations of the midsole. This may be used to create a unique density profile, appearance, or similar feature for the footwear article.
  • any number of material properties may be varied at any suitable location of a given midsole.
  • the materials used may be selected to provide an orthopedic function to the midsole. For example, a stiffer material may be provided to the first sub-cavity 120 if the wearer has forefoot strike. Conversely, a stiffer material may be provided to the second sub-cavity 122 if the wearer has a heel strike gait.
  • a material of the first customized orthopedic piece 105-1 may be to assist with forefoot strike.
  • a material of the second customized orthopedic piece 105-2 may be to assist with heel strike
  • a customized orthopedic piece 105 may be 3D printed in the form of a 3D printed lattice (e.g. a structure of nodes and beams and/or struts) using any suitable material (e.g. plastic, foam, and the like).
  • a 3D printed lattice, and the like may have an open configuration, such that injection material may flow into spaces in the lattice, which may allow yet further customizability of materials properties of a midsole.
  • such a 3D printed lattice, and the like may have a closed configuration, such that injection material may not flow into spaces in the lattice; rather, external surfaces of the 3D printed lattice may be sealed (e.g. during the 3D printing), creating air and/or gas pockets within a customized 9 orthopedic piece 105 and a midsole, which may allow yet further customizability of materials properties of a midsole.
  • open and closed configurations of customized orthopedic pieces may be formed in any suitable manner (e.g. not just with 3D printing)
  • the first customized orthopedic piece 105- 1 may be an example of a customized orthopedic piece 105 having an open configuration
  • the second customized orthopedic piece 105-2 may be an example of a customized orthopedic piece 105 having a closed configuration.
  • a customized orthopedic piece 105 may comprise any suitable material including, but not limited to, foam, rubber, plastic, metal, wood, and the like, and further may be of any suitable shape and/or configuration. Indeed, while as depicted the customized orthopedic pieces 105 are in the form of disks, the customized orthopedic pieces 105 may be in any suitable shape and/or configuration including, but not limited to, annuluses and/or donut shapes (e.g. to allow for corns, and the like, extending from a bottom of a foot), concave shapes, convex shapes, irregular shapes, and the like, as well as balloons, and the like, containing materials such as water, oil, gels, fluids of given viscosities, and the like.
  • a customized orthopedic piece 105 may be generated using biometric data, which may be acquired by any suitable technique, such as a 3D scan or other measurement technique to capture the shape of the foot, including, but not limited to, pressure plate analysis, gait analysis, or similar biometric measurement techniques. Such captured data may be used to determine the structure and composition of a midsole to be manufactured including a customized orthopedic piece 105, a position and/or shape of separating wall 130 (and whether the mold cavity 108 is to be divided, or not, into two sub-cavities, or more than two sub-cavities), material properties of the injection molded materials, stiffness of stiffeners of the support piece 104, and the like.
  • biometric data may be acquired by any suitable technique, such as a 3D scan or other measurement technique to capture the shape of the foot, including, but not limited to, pressure plate analysis, gait analysis, or similar biometric measurement techniques.
  • Such captured data may be used to determine the structure and composition of a midsole to be manufactured including a customized orthopedic piece 105, a position
  • the article 103 generally remains in the midsole after injection of the injection molding material to provide an orthopedic function to the midsole. As 10 such, in addition to customizing the midsole, as described above, the characteristics of the article 103 may be selected as specific to a wearer or group of wearers.
  • FIG 2 depicts further details of the artide 103.
  • the artide 103 indudes the support piece 104 and the customized orthopedic piece 105 attached thereto, for example at locations selected according to biometric data.
  • the support piece 104 includes a stiffener 206 that forms the substantial portion of the support piece 104, with the separating wall 130 extending vertically from the stiffener 206 to isolate the sub-cavities 120, 122 from one another.
  • the separating wall 130 indudes the injection opening 107 to receive an injection needle.
  • the stiffener 206 is generally to support the customized orthopedic piece 105 attached thereto, as well as to support and/or contact with materials injected into the mold cavity 108, and to contact an outsole of the footwear artide.
  • the stiffener 206 remains with the artide 103 in the midsole after injection of the midsole materials.
  • the stiffener 206 may provide an orthopedic function to the midsole. For example, the material, thickness, and geometry of the stiffener 206 may be selected based on a wearer’s orthopedic needs.
  • the stiffener 206 may indude bonding openings 208 to allow bonding of injected midsole material to the outsole of the footwear artide. That is, material injected in the vidnity of the stiffener 206 may flow through the bonding openings 208 to contact the outsole, so that the midsole and outsole are bonded together in the vidnity of the stiffener 206.
  • the stiffener 206 may be shaped and sized to extend the full width and length of the mold cavity 108. In other examples, the stiffener 206 may be smaller than the mold cavity 108.
  • the toe of the footwear artide points in a direction 220.
  • the first customized orthopedic piece 105-1 attached to a 11 forefoot region of the support piece 104 and/or the stiffener 206 thereof
  • the second customized orthopedic piece 105-2 is attached to a heel region of the support piece 104 and/or the stiffener 206 thereof.
  • the customized orthopedic pieces 105 may be attached to the support piece 104, and/or stiffener 206 thereof, by three dimensionally printing the customized orthopedic pieces 105 together with the support piece 104 and/or stiffener 206.
  • the customized orthopedic pieces 105 may be generated separate from the support piece 104 and/or stiffener 206 and attached thereto using glue, thermal bonding, and the like.
  • the customized orthopedic pieces 105 and the support piece 104 and/or stiffener 206 may be three dimensionally printed separate from each other, and then attached thereafter, or the customized orthopedic pieces 105 and the support piece 104 and/or stiffener 206 may be three dimensionally printed together as an integrated piece.
  • the customized orthopedic pieces 105 and the support piece 104 and/or stiffener 206 may be generated in any suitable manner (e.g. other than three dimensional printing).
  • a customized orthopedic piece 105 may be attached to the support piece 104 at a location based on biometric data.
  • the biometric data may indicate that a customized orthopedic piece 105 is to be located in a given location in a footwear article to interact with a foot of a wearer in a particular corresponding location when the wearer is wearing the footwear article.
  • a shape of the support piece 104, as well as a shape of a footwear article into which the support piece 104 is to be incorporated e.g. a shape of a midsole into which the support piece 104 is to be incorporated, and a shape of a corresponding upper), may be used to determine the location and/or position and/or orientation of the support piece 104 in the footwear article.
  • locations of the support piece 104 relative to the footwear article may mapped, as well as locations of the support piece 104 relative to a foot wearing the footwear article.
  • the 12 corresponding location of the support piece 104 may be determined from the mapping between support piece locations and footwear locations and/or foot locations, and the customized orthopedic piece 105 may be attached to the support piece 104 accordingly.
  • a robot attaching the customized orthopedic piece 105 to the support piece 104 may be programmed with the location and/or orientation of the customized orthopedic piece 105 relative to the support piece 104, and/or a human user performing the attachment may be provided with the location and/or orientation of the customized orthopedic piece 105 relative to the support piece 104, and/or 3D printing data for a combination of the customized orthopedic piece 105 and the support piece 104 may be determined using the location and/or orientation of the customized orthopedic piece 105 relative to the support piece 104.
  • FIG. 3 shows a cross-sectional view of the example apparatus of FIG. 1 with material injected into the mold cavity 108.
  • FIG. 3 shows a mold frame that is closed around a lasted upper 118.
  • An outsole 302 may be provided to a bottom frame 114, so that the outsole 302, lasted upper 118, and opposing side frames 110 enclose a midsole mold cavity 108.
  • the article 103 is inserted into the midsole mold cavity 108 to split the midsole mold cavity 108 into the first sub-cavity 120 and the second sub-cavity 122.
  • an injection needle 304 was inserted into the midsole mold cavity 108 and through the injection opening 107 in the separating wall 130, so that a tip 309 of the injection needle 304 was positioned to inject material into the first sub-cavity 120.
  • the injection needle 304 was pushed through the injection opening 107, so that the tip 309 was inside the first sub-cavity 120.
  • the injection opening 107 may be sized to tightly fit the injection needle 304, so that the supporting wall 130 seals against the injection needle 304 to prevent backflow of material from the first sub-cavity 120 to the second sub-cavity 122.
  • a first injection molding material 310 has been injected through the injection needle 304 and into the first midsole sub- 13 cavity 120, for example around and into the first customized orthopedic piece 105-1 having the open configuration.
  • the injection needle 304 was then withdrawn from the first sub-cavity 120, so that the tip 309 of the injection needle 304 was located inside the second midsole sub-cavity 122, and a second injection molding material 312 was injected into the second sub-cavity 122 and around the second customized orthopedic piece 105-2 having the closed configuration.
  • a void and/or air- pocket is hence present in the midsole being manufactured (e.g. other than any internal structure of the customized orthopedic piece 105-2).
  • the injection needle 304 may be fully withdrawn and another injection needle used to inject the second injection molding material 312.
  • injection needles may be inserted into the sub-cavities 120, 122 from different angles and/or different directions such that the injection molding materials 310, 312 may be injected simultaneously, and the like; in these examples, the injection opening 107 is optional and/or is omitted.
  • the first injection molding material 310 may also be injected into the second sub-cavity 122 and around the second customized orthopedic piece 105-2.
  • control of position of the injection needle 304 (and/or injection needles) may be performed by a robot that has been provided with the locations of the sub-cavities 120, 122 such that the robot may control the position of the injection needle 304 (and/or injection needles) accordingly.
  • the injection molding materials 310, 312 may adhere to the outsole 302 (e.g. via the bonding openings 208), the upper 118, and surface of the support piece 104 facing the sub-cavities 120, 122.
  • FIG. 4 depicts a footwear article 400 produced by the process shown in FIG. 3, the footwear article 400 including a composite midsole 420 that includes the injection molding materials 310, 312 and the customized orthopedic pieces 105. 14
  • the injection molding materials 310, 312 may comprise polyurethane injected material of a first durometer hardness and the customized orthopedic pieces 105 may comprise three-dimensionally printed components and/or lattice structures having a second durometer hardness different from the first durometer hardness.
  • the footwear article 400 may comprise the midsole 420 including: polyurethane injected material (e.g. the injection molding materials 310, 312) of a first durometer hardness; a customized orthopedic piece 105 comprising a three-dimensionally printed lattice structure having a second durometer hardness different from the first durometer hardness; and the support piece 104 that supports the polyurethane injected material, a customized orthopedic piece 105 attached to the support piece 104.
  • polyurethane injected material e.g. the injection molding materials 310, 312
  • a customized orthopedic piece 105 comprising a three-dimensionally printed lattice structure having a second durometer hardness different from the first durometer hardness
  • the support piece 104 that supports the polyurethane injected material, a customized orthopedic piece 105 attached to the support piece 104.
  • any suitable material may be respectively used for the injection molding materials 310, 312 and/or the customized orthopedic pieces 105.
  • a customized orthopedic piece 105 is based on, and/or generated from, biometric data.
  • the second customized orthopedic piece 105-2 may be attached to the support piece 104 at a location different from the first customized orthopedic piece 105-1.
  • the footwear article 400 may comprise as few as one customized orthopedic piece 105, or more than two customized orthopedic pieces 105.
  • a three-dimensional printed lattice of a customized orthopedic piece 105 may have an open configuration, there the customized orthopedic piece 105 includes a portion of the polyurethane injected material therein, for example as with the second customized orthopedic piece 105-2.
  • a three-dimensional printed lattice of a customized orthopedic piece 105 may have a closed configuration, such that the customized orthopedic piece 105 excludes the polyurethane injected material, for example as with the first customized orthopedic piece 105-1 (e.g. to 15 form a void in a midsole).
  • a customized orthopedic piece may form a void using any suitable configuration; for example while the customized orthopedic piece 105-1 has been described with respect to a closed 3D printed lattice structure, in other examples, the customized orthopedic piece 105-1 may have no structure therein.
  • Fig. 4 also shows example profiles of the customized orthopedic pieces 105.
  • the first customized orthopedic piece 105- 1 has a flat profile facing the direction of the upper 118, such that a forefoot region of a foot wearing the footwear article 400 will place pressure on the first customized orthopedic piece 105-1 (and the first injection molded material 310) via the flat profile.
  • the second customized orthopedic piece 105-2 has a concave profile facing the direction of the upper 118, such that a hear region of a foot wearing the footwear article 400 will place pressure on the second customized orthopedic piece 105-2 (and the second injection molded material 312) via the concave profile, which may provide relief for plantar fasciitis, corns, and the like, in the region of the second customized orthopedic piece 105-2 at the midsole 420.
  • FIG. 5 depicts an alterative example article 503 that is similar to article 103, with like components having like numbers, but in a “500” series rather than a “100” or “200” series.
  • the article 503 may be used in place of the article 103 in the system 100.
  • the toe of the footwear article points in a direction 520.
  • the article 503 comprises a support piece 504 with a customized orthopedic piece 505 attached thereto, a stiffener 506, and bonding openings 508 therethrough.
  • the article 503 includes one customized orthopedic piece 505, and no separating wall 130.
  • only one injection molding material may be used, which is supported by the stiffener 506.
  • the article 503 comprises: a support piece 504 insertable into a mold cavity of a mold for a midsole of a footwear article (e.g. 16 similar to the article 103 as depicted in FIG. 1); and a customized orthopedic piece 105 attached to the support piece 504.
  • the support piece 504 is generally to support a first material injected into the mold cavity, and the customized orthopedic piece 505 is of a second material having a differing material property to the first material.
  • the materials may be of different durometer hardnesses.
  • FIG. 6 shows another example article 603 that is similar to article 103, with like components having like numbers, but in a “600” series rather than a “100” or “200” series.
  • the article 603 may be used in place of the article 103 in the system 100 to divide the mold cavity 108 into two sub-cavities.
  • the article 603 comprises a support piece 604 with a customized orthopedic pieces 605-1 , 605-2 attached thereto, a stiffeners 606-1 606-2, and respective bonding openings 608-1 , 608-2 therethrough, as well as a separating wall 630 with an injection opening 607 therethrough (e.g. such that the injection needle 306 may be inserted therethrough).
  • the article 603 includes a lower stiffener 606-1 and an upper stiffener 606-2, with the separating wall 630 joining the lower stiffener 606-1 and the upper stiffener 606-2.
  • the stiffeners 606-1 , 606-2 may provide respective orthopedic function to the midsole.
  • respective materials, thicknesses, and geometries of the stiffeners 606-1 , 606-2 may be selected based on a wearer's orthopedic needs.
  • the stiffeners 606-1 , 606-2 may include respective bonding openings 608 to allow bonding of injected midsole material to the upper of the footwear article. That is, material injected in the vicinity of the stiffeners 606-1 , 606-2 may flow through the respective bonding openings 608-1 , 608-2 to respectively contact an outsole and a upper, so that the midsole, outsole and upper are bonded together in the vicinity of the stiffeners 606-1 , 606-2. 17
  • the stiffeners 606-1 , 606-2 may be shaped and sized to extend the full width and length of a respective sub-cavity. In other examples, stiffeners 606-1, 606.
  • the toe of the footwear article points in a direction 620.
  • the lower stiffener 606-1 is at the forefoot and the upper stiffener 606-2 is at the heel.
  • the toe of the footwear article points opposite the direction 620, with the lower stiffener 606-1 being at the heel and the upper stiffener 606-2 being at the toe.
  • the relative orientation of the stiffeners 606-2, 606-1 may be selected based on the orthopedic function provided.
  • the first customized orthopedic piece 605-1 is attached to an upper surface of the stiffener 606-1
  • the second customized orthopedic piece 605-2 is attached to a lower surface of the stiffener 606-1
  • the article 603 illustrates that customized orthopedic piece may be attached to any suitable surface of a support piece depending, for example, on a geometric configuration of a support piece.
  • FIG. 7 shows another example article 703, with like components having like numbers, but in a “700” series rather than a “100” or “200” series.
  • the article 703 may be used in place of the article 103 in the system 100 to divide the mold cavity 108 into two sub-cavities.
  • the toe of the footwear article may point in a direction 720.
  • the article 703 comprises a support piece 704 with a customized orthopedic piece 705 attached thereto, for example to an underside of a stiffener 706, and bonding openings 708 therethrough, as well as a separating wall 730 with an injection opening 707 therethrough (e.g. such that the injection needle 306 may be inserted therethrough).
  • the article 703 is similar to the article 603, but includes one stiffener 706, which may be an upper stiffener or a lower stiffener, depending on an orientation of the article 703 with respect to the mold cavity 108. 18
  • customized orthopedic pieces may “float" in a midsole.
  • a second orthopedic piece may be positioned in the mold cavity 108 using any suitable technique in a region not occupied by the article 703.
  • the customized orthopedic piece 705 would be located in one of the subcavities and a second customized orthopedic piece may be located in the other of the sub-cavities, for example prior to injection of injection molded material.
  • FIG. 8 shows another example article 803, with like components having like numbers, but in an “800” series rather than a “100” or “200” series.
  • the article 803 may be used in place of the article 103 in the system 100 to divide the mold cavity 108 into three subcavities.
  • the article 803 includes a support piece 804 and three customized orthopedic piece 805-1 , 805-2, 805-3 attached thereto.
  • the support piece 804 includes three stiffeners 806-1 , 806-2, 806-3, with respective bonding openings 808-1, 808-2, 808-3 therethrough.
  • Adjacent stiffeners 806-1, 806-2, 806-3 are joined via respective supporting walls 830-1 , 830-2, with injection needle openings 807 through the supporting walls 830-1 , 830-2 (though only one injection opening 807 is visible in FIG. 8).
  • the supporting walls 830-1 , 830-2 extend vertically to isolate three adjacent sub-cavities from one another.
  • Opposing end stiffeners 806-1 , 806-2 extends from respective supporting walls 830-1 , 830-2, and a central stiffener 806-3 extends between the supporting walls 830-1 , 830-2.
  • a stiffener 806-1 , 806-2, 806-3 may contact the upper or outsole of the toe region, arch region, or heel region of the footwear article.
  • a stiffener 806-1 , 806-2, 806-3 may provide an orthopedic function to its location in the midsole. 19
  • a first customized orthopedic piece 805-1 is attached to an upper surface of the stiffener 806-1
  • the second customized orthopedic piece 805-2 is attached to a respective upper surface of the stiffener 806-2
  • the third customized orthopedic piece 805-3 is attached to a lower surface of the stiffener 806-3.
  • the article 803 further illustrates that customized orthopedic piece may be attached to any suitable surface of a support piece depending, for example, on a geometric configuration of a support piece.
  • the article 803 includes three customized orthopedic pieces 805-1 , 805-2, 805-3, the article 803 may includes any suitable number of customized orthopedic pieces.
  • any number of customized orthopedic pieces, stiffeners, supporting walls may be provided.
  • a support piece may isolate subcavities along a length of a midsole to provide a midsole orthopedic profile along the length of the footwear article.
  • a support piece may alternatively isolate sub-cavities along a width of a midsole to provide a midsole orthopedic profile along the width of the footwear article depending, for example, of placement of supporting walls of a support piece.
  • the supporting wall 130 may be 90° (and/or any other suitable angle) than from the orientation depicted, with the length of the supporting wall 130 being the longitudinal length of the article 103 (e.g. rather than, as depicted, a width of the article 103).
  • customized orthopedic pieces may be attached to the support pieces accordingly.
  • FIG. 9 shows an example method 900 of manufacture of a midsole of a footwear article using a support piece with a customized orthopedic piece (and/or customized orthopedic pieces) placed inside a midsole mold cavity.
  • the method 900 may be performed by the example system 100 of FIG. 1.
  • the method may be performed by other apparatuses.
  • the method begins at block 902.
  • biometric data of a wearer’s foot is captured. This may be done by a three-dimensional (3D) scan or other measurement technique to 20 capture the shape of the foot, pressure plate analysis, gait analysis, or similar biometric measurement techniques. Such captured data may be used to determine the structure and composition of the midsole to be manufactured including, but not limited, a shape, size, location and materials properties of customized orthopedic pieces, support pieces, as well as materials for injection.
  • 3D three-dimensional
  • an orthopedic analysis of an individual wearer of the footwear may be performed to select or configure customized orthopedic pieces and/or a support piece.
  • the shape, size, geometry, and material of the customized orthopedic pieces and/or a support piece, as well as any stiffeners provided to the support piece may be selected as specific to the wearer.
  • the number of zones of midsole material variance may be selected as specific to the wearer, as well as a number of customized orthopedic pieces and/or a support piece, as well as any stiffeners provided to the support piece.
  • a support piece may be selected from a library of stock support pieces.
  • a customized orthopedic piece may be selected from a library of stock orthopedic pieces (e.g. that have been previously customized to provide specific orthopedic functions).
  • a support piece is generated, for example using 3D printing and/or any other suitable technique, based on the biometric data.
  • a customized orthopedic piece is generated (and/or customized orthopedic pieces are generated), for example using 3D printing and/or any other suitable technique, based on the biometric data.
  • the biometric data may be translated into 3D printing data and/or used to generate 3D printing data.
  • a customized orthopedic piece (and/or customized orthopedic pieces) is attached to the support piece to generate the article 103 and/or the article 503 and/or the article 603 and/or the article 703 and/or the article 803, and the like, using any suitable technique.
  • a customized orthopedic piece is attached to the support piece to a location of the 21 support piece based on the biometric data, which may be used to determine where to position the customized orthopedic piece at the support piece to provide a respective orthopedic function to a corresponding location of a user's foot.
  • customized orthopedic piece may be positioned at a support piece by a robot or human operator.
  • attaching a customized orthopedic piece to a location of the support piece based on the biometric data may comprise gluing the customized orthopedic piece to the support piece at the location, based on the biometric data.
  • attaching a customized orthopedic piece to a location of the support piece based on the biometric data comprises thermally attaching the customized orthopedic piece to the support piece at the location, based on the biometric data.
  • any suitable technique may be used to attach customized orthopedic pieces to locations of a support piece.
  • a customized orthopedic piece and a support piece may be 3D printed together such that a customized support piece is integrated with a support piece.
  • the blocks 906, 908, 910 may be combined.
  • the support piece may comprises a three- dimensional printed component
  • the customized orthopedic piece may comprise a three-dimensional printed lattice integrated with the three- dimensional printed component of the support piece
  • the article generated at the block 910 is inserted into a midsole mold cavity.
  • the article includes a support piece, with a customized orthopedic piece (and/or pieces) attached thereto at a location based on the biometric data.
  • the article may be positioned in the cavity by a robot or human operator.
  • An upper of the footwear article may be provided to the mold cavity on, for example, a last. The mold cavity may then be closed.
  • an injection needle at the midsole mold cavity is positioned to inject a material into the midsole cavity defined by the article 22 and/or the support piece.
  • the article may separate the midsole cavity into two sub-cavities and the block 914 may include positioning the injection needle to inject first material into a first midsole subcavity defined by the support piece.
  • the injection needle may be pushed through an opening in the support piece.
  • a first material e.g. a first injection molding material
  • the first material may be selected to have a specific property, such as material composition, density, color, stiffness, or similar, that may be tailored to the specific footwear article or the intended wearer, for example based on the biometric data.
  • the method 900 may end after the block 916, for example when only one cavity is present in the midsole cavity (e.g. as when the article 503 is used with the method 900).
  • the first material injected at the block 916 may have a first durometer hardness; and a second material of a customized orthopedic piece may have a second durometer hardness different from the first durometer hardness.
  • the same or a different injection needle is positioned to inject second injection molding material into a second midsole sub-cavity defined by the support piece.
  • the injection needle may be retracted from the opening in the support piece, inserted through a different opening in the support piece, or inserted into the cavity from a different direction.
  • a second injection molding material is injected into the second sub-cavity to fill the second sub-cavity with second material.
  • the second material may be selected to have a specific property different from the first injection molding material, such as material composition, density, color, stiffness, or similar, that may be tailored to the specific footwear article or the intended wearer.
  • the method 900 ends at block 922 with the formation of a midsole having an arrangement of materials of different properties and an integral support piece.
  • the method 900 may comprise submethods and/or particular blocks of the method 900 may be performed by different entities.
  • the block 904 may comprise a stand-alone method performed at a first entity and/or at a first location.
  • the blocks 906, 908, 910 may be performed separately, in different locations and/or by different entities, and/or different combinations blocks 906, 908, 910 may be performed together; for example, support pieces and customized orthopedic pieces may be generated at different facilities or a same facility; and/or customized orthopedic pieces may be attached to a support piece at a same or different facility from where the customized orthopedic pieces and the support piece are generated.
  • the blocks 912 to 920 may be performed at a same or different facility from where the customized orthopedic pieces and the support piece are generated and/or attached. Hence, the blocks 912 to 920 may comprise a stand-alone method. Furthermore, as has already been discussed, when only one injection molding material is used to form a midsole, the blocks 912 to 916 may comprise a standalone method.
  • Customized orthopedic pieces may be positioned on support pieces to provide customized orthopedic functions.

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Abstract

An example article includes a support piece. The support piece comprises a customized orthopedic piece. The support piece is to support a first material. The customized orthopedic piece is of a second material having a differing material property to the first material.

Description

FOOTWEAR MIDSOLES WITH A SUPPORT PIECE AND A CUSTOMIZED
ORTHOPEDIC PIECE
BACKGROUND
[0001] Footwear tends to be mass produced with variance among a specific style or type of footwear typically being limited to size. Mass production of footwear is facilitated by industrial processes, such as injection molding, that are effective in keeping costs down when many of the same item are made.
BRIEF DESCRIPTION OF THE DRAWINGS
[0002] FIG. 1 is a perspective view of an example apparatus to injection mold a midsole of a footwear article with an article that includes a support piece inserted into a mold cavity to isolate materials of different properties injected into different sub-cavities of the mold, the support piece having customized orthopedic pieces attached thereto.
[0003] FIG. 2 is a top perspective view of the article of FIG. 1 that includes the support piece having the customized orthopedic pieces attached thereto.
[0004] FIG. 3 is a cross-sectional view of the example apparatus of FIG. 1 with material injected onto the support piece.
[0005] FIG. 4 is a cross-sectional view of a footwear article with an injection molded midsole and integrated support piece with customized orthopedic pieces as produced by the apparatus of FIG. 1 .
[0006] FIG. 5 is a top perspective view of another example support piece having customized orthopedic pieces attached thereto.
[0007] FIG. 6 is a top perspective view of another example support piece having customized orthopedic pieces attached thereto, with upper and lower stiffeners.
[0008] FIG. 7 is a top perspective view of another example support piece with ax upper or lower stiffener. 2
[0009] FIG. 8 is a top perspective view of another example support piece with stiffeners.
[0010] FIG. 9 is a flowchart of an example method of molding a midsole of a footwear article using an article that includes a support piece and a customized orthopedic piece attached thereto.
DETAILED DESCRIPTION
[0011] Footwear often lacks customizable features or features specific to an individual wearer or small group of wearers. The mass production technologies that keep costs low also tend to inhibit wearer-specific features. A midsole may be injection molded with one shot of polyurethane (PU) foam or similar material. Such midsoles therefore tend to have homogenous material properties. If not homogenous, then the material properties are often unpredictable due to chaotic flow of injected material.
[0012] According to the present specification, when molding a footwear article, such as a shoe, a midsole may be customized by inserting a support piece with a customized orthopedic piece and/or orthopedic pieces attached thereto into a midsole mold cavity. A customized orthopedic piece may be generated using biometric data of a particular wearer, for example to customize the customized orthopedic piece, and the midsole, according to a particular orthopedic configuration of the wearer and/or to provide a particular orthopedic function and/or provide particular performance to the wearer. For example, the biometric data may indicate that the wearer has corns at a first location at a bottom of a foot, and needs particular support at a second location at the bottom of the foot; while such support pieces may allow for a certain level of customization, it may not be sufficient to address particular types of orthopedic issues. As such, according to the present specification, customized orthopedic pieces may be generated, for example using three-dimensional (3D) printing, and/or any suitable technique, from the biometric data to provide orthopedic relief and/or support for locations of the foot, and/or to provide any other suitable orthopedic function using the midsole. 3
[0013] Furthermore, a support piece may be provided with one customized orthopedic piece, or more than one customized orthopedic piece, depending on the orthopedic function and/or functions of the midsole. As used herein, the term “orthopedic function” generally includes functionality which may improve athletic performance, and the like, for a wearer of a footwear article with a customized orthopedic piece incorporated therein. Hence, the term “orthopedic function” may alternatively be referred to as a “performance function” and/or “performance enhancing function”; similarly the term “customized orthopedic piece” may alternatively be referred to as a “customized performance piece” and/or “customized performance-enhancing piece”.
[0014] Furthermore, a customized orthopedic piece may be attached to the support piece at a location based on the biometric data such that the customized orthopedic piece is positioned to provide orthopedic relief and/or support and/or any other suitable orthopedic function for a corresponding location of the foot.
[0015] In some examples, the support piece comprises a stiffener, and/or stiffeners, that may be about the length and width of the midsole. In these examples, the support piece may be to support a first material (e.g. a polyurethane injected material) received during injection molding of the midsole, and the customized orthopedic piece may be of a second material, with the first and second materials having differing material properties including, but not limited to, different durometer hardnesses, and the like, to provide respective orthopedic functions to the midsole.
[0016] A customized orthopedic piece may be attached to the support piece in any suitable manner, including, but not limited to: 3D printing the customized orthopedic piece and the support piece together (e.g. of different materials) such that the customized orthopedic piece is integrated with the support piece; gluing the customized orthopedic piece to the support piece; thermally attaching the customized orthopedic piece to the support piece; and/or using any other suitable technique. 4
[0017] However, the support piece may be provided in the form of a baffle to divide the mold cavity into sub-cavities, which may be injected with materials having different properties, which may be selected to provide further orthopedic function to the midsole. In these examples, the support piece, in the form of the baffle, isolates the sub-cavities so that the different materials may be precisely injected into the desired locations.
[0018] Regardless of whether the support piece provides for one, or more than one injection molding material, the support piece and the customized orthopedic piece (and/or customized orthopedic pieces) remains in place and becomes part of the midsole. Hence, a support piece with a customized orthopedic piece attached thereto, allows for orthopedic function(s) to be provided by the material(s) supported by the support piece and by the customized orthopedic piece(s), and furthermore the orthopedic function(s) may be customized for a specific individual wearer or a small group of wearers with similar orthopedic conditions.
[0019] An aspect of the present specification provides an article comprising: a support piece comprising a customized orthopedic piece, wherein the support piece is to support a first material, and the customized orthopedic piece is of a second material having a differing material property to the first material.
[0020] Another aspect of the present specification provides a footwear article comprising: a midsole including: polyurethane injected material of a first durometer hardness; a customized orthopedic piece comprising a three- dimensionally printed lattice structure having a second durometer hardness different from the first durometer hardness; and a support piece that supports the polyurethane injected material, the customized orthopedic piece attached to the support piece.
[0021 ] Another aspect of the present specification provides a method comprising: inserting a support piece into a midsole mold cavity, the support piece comprising a customized orthopedic piece at a location based on biometric data; positioning an injection needle at the midsole mold cavity; and 5 injecting, using the injection needle, a first material into the midsole mold cavity; the first material having a first durometer hardness; and a second material of the customized orthopedic piece having a second durometer hardness different from the first durometer hardness
[0022] FIG. 1 shows an example system 100 to injection mold a midsole of a footwear article, such as a shoe. The system 100 may be used with an injection molding machine, such as a carousel-type machine that rotates a plurality of molds to different stations. The example system 100 may be a mold or part of a mold of such an injection molding machine. The apparatus includes a mold frame 102.
[0023] The mold frame 102 defines a mold cavity 108. The mold frame 102 may include opposing side frames 110, 112 and a bottom frame 114. The mold frame 102 receives a last 116 that carries an upper 118 of a footwear article that is under manufacture to enable the molding of a midsole onto the upper 118.
The side frames 110, 112, bottom frame 114, and the last 116 may be movable with respect to each other to open and close the mold cavity 108. The opposing side frames 110, 112, bottom frame 114, and upper 118, as carried by the last 116, may be brought into mutual engagement to close the mold cavity 108. Material, such as polyurethane (PU), thermoplastic polyurethane (TPU), rubber, or the like, may be injected into the closed mold cavity 108 to form a midsole.
[0024] As depicted, an article 103, described in more detail with respect to
FIG. 2, is insertable into the mold cavity 108. The article 103 generally includes a support piece 104 and customized orthopedic pieces 105-1, 105-2 attached thereto. The support piece 104 is generally to receive at least a first material compatible with injection molding and support the customized orthopedic pieces 105-1, 105-2. As depicted, the support piece 104 has two customized orthopedic pieces 105-1, 105-2, attached thereto including: a first customized orthopedic piece 105-1 attached to a forefoot region of the support piece 104, and a second customized orthopedic piece 105-2 attached to a heel region of the support piece 104. The customized orthopedic pieces 105-1, 105-2 are 6 interchangeably referred to hereafter, collectively, as the customized orthopedic pieces 105 and, generically, as a customized orthopedic piece 105.
[0025] While the article 103 is depicted with two customized orthopedic pieces 105, the article 103 may include as few as one customized orthopedic piece 105, or more than two customized orthopedic pieces 105. Hence, the support piece 104 comprises a customized orthopedic piece 105 and/or more than one customized orthopedic pieces 105. A customized orthopedic piece 105 is generally of a second material having differing material properties to the first material (e.g. an injection mold material) supported the support piece 104. Examples of material properties which differ may include, but are not limited to, durometer hardness, density, material composition (e.g., PU vs. TPU), color, stiffness, and the like.
[0026] As depicted, the support piece 104 is provided in the form of a baffle which divides the mold cavity 108 into a first sub-cavity 120 and a second subcavity 122. For example, as depicted, the support piece 104 includes a separating wall 130 that divides the mold cavity 108 into a first sub-cavity 120 and a second sub-cavity 122.
[0027] The support piece 104, as depicted, hence isolates a first material injected into the first sub-cavity 120 from a second material injected into the second sub-cavity 122. The second material may have a differing material property to the first material. Examples of material properties which differ include, but are not limited to, durometer hardness, density, material composition (e.g., PU vs. TPU), color, stiffness, and the like.
[0028] While as depicted the support piece 104 divides the mold cavity into two sub-cavities 120, 122, in other examples, the support piece 104 may be adapted to not divide the mold cavity 108 into sub-cavities, or, in other examples, the support piece 104 may be adapted to divide the mold cavity 108 into more than two sub-cavities. 7
[0029] Furthermore, the customized orthopedic pieces 105 may also have differing materials properties which may both differ from the materials properties of the materials injected into the two sub-cavities 120, 122.
[0030] Hence, by selecting a type of the support piece 104, one, or more than injection molded materials (e.g. depending on the type of the support piece 104), and materials properties thereof, may be customized, and by selecting one, or more than one, customized orthopedic piece 105, and materials properties thereof, may be customized. As such, a midsole produced using the system 100 and the article 103 may be highly customizable.
[0031] The support piece 104 may be made of a suitable material such as plastic or metal. Furthermore, the materials properties of the support piece 104 may be selected to provide a given stiffness which may provide yet more customizability to the midsole produced by the system 100. Hence, portions of the support piece 104, other than the separating wall 130, may be referred to as “stiffeners”, described in more detail below. For example, the position, geometry, thickness, or material of the support piece 104 may be selected to provide a customized stiffness (and/or more than one customized stiffness) characteristic to the midsole.
[0032] As depicted, the separating wall 130 is generally sufficiently strong and rigid to avoid significant deformation under pressure of injected material. While some deformation is tolerable, it should be understood that larger deformation may translate into less accuracy in the finished midsole.
[0033] The separating wall 130 may include an injection opening 107 to receive an injection molding needle to inject a first material into the first subcavity 120. After injection of the first material into the first sub-cavity 120, the different second material may be injected into the second sub-cavity 122. The first and second materials bond to the upper 118 and outsole as well as to the support piece 104, which ultimately forms part of the finished footwear article. 8
[0034] The support piece 104 as depicted hence allows a sequence of materials of different properties to be injected to make a customized midsole. A property, such as material composition, density, color, stiffness, and similar, may be varied at different locations of the midsole. This may be used to create a unique density profile, appearance, or similar feature for the footwear article.
Any number of material properties may be varied at any suitable location of a given midsole. The materials used may be selected to provide an orthopedic function to the midsole. For example, a stiffer material may be provided to the first sub-cavity 120 if the wearer has forefoot strike. Conversely, a stiffer material may be provided to the second sub-cavity 122 if the wearer has a heel strike gait.
[0035] Similarly, as mentioned above, different materials and/or different configurations, may be used for the customized orthopedic pieces 105 depending on an orthopedic function to be provided by a customized orthopedic piece 105. Furthermore, and continuing with the example above, as the first customized orthopedic piece 105-1 is located in the first sub-cavity 120, a material of the first customized orthopedic piece 105-1 may be to assist with forefoot strike. Similarly, and/or conversely, as the second customized orthopedic piece 105-2 is located in the second sub-cavity 122, a material of the second customized orthopedic piece 105-2 may be to assist with heel strike
[0036] In one example, a customized orthopedic piece 105 may be 3D printed in the form of a 3D printed lattice (e.g. a structure of nodes and beams and/or struts) using any suitable material (e.g. plastic, foam, and the like). In some examples, such a 3D printed lattice, and the like, may have an open configuration, such that injection material may flow into spaces in the lattice, which may allow yet further customizability of materials properties of a midsole.
[0037] In other examples, such a 3D printed lattice, and the like, may have a closed configuration, such that injection material may not flow into spaces in the lattice; rather, external surfaces of the 3D printed lattice may be sealed (e.g. during the 3D printing), creating air and/or gas pockets within a customized 9 orthopedic piece 105 and a midsole, which may allow yet further customizability of materials properties of a midsole. However, open and closed configurations of customized orthopedic pieces may be formed in any suitable manner (e.g. not just with 3D printing)
[0038] As will be described below, the first customized orthopedic piece 105- 1 may be an example of a customized orthopedic piece 105 having an open configuration, and the second customized orthopedic piece 105-2 may be an example of a customized orthopedic piece 105 having a closed configuration.
[0039] However, a customized orthopedic piece 105 may comprise any suitable material including, but not limited to, foam, rubber, plastic, metal, wood, and the like, and further may be of any suitable shape and/or configuration. Indeed, while as depicted the customized orthopedic pieces 105 are in the form of disks, the customized orthopedic pieces 105 may be in any suitable shape and/or configuration including, but not limited to, annuluses and/or donut shapes (e.g. to allow for corns, and the like, extending from a bottom of a foot), concave shapes, convex shapes, irregular shapes, and the like, as well as balloons, and the like, containing materials such as water, oil, gels, fluids of given viscosities, and the like. Indeed, a customized orthopedic piece 105 may be generated using biometric data, which may be acquired by any suitable technique, such as a 3D scan or other measurement technique to capture the shape of the foot, including, but not limited to, pressure plate analysis, gait analysis, or similar biometric measurement techniques. Such captured data may be used to determine the structure and composition of a midsole to be manufactured including a customized orthopedic piece 105, a position and/or shape of separating wall 130 (and whether the mold cavity 108 is to be divided, or not, into two sub-cavities, or more than two sub-cavities), material properties of the injection molded materials, stiffness of stiffeners of the support piece 104, and the like.
[0040] The article 103 generally remains in the midsole after injection of the injection molding material to provide an orthopedic function to the midsole. As 10 such, in addition to customizing the midsole, as described above, the characteristics of the article 103 may be selected as specific to a wearer or group of wearers.
[0041] Attention is next directed to FIG 2 which depicts further details of the artide 103. The artide 103 indudes the support piece 104 and the customized orthopedic piece 105 attached thereto, for example at locations selected according to biometric data.
[0042] The support piece 104 includes a stiffener 206 that forms the substantial portion of the support piece 104, with the separating wall 130 extending vertically from the stiffener 206 to isolate the sub-cavities 120, 122 from one another. The separating wall 130 indudes the injection opening 107 to receive an injection needle.
[0043] The stiffener 206 is generally to support the customized orthopedic piece 105 attached thereto, as well as to support and/or contact with materials injected into the mold cavity 108, and to contact an outsole of the footwear artide. The stiffener 206 remains with the artide 103 in the midsole after injection of the midsole materials. The stiffener 206 may provide an orthopedic function to the midsole. For example, the material, thickness, and geometry of the stiffener 206 may be selected based on a wearer’s orthopedic needs.
[0044] As depicted, the stiffener 206 may indude bonding openings 208 to allow bonding of injected midsole material to the outsole of the footwear artide. That is, material injected in the vidnity of the stiffener 206 may flow through the bonding openings 208 to contact the outsole, so that the midsole and outsole are bonded together in the vidnity of the stiffener 206.
[0045] The stiffener 206 may be shaped and sized to extend the full width and length of the mold cavity 108. In other examples, the stiffener 206 may be smaller than the mold cavity 108.
[0046] As depicted, the toe of the footwear artide points in a direction 220. Hence as depicted, the first customized orthopedic piece 105-1 attached to a 11 forefoot region of the support piece 104 and/or the stiffener 206 thereof, and the second customized orthopedic piece 105-2 is attached to a heel region of the support piece 104 and/or the stiffener 206 thereof.
[0047] As mentioned previously, the customized orthopedic pieces 105 may be attached to the support piece 104, and/or stiffener 206 thereof, by three dimensionally printing the customized orthopedic pieces 105 together with the support piece 104 and/or stiffener 206. However, the customized orthopedic pieces 105 may be generated separate from the support piece 104 and/or stiffener 206 and attached thereto using glue, thermal bonding, and the like. Indeed, the customized orthopedic pieces 105 and the support piece 104 and/or stiffener 206 may be three dimensionally printed separate from each other, and then attached thereafter, or the customized orthopedic pieces 105 and the support piece 104 and/or stiffener 206 may be three dimensionally printed together as an integrated piece. However, the customized orthopedic pieces 105 and the support piece 104 and/or stiffener 206 may be generated in any suitable manner (e.g. other than three dimensional printing).
[0048] As mentioned previously, a customized orthopedic piece 105 may be attached to the support piece 104 at a location based on biometric data. For example, the biometric data may indicate that a customized orthopedic piece 105 is to be located in a given location in a footwear article to interact with a foot of a wearer in a particular corresponding location when the wearer is wearing the footwear article. A shape of the support piece 104, as well as a shape of a footwear article into which the support piece 104 is to be incorporated (e.g. a shape of a midsole into which the support piece 104 is to be incorporated, and a shape of a corresponding upper), may be used to determine the location and/or position and/or orientation of the support piece 104 in the footwear article. As such locations of the support piece 104 relative to the footwear article may mapped, as well as locations of the support piece 104 relative to a foot wearing the footwear article. As such, when the biometric data indicates that a customized orthopedic piece 105 is to be located at a specific position and orientation relative to a foot of a wearer of the footwear article, the 12 corresponding location of the support piece 104 may be determined from the mapping between support piece locations and footwear locations and/or foot locations, and the customized orthopedic piece 105 may be attached to the support piece 104 accordingly. For example, a robot attaching the customized orthopedic piece 105 to the support piece 104 may be programmed with the location and/or orientation of the customized orthopedic piece 105 relative to the support piece 104, and/or a human user performing the attachment may be provided with the location and/or orientation of the customized orthopedic piece 105 relative to the support piece 104, and/or 3D printing data for a combination of the customized orthopedic piece 105 and the support piece 104 may be determined using the location and/or orientation of the customized orthopedic piece 105 relative to the support piece 104.
[0049] Attention is next directed to FIG. 3 which shows a cross-sectional view of the example apparatus of FIG. 1 with material injected into the mold cavity 108. In particular, FIG. 3 shows a mold frame that is closed around a lasted upper 118. An outsole 302 may be provided to a bottom frame 114, so that the outsole 302, lasted upper 118, and opposing side frames 110 enclose a midsole mold cavity 108. The article 103 is inserted into the midsole mold cavity 108 to split the midsole mold cavity 108 into the first sub-cavity 120 and the second sub-cavity 122. As depicted, an injection needle 304 was inserted into the midsole mold cavity 108 and through the injection opening 107 in the separating wall 130, so that a tip 309 of the injection needle 304 was positioned to inject material into the first sub-cavity 120. For example, the injection needle 304 was pushed through the injection opening 107, so that the tip 309 was inside the first sub-cavity 120. The injection opening 107 may be sized to tightly fit the injection needle 304, so that the supporting wall 130 seals against the injection needle 304 to prevent backflow of material from the first sub-cavity 120 to the second sub-cavity 122.
[0050] As also depicted in FIG. 3, a first injection molding material 310 has been injected through the injection needle 304 and into the first midsole sub- 13 cavity 120, for example around and into the first customized orthopedic piece 105-1 having the open configuration.
[0051] The injection needle 304 was then withdrawn from the first sub-cavity 120, so that the tip 309 of the injection needle 304 was located inside the second midsole sub-cavity 122, and a second injection molding material 312 was injected into the second sub-cavity 122 and around the second customized orthopedic piece 105-2 having the closed configuration. As the second customized orthopedic piece 105-2 has a closed configuration, a void and/or air- pocket is hence present in the midsole being manufactured (e.g. other than any internal structure of the customized orthopedic piece 105-2).
[0052] Alternatively, the injection needle 304 may be fully withdrawn and another injection needle used to inject the second injection molding material 312. Alternatively, injection needles may be inserted into the sub-cavities 120, 122 from different angles and/or different directions such that the injection molding materials 310, 312 may be injected simultaneously, and the like; in these examples, the injection opening 107 is optional and/or is omitted. Alternatively, the first injection molding material 310 may also be injected into the second sub-cavity 122 and around the second customized orthopedic piece 105-2. It is further understood that control of position of the injection needle 304 (and/or injection needles) may be performed by a robot that has been provided with the locations of the sub-cavities 120, 122 such that the robot may control the position of the injection needle 304 (and/or injection needles) accordingly.
[0053] The injection molding materials 310, 312 may adhere to the outsole 302 (e.g. via the bonding openings 208), the upper 118, and surface of the support piece 104 facing the sub-cavities 120, 122.
[0054] The mold may be opened and the last 116 carrying a footwear article may be removed. For example, FIG. 4, depicts a footwear article 400 produced by the process shown in FIG. 3, the footwear article 400 including a composite midsole 420 that includes the injection molding materials 310, 312 and the customized orthopedic pieces 105. 14
[0055] In a particular example, the injection molding materials 310, 312 may comprise polyurethane injected material of a first durometer hardness and the customized orthopedic pieces 105 may comprise three-dimensionally printed components and/or lattice structures having a second durometer hardness different from the first durometer hardness.
[0056] Indeed, in yet another particular example, the footwear article 400 may comprise the midsole 420 including: polyurethane injected material (e.g. the injection molding materials 310, 312) of a first durometer hardness; a customized orthopedic piece 105 comprising a three-dimensionally printed lattice structure having a second durometer hardness different from the first durometer hardness; and the support piece 104 that supports the polyurethane injected material, a customized orthopedic piece 105 attached to the support piece 104. However, any suitable material (and/or configuration) may be respectively used for the injection molding materials 310, 312 and/or the customized orthopedic pieces 105.
[0057] Has already been described, a customized orthopedic piece 105 is based on, and/or generated from, biometric data.
[0058] Furthermore, as depicted, the second customized orthopedic piece 105-2 may be attached to the support piece 104 at a location different from the first customized orthopedic piece 105-1. However, as described above, the footwear article 400 may comprise as few as one customized orthopedic piece 105, or more than two customized orthopedic pieces 105.
[0059] As also previously described, a three-dimensional printed lattice of a customized orthopedic piece 105 may have an open configuration, there the customized orthopedic piece 105 includes a portion of the polyurethane injected material therein, for example as with the second customized orthopedic piece 105-2. As also previously described, a three-dimensional printed lattice of a customized orthopedic piece 105 may have a closed configuration, such that the customized orthopedic piece 105 excludes the polyurethane injected material, for example as with the first customized orthopedic piece 105-1 (e.g. to 15 form a void in a midsole). However, in general, a customized orthopedic piece may form a void using any suitable configuration; for example while the customized orthopedic piece 105-1 has been described with respect to a closed 3D printed lattice structure, in other examples, the customized orthopedic piece 105-1 may have no structure therein.
[0060] Fig. 4 also shows example profiles of the customized orthopedic pieces 105. For example, as depicted the first customized orthopedic piece 105- 1 has a flat profile facing the direction of the upper 118, such that a forefoot region of a foot wearing the footwear article 400 will place pressure on the first customized orthopedic piece 105-1 (and the first injection molded material 310) via the flat profile. In contrast, as depicted, the second customized orthopedic piece 105-2 has a concave profile facing the direction of the upper 118, such that a hear region of a foot wearing the footwear article 400 will place pressure on the second customized orthopedic piece 105-2 (and the second injection molded material 312) via the concave profile, which may provide relief for plantar fasciitis, corns, and the like, in the region of the second customized orthopedic piece 105-2 at the midsole 420.
[0061] Attention is next directed to FIG. 5, which depicts an alterative example article 503 that is similar to article 103, with like components having like numbers, but in a “500” series rather than a “100" or “200" series. The article 503 may be used in place of the article 103 in the system 100. As depicted, the toe of the footwear article points in a direction 520.
[0062] For example, the article 503 comprises a support piece 504 with a customized orthopedic piece 505 attached thereto, a stiffener 506, and bonding openings 508 therethrough. However, in contrast to the article 103, the article 503 includes one customized orthopedic piece 505, and no separating wall 130. Hence, when the article 503 is used to manufacture a footwear article, only one injection molding material may be used, which is supported by the stiffener 506.
[0063] Put another way, the article 503 comprises: a support piece 504 insertable into a mold cavity of a mold for a midsole of a footwear article (e.g. 16 similar to the article 103 as depicted in FIG. 1); and a customized orthopedic piece 105 attached to the support piece 504. The support piece 504 is generally to support a first material injected into the mold cavity, and the customized orthopedic piece 505 is of a second material having a differing material property to the first material. For example, the materials may be of different durometer hardnesses.
[0064] FIG. 6 shows another example article 603 that is similar to article 103, with like components having like numbers, but in a “600" series rather than a “100” or “200” series. The article 603 may be used in place of the article 103 in the system 100 to divide the mold cavity 108 into two sub-cavities.
[0065] For example, the article 603 comprises a support piece 604 with a customized orthopedic pieces 605-1 , 605-2 attached thereto, a stiffeners 606-1 606-2, and respective bonding openings 608-1 , 608-2 therethrough, as well as a separating wall 630 with an injection opening 607 therethrough (e.g. such that the injection needle 306 may be inserted therethrough).
[0066] However, in contrast to the article 103, the article 603 includes a lower stiffener 606-1 and an upper stiffener 606-2, with the separating wall 630 joining the lower stiffener 606-1 and the upper stiffener 606-2.
[006η The stiffeners 606-1 , 606-2 may provide respective orthopedic function to the midsole. For example, respective materials, thicknesses, and geometries of the stiffeners 606-1 , 606-2 may be selected based on a wearer's orthopedic needs.
[0068] The stiffeners 606-1 , 606-2 may include respective bonding openings 608 to allow bonding of injected midsole material to the upper of the footwear article. That is, material injected in the vicinity of the stiffeners 606-1 , 606-2 may flow through the respective bonding openings 608-1 , 608-2 to respectively contact an outsole and a upper, so that the midsole, outsole and upper are bonded together in the vicinity of the stiffeners 606-1 , 606-2. 17
[0069] The stiffeners 606-1 , 606-2 may be shaped and sized to extend the full width and length of a respective sub-cavity. In other examples, stiffeners 606-1, 606.
[0070] In some examples, the toe of the footwear article points in a direction 620. Hence, the lower stiffener 606-1 is at the forefoot and the upper stiffener 606-2 is at the heel. In other examples, the toe of the footwear article points opposite the direction 620, with the lower stiffener 606-1 being at the heel and the upper stiffener 606-2 being at the toe. The relative orientation of the stiffeners 606-2, 606-1 may be selected based on the orthopedic function provided.
[0071] In particular, as depicted, the first customized orthopedic piece 605-1 is attached to an upper surface of the stiffener 606-1 , and the second customized orthopedic piece 605-2 is attached to a lower surface of the stiffener 606-1. Hence, the article 603 illustrates that customized orthopedic piece may be attached to any suitable surface of a support piece depending, for example, on a geometric configuration of a support piece.
[0072] Attention is next directed to FIG. 7 which shows another example article 703, with like components having like numbers, but in a “700” series rather than a “100” or “200” series. The article 703 may be used in place of the article 103 in the system 100 to divide the mold cavity 108 into two sub-cavities. As depicted, the toe of the footwear article may point in a direction 720.
[0073] For example, the article 703 comprises a support piece 704 with a customized orthopedic piece 705 attached thereto, for example to an underside of a stiffener 706, and bonding openings 708 therethrough, as well as a separating wall 730 with an injection opening 707 therethrough (e.g. such that the injection needle 306 may be inserted therethrough). Hence, the article 703 is similar to the article 603, but includes one stiffener 706, which may be an upper stiffener or a lower stiffener, depending on an orientation of the article 703 with respect to the mold cavity 108. 18
[0074] In yet further examples, which may also be illustrated by FIG. 7, customized orthopedic pieces may “float" in a midsole. For example, while the article 703 is shown as supporting the customized orthopedic piece 705, when the article 703 is placed in the mold cavity 108, a second orthopedic piece may be positioned in the mold cavity 108 using any suitable technique in a region not occupied by the article 703. Put another way, as the article 703 generally divides the mold cavity 108 into two sub-cavities (e.g. via the separating wall 730), the customized orthopedic piece 705 would be located in one of the subcavities and a second customized orthopedic piece may be located in the other of the sub-cavities, for example prior to injection of injection molded material.
[0075] Attention is next directed to FIG. 8 which shows another example article 803, with like components having like numbers, but in an “800" series rather than a “100” or “200” series. The article 803 may be used in place of the article 103 in the system 100 to divide the mold cavity 108 into three subcavities.
[0076] The article 803 includes a support piece 804 and three customized orthopedic piece 805-1 , 805-2, 805-3 attached thereto. The support piece 804 includes three stiffeners 806-1 , 806-2, 806-3, with respective bonding openings 808-1, 808-2, 808-3 therethrough. Adjacent stiffeners 806-1, 806-2, 806-3 are joined via respective supporting walls 830-1 , 830-2, with injection needle openings 807 through the supporting walls 830-1 , 830-2 (though only one injection opening 807 is visible in FIG. 8). The supporting walls 830-1 , 830-2 extend vertically to isolate three adjacent sub-cavities from one another.
[0077] Opposing end stiffeners 806-1 , 806-2 extends from respective supporting walls 830-1 , 830-2, and a central stiffener 806-3 extends between the supporting walls 830-1 , 830-2. Depending on the orientation of the article 803 in the midsole, a stiffener 806-1 , 806-2, 806-3 may contact the upper or outsole of the toe region, arch region, or heel region of the footwear article. A stiffener 806-1 , 806-2, 806-3 may provide an orthopedic function to its location in the midsole. 19
[0078] In particular, as depicted, a first customized orthopedic piece 805-1 is attached to an upper surface of the stiffener 806-1 , the second customized orthopedic piece 805-2 is attached to a respective upper surface of the stiffener 806-2, and the third customized orthopedic piece 805-3 is attached to a lower surface of the stiffener 806-3. Hence, the article 803 further illustrates that customized orthopedic piece may be attached to any suitable surface of a support piece depending, for example, on a geometric configuration of a support piece. Furthermore, while the article 803 includes three customized orthopedic pieces 805-1 , 805-2, 805-3, the article 803 may includes any suitable number of customized orthopedic pieces.
[0079] In other examples, any number of customized orthopedic pieces, stiffeners, supporting walls may be provided. A support piece may isolate subcavities along a length of a midsole to provide a midsole orthopedic profile along the length of the footwear article. However, a support piece may alternatively isolate sub-cavities along a width of a midsole to provide a midsole orthopedic profile along the width of the footwear article depending, for example, of placement of supporting walls of a support piece. For example, with brief reference back to FIG. 2, the supporting wall 130 may be 90° (and/or any other suitable angle) than from the orientation depicted, with the length of the supporting wall 130 being the longitudinal length of the article 103 (e.g. rather than, as depicted, a width of the article 103). Furthermore, customized orthopedic pieces may be attached to the support pieces accordingly.
[0080] FIG. 9 shows an example method 900 of manufacture of a midsole of a footwear article using a support piece with a customized orthopedic piece (and/or customized orthopedic pieces) placed inside a midsole mold cavity. The method 900 may be performed by the example system 100 of FIG. 1. The method may be performed by other apparatuses. The method begins at block 902.
[0081] At block 904, biometric data of a wearer’s foot is captured. This may be done by a three-dimensional (3D) scan or other measurement technique to 20 capture the shape of the foot, pressure plate analysis, gait analysis, or similar biometric measurement techniques. Such captured data may be used to determine the structure and composition of the midsole to be manufactured including, but not limited, a shape, size, location and materials properties of customized orthopedic pieces, support pieces, as well as materials for injection.
[0082] In particular, an orthopedic analysis of an individual wearer of the footwear may be performed to select or configure customized orthopedic pieces and/or a support piece. The shape, size, geometry, and material of the customized orthopedic pieces and/or a support piece, as well as any stiffeners provided to the support piece, may be selected as specific to the wearer. The number of zones of midsole material variance, may be selected as specific to the wearer, as well as a number of customized orthopedic pieces and/or a support piece, as well as any stiffeners provided to the support piece. Alternatively, a support piece may be selected from a library of stock support pieces. Similarly and alteratively, a customized orthopedic piece may be selected from a library of stock orthopedic pieces (e.g. that have been previously customized to provide specific orthopedic functions).
[0083] At block 906, a support piece is generated, for example using 3D printing and/or any other suitable technique, based on the biometric data.
[0084] At block 908, a customized orthopedic piece is generated (and/or customized orthopedic pieces are generated), for example using 3D printing and/or any other suitable technique, based on the biometric data.
[0085] Hence, in general, the biometric data may be translated into 3D printing data and/or used to generate 3D printing data.
[0086] At block 910, a customized orthopedic piece (and/or customized orthopedic pieces) is attached to the support piece to generate the article 103 and/or the article 503 and/or the article 603 and/or the article 703 and/or the article 803, and the like, using any suitable technique. In particular, a customized orthopedic piece is attached to the support piece to a location of the 21 support piece based on the biometric data, which may be used to determine where to position the customized orthopedic piece at the support piece to provide a respective orthopedic function to a corresponding location of a user's foot. For example, customized orthopedic piece may be positioned at a support piece by a robot or human operator.
[0087] In some examples, attaching a customized orthopedic piece to a location of the support piece based on the biometric data may comprise gluing the customized orthopedic piece to the support piece at the location, based on the biometric data. Similarly, in other examples, attaching a customized orthopedic piece to a location of the support piece based on the biometric data comprises thermally attaching the customized orthopedic piece to the support piece at the location, based on the biometric data. However, any suitable technique may be used to attach customized orthopedic pieces to locations of a support piece.
[0088] In particular, in some examples, a customized orthopedic piece and a support piece may be 3D printed together such that a customized support piece is integrated with a support piece. In these examples, the blocks 906, 908, 910 may be combined. Put another way, the support piece may comprises a three- dimensional printed component, and the customized orthopedic piece may comprise a three-dimensional printed lattice integrated with the three- dimensional printed component of the support piece
[0089] At block 912, the article generated at the block 910 is inserted into a midsole mold cavity. As has already been described, the article includes a support piece, with a customized orthopedic piece (and/or pieces) attached thereto at a location based on the biometric data. The article may be positioned in the cavity by a robot or human operator. An upper of the footwear article may be provided to the mold cavity on, for example, a last. The mold cavity may then be closed.
[0090] At block 914, an injection needle at the midsole mold cavity is positioned to inject a material into the midsole cavity defined by the article 22 and/or the support piece. In particular, with reference to FIG. 3, the article may separate the midsole cavity into two sub-cavities and the block 914 may include positioning the injection needle to inject first material into a first midsole subcavity defined by the support piece. The injection needle may be pushed through an opening in the support piece.
[0091] At block 916, a first material (e.g. a first injection molding material) is injected into the midsole cavity, for example the first sub-cavity, to fill the first sub-cavity with the first material. The first material may be selected to have a specific property, such as material composition, density, color, stiffness, or similar, that may be tailored to the specific footwear article or the intended wearer, for example based on the biometric data.
[0092] In some examples, the method 900 may end after the block 916, for example when only one cavity is present in the midsole cavity (e.g. as when the article 503 is used with the method 900). In these examples, it is understood that the first material injected at the block 916 may have a first durometer hardness; and a second material of a customized orthopedic piece may have a second durometer hardness different from the first durometer hardness.
[0093] However, as depicted, at block 918, the same or a different injection needle is positioned to inject second injection molding material into a second midsole sub-cavity defined by the support piece. The injection needle may be retracted from the opening in the support piece, inserted through a different opening in the support piece, or inserted into the cavity from a different direction.
[0094] At block 920, a second injection molding material is injected into the second sub-cavity to fill the second sub-cavity with second material. The second material may be selected to have a specific property different from the first injection molding material, such as material composition, density, color, stiffness, or similar, that may be tailored to the specific footwear article or the intended wearer. 23
[0095] The method 900 ends at block 922 with the formation of a midsole having an arrangement of materials of different properties and an integral support piece.
[0096] It is further understood that the method 900 may comprise submethods and/or particular blocks of the method 900 may be performed by different entities. For example, it is understood that the block 904 may comprise a stand-alone method performed at a first entity and/or at a first location. It is further understood that the blocks 906, 908, 910 may be performed separately, in different locations and/or by different entities, and/or different combinations blocks 906, 908, 910 may be performed together; for example, support pieces and customized orthopedic pieces may be generated at different facilities or a same facility; and/or customized orthopedic pieces may be attached to a support piece at a same or different facility from where the customized orthopedic pieces and the support piece are generated. Similarly, the blocks 912 to 920 may be performed at a same or different facility from where the customized orthopedic pieces and the support piece are generated and/or attached. Hence, the blocks 912 to 920 may comprise a stand-alone method. Furthermore, as has already been discussed, when only one injection molding material is used to form a midsole, the blocks 912 to 916 may comprise a standalone method.
[0097] In view of the above, it should be apparent that the techniques described herein provide for readily customizable midsoles specific to a single wearer or group of wearers. Customized orthopedic pieces may be positioned on support pieces to provide customized orthopedic functions.
[0098] It should be recognized that features and aspects of the various examples provided above can be combined into further examples that also fall within the scope of the present disclosure. In addition, the figures are not to scale and may have size and shape exaggerated for illustrative purposes.

Claims

24 CLAIMS
1. An article comprising: a support piece comprising a customized orthopedic piece, wherein the support piece is to support a first material, and the customized orthopedic piece is of a second material having a differing material property to the first material.
2. The article of claim 1 , wherein the customized orthopedic piece comprises a three-dimensional printed component.
3. The article of claim 1 , wherein the support piece comprises a three- dimensional printed component, and the customized orthopedic piece comprises a three-dimensional printed lattice integrated with the three- dimensional printed component of the support piece.
4. The article of claim 1 , wherein the customized orthopedic piece is glued to the support piece.
5. The article of claim 1 , wherein the customized orthopedic piece is thermally attached to the support piece.
25
6. A footwear article comprising: a midsole including: polyurethane injected material of a first durometer hardness; a customized orthopedic piece comprising a three-dimensionally printed lattice structure having a second durometer hardness different from the first durometer hardness; and a support piece that supports the polyurethane injected material, the customized orthopedic piece attached to the support piece.
7. The footwear article of claim 6, wherein the customized orthopedic piece is based on biometric data.
8. The footwear article of claim 6, further comprising a second customized orthopedic piece attached to the support piece at a location different from the customized orthopedic piece.
9. The footwear article of claim 6, wherein the three-dimensionally printed lattice of the customized orthopedic piece has an open configuration, and wherein the customized orthopedic piece includes a portion of the polyurethane injected material therein.
10. The footwear article of claim 6, wherein the three-dimensionally printed lattice of the customized orthopedic piece has a closed configuration, and wherein the customized orthopedic piece excludes the polyurethane injected material. 26
11. A method comprising: inserting a support piece into a midsole mold cavity, the support piece comprising a customized orthopedic piece at a location based on biometric data; positioning an injection needle at the midsole mold cavity; and injecting, using the injection needle, a first material into the midsole mold cavity; the first material having a first durometer hardness; and a second material of the customized orthopedic piece having a second durometer hardness different from the first durometer hardness.
12. The method of claim 11 , further comprising: attaching the customized orthopedic piece to the location of the support piece based on the biometric data.
13. The method of claim 12, wherein the attaching the customized orthopedic piece to the location of the support piece based on the biometric data comprises gluing the customized orthopedic piece to the support piece at the location, based on the biometric data.
14. The method of claim 12, wherein the attaching the customized orthopedic piece to the location of the support piece based on the biometric data comprises thermally attaching the customized orthopedic piece to the support piece at the location, based on the biometric data.
15. The method of claim 11 , wherein the customized orthopedic piece is integrated with the support piece.
PCT/US2020/025951 2020-03-31 2020-03-31 Footwear midsoles with a support piece and a customized orthopedic piece WO2021201842A1 (en)

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Application Number Priority Date Filing Date Title
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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
RU2427298C2 (en) * 2007-03-23 2011-08-27 Фрассон С.Р.Л. Anti-skid protector and method for its fabrication
US8225532B2 (en) * 2009-02-12 2012-07-24 Pepper Gate Footwear, Inc. Shoe and removably securable shoe insert
US8640363B2 (en) * 2013-03-19 2014-02-04 Henry Hsu Article of footwear with embedded orthotic devices

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
RU2427298C2 (en) * 2007-03-23 2011-08-27 Фрассон С.Р.Л. Anti-skid protector and method for its fabrication
US8225532B2 (en) * 2009-02-12 2012-07-24 Pepper Gate Footwear, Inc. Shoe and removably securable shoe insert
US8640363B2 (en) * 2013-03-19 2014-02-04 Henry Hsu Article of footwear with embedded orthotic devices

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