阅读说明：本技术 将鞋外底施加到鞋类物品的方法 (Method of applying an outsole to an article of footwear ) 是由 沙恩·S·科哈楚 吉尔·D·默芬 于 2020-04-24 设计创作，主要内容包括：一种形成用于鞋类物品的鞋底结构的方法。该方法包括提供由第一聚合物材料形成的鞋底夹层元件。该方法还包括将包含未固化的第二聚合物材料的鞋外底材料沉积在鞋底夹层元件的外表面上,和模制鞋底夹层元件和鞋外底材料以赋予鞋外底材料鞋外底轮廓,以及将鞋底夹层元件的外表面上的鞋外底材料固化。(A method of forming a sole structure for an article of footwear. The method includes providing a midsole element formed from a first polymer material. The method also includes depositing an outsole material comprising an uncured second polymer material on an outer surface of the midsole element, and molding the midsole element and the outsole material to impart an outsole material outsole profile to the outsole material, and curing the outsole material on the outer surface of the midsole element.)

1. A method of forming a sole structure for an article of footwear, the method comprising:

providing a midsole element formed from a first polymer material;

depositing an outsole material comprising an uncured second polymer material on an outer surface of the midsole element;

molding the midsole element and the outsole material to impart an outsole profile to the outsole material; and

curing the outsole material on the outer surface of the midsole element.

2. The method of claim 1, wherein the first polymeric material is a foamed material.

3. The method of claim 1, wherein the second polymeric material is a polyurethane.

4. The method of claim 3, wherein the second polymeric material is polyurea.

5. The method of claim 1, wherein the midsole element is a finished midsole.

6. The method of claim 5, wherein the molding step comprises a cold pressing process.

7. The method according to claim 1, wherein the midsole element is a midsole preform.

8. The method of claim 7, wherein the molding step comprises a compression molding process.

9. The method of claim 1, further comprising partially curing the second polymer material prior to molding the midsole element and the outsole material.

10. The method of claim 1, wherein the outsole material comprises a particulate additive.

11. The method of claim 1, further comprising masking the outer surface of the midsole element.

12. A method of forming a sole structure for an article of footwear, the method comprising:

providing a midsole element formed from a foamed polymer material;

depositing an outsole material comprising an uncured polyurethane material on an outer surface of the midsole element;

molding the midsole element and the outsole material to impart an outsole profile to the outsole material; and

curing the outsole material on the outer surface of the midsole element.

13. The method of claim 12, wherein the uncured polyurethane material is polyurea.

14. The method of claim 12, wherein the midsole element is a finished midsole.

15. The method of claim 14, wherein the molding step comprises a cold pressing process.

16. The method according to claim 12, wherein the midsole element is a midsole preform.

17. The method of claim 16, wherein the molding step comprises a compression molding process.

18. The method of claim 12, further comprising partially curing the polyurethane material prior to molding the midsole element and the outsole material.

19. The method of claim 12, wherein the outsole material includes a particulate additive.

20. The method according to claim 12, further comprising masking the outer surface of the midsole element.

FIELD

The present disclosure relates generally to sole structures for articles of footwear, and more particularly to methods of applying an outsole to a sole structure.

Background

This section provides background information related to the present disclosure that is not necessarily prior art.

Articles of footwear conventionally include an upper and a sole structure. The upper may be formed from any suitable material that receives, secures, and supports the foot on the sole structure. The upper may cooperate with laces, straps, or other fasteners to adjust the fit of the upper around the foot. A bottom portion of the upper, proximate a bottom surface of the foot, is attached to the sole structure.

The sole structure generally includes a layered arrangement (layered arrangement) that extends between the ground surface and the upper. One layer of the sole structure includes an outsole that provides both wear-resistance and traction with the ground surface. The outsole may be formed, at least in part, of rubber or other material that imparts durability and wear-resistance, as well as enhancing traction with the ground surface. Another layer of the sole structure includes a midsole that is disposed between the outsole and the upper. The midsole provides cushioning for the foot and may be formed, in part, from a polymer foam material that resiliently compresses under an applied load to cushion the foot by attenuating ground reaction forces. The midsole may additionally or alternatively incorporate a fluid-filled bladder (or bladders) to increase the durability of the sole structure and to provide cushioning to the foot by resiliently compressing under an applied load to attenuate ground reaction forces. The sole structure may also include a comfort-enhancing insole or sockliner positioned within the void (void) proximate the bottom portion of the upper, and a strobel attached to the upper and disposed between the midsole and the insole or sockliner.

Drawings

The drawings described herein are for illustration purposes only of selected configurations and are not intended to limit the scope of the present disclosure.

FIG. 1 is a perspective view of an article of footwear formed in accordance with the principles of the present disclosure;

FIG. 2A is a perspective view of one step of a method of producing the sole structure of FIG. 1, illustrating the application of an outer sole layer to the sole structure;

FIG. 2B is a schematic view of another step of the method of producing the sole structure of FIG. 1, showing the sole structure in a molding operation;

FIG. 2C is a perspective view of another step of the method of producing the sole structure of FIG. 1, showing the sole structure in a molded state;

FIG. 3A is a perspective view of a step of another method of producing the sole structure of FIG. 1, illustrating the application of an outer sole layer to the sole structure;

FIG. 3B is a schematic view of another step of the method of producing the sole structure of FIG. 1, showing the sole structure in a molding operation;

FIG. 3C is a perspective view of another step of the method of producing the sole structure of FIG. 1, showing the sole structure in a molded state;

FIG. 4 is a perspective view of another method of applying an outsole layer to a sole structure according to the principles of the present disclosure; and

fig. 5 is a perspective view of another method of applying an outsole layer to a sole structure according to the principles of the present disclosure.

Corresponding reference characters indicate corresponding parts throughout the drawings.

Detailed Description

Exemplary configurations will now be described more fully with reference to the accompanying drawings. The exemplary configurations are provided so that this disclosure will be thorough and will fully convey the scope of the disclosure to those skilled in the art. Specific details are set forth such as examples of specific components, devices, and methods in order to provide a thorough understanding of the configurations of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example configurations may be embodied in many different forms, and that specific details and example configurations should not be construed as limiting the scope of the disclosure.

The terminology used herein is for the purpose of describing particular example configurations only and is not intended to be limiting. As used herein, the singular articles "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms "comprises," "comprising," "including," and "having" are inclusive and therefore specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. Additional or alternative steps may be employed.

When an element or layer is referred to as being "on," "engaged to," "connected to," "attached to" or "coupled to" another element or layer, it may be directly on, engaged, connected, attached or coupled to the other element or layer or intervening elements or layers may be present. In contrast, when an element is referred to as being "directly on," "directly engaged to," "directly connected to," "directly attached to" or "directly coupled to" another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a similar manner (e.g., "between," "adjacent" with respect to "directly adjacent," etc.). As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.

The terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections. These elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as "first," "second," and other numerical terms do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, first component, first region, first layer, or first section discussed below could be termed a second element, second component, second region, second layer, or second section without departing from the teachings of the example configurations.

One aspect of the present disclosure provides a method of forming a sole structure for an article of footwear. The method includes (i) providing a midsole element formed from a first polymeric material, and (ii) depositing an outsole material comprising an uncured second polymeric material on an outer surface of the midsole element. The method also includes molding the midsole element and the outsole material to impart an outsole material outsole profile to the outsole material, and curing the outsole material on an outer surface of the midsole element.

Implementations of the disclosure may include one or more of the following optional features. In some embodiments, the first polymeric material may be a foamed material.

In some examples, the second polymeric material may be a polyurethane. Optionally, the second polymeric material may be a polyurea. The midsole element may be a finished midsole.

In some configurations, the molding step comprises a cold pressing process. The midsole element may be a midsole preform.

In some embodiments, the molding step comprises a compression molding process. The method may further include partially curing the second polymer material prior to molding the midsole element and the outsole material. In addition, the outsole material may include particulate additives. The method may include masking an outer surface of the midsole element.

Another aspect of the disclosure provides a method of forming a sole structure for an article of footwear. The method includes providing a midsole element formed from a foamed polymer material. The method also includes (i) depositing an outsole material comprising an uncured polyurethane material on an outer surface of the midsole element, (ii) molding the midsole element and the outsole material to impart an outsole material outsole profile to the outsole material, and (iii) curing the outsole material on the outer surface of the midsole element.

Implementations of the disclosure may include one or more of the following optional features. In some embodiments, the uncured polyurethane material may be polyurea.

In some embodiments, the midsole element may be a finished midsole. Additionally or alternatively, the molding step may include a cold pressing process.

In some configurations, the midsole element may be a midsole preform.

The molding step may include a compression molding process.

In another example, the method may include partially curing the polyurethane material prior to molding the midsole element and the outsole material. The outsole material may include particulate additives.

In some configurations, the method includes masking an outer surface of the midsole element.

Referring to fig. 1, an article of footwear 10 includes an upper 100 and a sole structure 200. Article of footwear 10 may be divided into one or more regions. These areas may include forefoot region 12, midfoot region 14, and heel region 16. Forefoot region 12 corresponds with the phalanges and metatarsals of the foot. Midfoot region 14 may correspond with the arch region of the foot, and heel region 16 may correspond with rear portions of the foot, including the calcaneus bone. Footwear 10 may also include a forward end 18 associated with a forward-most point of forefoot region 12, and a rearward end 20 corresponding with a rearward-most point of heel region 16.Longitudinal axis A of footwear 10_FExtends along the length of footwear 10 from a forward end 18 to a rearward end 20, and generally divides footwear 10 into a lateral side 22 and a medial side 24. Accordingly, lateral side 22 and medial side 24 correspond with opposite sides of footwear 10, respectively, and extend through regions 12, 14, 16.

Upper 100 includes an interior surface that defines an interior void 102, interior void 102 being configured to receive and secure a foot for support on sole structure 200. Upper 100 may be formed from one or more materials that are stitched or adhesively bonded together to form interior void 102. Suitable materials for the upper may include, but are not limited to, mesh, textile (textile), foam, leather, and synthetic leather. The materials may be selected and positioned to impart properties of durability, breathability, abrasion resistance, flexibility, and comfort.

In some examples, upper 100 includes a strobel having a bottom surface opposite sole structure 200 and an opposite top surface defining a footbed (foundation) of interior cavity 102. Stitching or an adhesive may secure the strobel to upper 100. The footbed may be contoured to conform to the contours of the bottom surface of the foot (e.g., the sole of a foot). Optionally, upper 100 may also incorporate additional layers, such as an insole or sockliner, which may be disposed on the strobel and placed within interior void 102 of upper 100 to receive the plantar surface of the foot, thereby enhancing the comfort of article of footwear 10. An ankle opening 104 in heel region 16 may provide access to interior cavity 102. For example, ankle opening 104 may receive the foot to secure the foot within void 102 and facilitate entry and removal of the foot from interior void 102.

In some examples, one or more fasteners may extend along upper 100 to adjust the fit of interior void 102 around the foot and to accommodate entry and removal of the foot from interior void 102. The fasteners may include laces, straps, cords, hook-and-loops, or any other suitable type of fastener. Upper 100 may include a tongue portion that extends between interior void 102 and the fastener. Although upper 100 of the present disclosure is illustrated as a closed upper for a shoe, the principles of the present disclosure may be applied to other types of footwear having alternative upper styles, such as, for example, sandals and boots.

With continued reference to fig. 1, sole structure 200 includes a midsole 202 configured to provide cushioning properties to sole structure 200, and an outsole 204 configured to provide ground-engaging surface 26 of article of footwear 10. Unlike conventional sole structures in which the outsole includes one or more preformed polymer layers that are mechanically or adhesively attached to the midsole 202, the outsole 204 of the present disclosure is applied in a multi-step process in which the outsole material 204a is initially applied to the midsole elements 202a, 202b in an aqueous or fluid state and then molded and cured to provide one type of elastomeric top coat on the outer surface 206 of the midsole 202.

The midsole 202 may be formed from one or more components selected to impart properties of cushioning and stability. In the illustrated example, the midsole 202 comprises a unitary foam structure that extends continuously from the forward end 18 to the rearward end 20 of the article of footwear 10. However, in other examples, the midsole 202 may be a composite structure having more than one foam support element and/or fluid-filled bladder that cooperate to form the midsole 202.

The outer surface 206 of the midsole 202 may be described as including a top surface 208, the top surface 208 configured to face the strobel of the upper 100 and to define the contours of the footbed of the interior cavity 102. The bottom surface 210 of the midsole 202 is formed on the side opposite the top surface 208. A perimeter side surface 212 of the midsole extends from the top surface 208 to the bottom surface 210 and forms an outer perimeter contour of the sole structure 200. Although the present disclosure shows the outsole material 204a being applied on the bottom surface 210 of the midsole 202, in other examples, the outsole material 204a may be at least partially deposited onto the peripheral side surface 212 of the midsole 202 such that the outsole 204 extends over the midsole 202 when cured.

As described above, the midsole 202 includes a resilient polymer material, such as foam or rubber, to impart cushioning, responsiveness, and energy distribution properties to the wearer's foot. In the illustrated example, the midsole 202 includes a single element formed from a single foam material. However, in other examples, midsole 202 may include more than one foam element and/or may be formed from more than one foam material to impart different performance properties to areas of sole structure 200. For example, a first foam element may be formed from a foam material that provides greater cushioning and impact distribution, while other foam elements are formed from a foam material having greater stiffness to provide increased lateral stiffness.

Exemplary elastic polymeric materials for midsole 202 may include materials based on foaming or molding one or more polymers, such as one or more elastomers (e.g., thermoplastic elastomers (TPEs)). The one or more polymers may include aliphatic polymers, aromatic polymers, or a mixture of both; and may comprise homopolymers, copolymers (including terpolymers), or mixtures of the two.

In some aspects, the one or more polymers can include an olefinic homopolymer, an olefinic copolymer, or a blend thereof. Examples of olefinic polymers include polyethylene, polypropylene, and combinations thereof. In other aspects, the one or more polymers can include one or more ethylene copolymers, such as ethylene-vinyl acetate (EVA) copolymers, EVOH copolymers, ethylene-ethyl acrylate copolymers, ethylene-unsaturated mono fatty acid copolymers, and combinations thereof.

In further aspects, the one or more polymers may include one or more polyacrylates such as polyacrylic acid, esters of polyacrylic acid, polyacrylonitrile, polyacrylic acetate, polymethyl acrylate, polyethyl acrylate, polybutyl acrylate, polymethyl methacrylate, and polyvinyl acetate; including their derivatives, their copolymers, and any combination thereof.

In still further aspects, the one or more polymers can include one or more ionomer polymers. In these aspects, the ionomer polymer may include a polymer having carboxylic acid functional groups, sulfonic acid functional groups, salts thereof (e.g., sodium, magnesium, potassium, etc.), and/or anhydrides thereof. For example, the ionomer polymer may include one or more fatty acid modified ionomer polymers, polystyrene sulfonate, ethylene-methacrylic acid copolymers, and combinations thereof.

In further aspects, the one or more polymers can include one or more styrene block copolymers, such as acrylonitrile butadiene styrene block copolymers, styrene acrylonitrile block copolymers, styrene ethylene butylene styrene block copolymers, styrene ethylene butadiene styrene block copolymers, styrene ethylene propylene styrene block copolymers, styrene butadiene styrene block copolymers, and combinations thereof.

In further aspects, the one or more polymers can include one or more polyamide copolymers (e.g., polyamide-polyether copolymers) and/or one or more polyurethanes (e.g., crosslinked polyurethanes and/or thermoplastic polyurethanes). Alternatively, the one or more polymers may include one or more natural and/or synthetic rubbers, such as butadiene and isoprene.

When the elastic polymer material is a foamed polymer material, the foamed material may be foamed using a physical foaming agent that changes phase to a gas based on a change in temperature and/or pressure, or using a chemical foaming agent that forms a gas when heated above its activation temperature. For example, the chemical blowing agent may be an azo compound, such as azodicarbonamide, sodium bicarbonate, and/or an isocyanate.

In some embodiments, the foamed polymeric material may be a crosslinked foamed material. In these embodiments, a peroxide-based crosslinking agent, such as dicumyl peroxide, may be used. In addition, the foamed polymeric material may include one or more fillers such as pigments, modified or natural clays, modified or unmodified synthetic clays, talc, glass fibers, glass dust, modified or natural silica, calcium carbonate, mica, paper, wood flour, and the like.

The resilient polymeric material may be formed using a molding process. In one example, when the elastomeric polymeric material is a molded elastomer, the uncured elastomer (e.g., rubber) may be mixed with optional fillers and cure packages such as sulfur-based cure packages or peroxide-based cure packages in a Banbury mixer (Banbury mixer), calendered, formed (formed in a shape), placed in a mold, and cured.

In another example, when the elastic polymeric material is a foamed material, the material may be foamed during a molding process, such as an injection molding process. The thermoplastic polymer material may be melted in the barrel of the injection molding system and combined with a physical or chemical blowing agent and optionally a cross-linking agent and then injected into the mold under conditions that activate the blowing agent, thereby forming a molded foam.

Optionally, when the resilient polymeric material is a foam, the foam may be a compression molded foam. Compression molding may be used to alter the physical properties of the foam (e.g., density, stiffness, and/or hardness), or to alter the physical appearance of the foam (e.g., fuse two or more foam pieces, shape the foam, etc.), or both.

The compression molding process desirably begins by forming one or more foam preforms, such as by injection molding and foaming a polymeric material, by forming foamed particles or beads, by cutting foamed flakes, and the like. A compression molded foam may then be produced by placing one or more preforms formed of a foamed polymeric material in a compression mold and applying sufficient pressure to the one or more preforms to compress the one or more preforms in a closed mold. Once the mold is closed, sufficient heat and/or pressure is applied to one or more preforms in the closed mold for a sufficient duration to alter the preforms by forming a skin on the outer surface of the compression molded foam, to fuse individual foam particles to one another, to permanently increase the density of the foam, or any combination thereof. After the heating and/or application of pressure, the mold is opened and the molded foam article is removed from the mold.

As discussed in more detail below, the outsole material 204a is initially provided to the midsole elements 202a, 202b in an uncured, fluid state, whereby the contours of the finished outsole 204 are then imparted and cured in a subsequent molding process. Outsole material 204a is selected to impart properties of wear resistance, durability, and traction. In some examples, outsole material 204 includes an elastomeric material having one or more thermoplastic polymers and/or one or more crosslinkable polymers. In one aspect, the elastomeric material may include one or more thermoplastic elastomeric materials, such as one or more Thermoplastic Polyurethane (TPU) copolymers, one or more ethylene-vinyl alcohol (EVOH) copolymers, and the like.

As used herein, "polyurethane" refers to copolymers (including oligomers) containing urethane groups (-N (C ═ O) O-). In addition to urethane groups, these polyurethanes may contain additional groups such as ester, ether, urea, allophanate, biuret, carbodiimide, oxazolidinyl, isocyanurate, uretdione (uretdione), carbonate, and the like. In one aspect, one or more of the polyurethanes may be produced by polymerizing one or more isocyanates with one or more polyols to produce copolymer chains having (-N (C ═ O) O-) linkages.

Examples of suitable isocyanates for producing the polyurethane copolymer chains include diisocyanates, such as aromatic diisocyanates, aliphatic diisocyanates, and combinations thereof. Examples of suitable aromatic diisocyanates include Toluene Diisocyanate (TDI), TDI adduct with Trimethylolpropane (TMP) (adduct), methylene diphenyl diisocyanate (MDI), Xylene Diisocyanate (XDI), tetramethylxylylene diisocyanate (TMXDI), Hydrogenated Xylene Diisocyanate (HXDI), naphthalene 1, 5-diisocyanate (NDI), 1, 5-tetrahydronaphthalene diisocyanate, p-phenylene diisocyanate (PPDI), 3 ' dimethyldiphenyl-4, 4 ' -diisocyanate (DDDI), 4 ' -dibenzyl diisocyanate (DBDI), 4-chloro-1, 3-phenylene diisocyanate, and combinations thereof. In some embodiments, the copolymer chains are substantially free of aromatic groups.

In a particular aspect, the polyurethane polymer chain is produced from a diisocyanate comprising HMDI, TDI, MDI, H12 aliphatic, and combinations thereof. In one aspect, the thermoplastic TPU may include a polyester-based TPU, a polyether-based TPU, a polycaprolactone-based TPU, a polycarbonate-based TPU, a polysiloxane-based TPU, or a combination thereof.

In another aspect, the polymer layer may be formed from one or more of the following: EVOH copolymers, poly (vinyl chloride), polyvinylidene polymers and copolymers (e.g., polyvinylidene chloride), polyamides (e.g., amorphous polyamides), amide-based copolymers, acrylonitrile polymers (e.g., acrylonitrile-methyl acrylate copolymers), polyethylene terephthalate, polyetherimides, polyacrylimides, and other polymeric materials known to have relatively low gas transmission rates. Blends of these materials and blends with the TPU copolymers described herein and optionally including combinations of polyimides and crystalline polymers are also suitable.

Referring to fig. 2A-2C, one example of a method of forming sole structure 200 is illustrated. In this example, the midsole element 202a is provided in a substantially final form, wherein the overall shape and contour of the outer surface 206 of the final midsole 202 is imparted in a previously completed molding process, and the material of the midsole element 202a is fully cured. Thus, the surfaces 208, 210, 212 of the midsole element 202a are identical to the surfaces 208, 210, 212 of the molded midsole 202 described above. Because the midsole element 202a is in a substantially final form, the outsole 204 may be molded using a cold pressing method, as discussed below.

Fig. 2A illustrates an initial step of the method, wherein uncured outsole material 204a is deposited on the outer surface 206 of the midsole element 202A. In this example, the midsole element 202a is formed from a polymer foam material that has been previously cured such that the outer surface 206 of the midsole element 202a is in a substantially final form. The application of outsole material 204a to the fully formed midsole element 202a is particularly suitable for midsoles formed from injection molded foam for several reasons. For example, injection molded foam is formed by injecting molten polymer material into a closed mold cavity, which makes it impractical to apply outsole material 204a to midsole element 202a prior to molding. In addition, injection molded foams often undergo post-cure expansion after pressure is released from the mold. Because the cured outsole material 204a is unlikely to expand at the same rate as the cured material of the midsole 202, applying the outsole material 204a prior to curing the midsole 202 may result in shrinkage of the midsole 202 and/or separation of the outsole 204.

Still referring to fig. 2A, the outsole material 204a is initially applied to the outer surface 206 of the midsole element 202A in an uncured, fluid state. An applied thickness T of outsole material 204a on an outer surface 206 of the midsole element 202a_204aAre selected to accommodate manufacturing processes (e.g., molding) and performance characteristics (e.g., traction, wear resistance, cushioning, durability). For example, outsole material 204a may be of greater thickness T in areas where molded outsole 204 is to have a greater thickness, or in areas where lugs or traction elements of outsole 204 may be formed_204aIs applied.

In the illustrated example, the outsole material 204a is applied to the midsole element 202a using a deposition process, wherein the outsole material 204a is deposited on the outer surface 206 of the midsole element 202a by the applicator 300. Thus, the thickness T of outsole material 204a_204aMay be controlled by adjusting operating parameters of applicator 300 such as, for example, deposition rate, number of passes, droplet size, and/or application temperature.

Although the illustrated example shows a single outsole material 204a deposited on the bottom surface 210 of the midsole element 202a, in some examples, the outsole material 204a may be deposited on the peripheral side surface 212. Additionally or alternatively, more than one outsole material 204a may be deposited in different areas of outer surface 206 to provide sole structure 200 with desired properties. For example, outsole material 204a having greater wear resistance may be deposited in areas of sole structure 200 associated with increased ground contact frequency or force, while outsole material 204a having greater flexibility may be applied in midfoot region 14 of sole structure 200.

The illustrated example shows a jet deposition process for applying outsole material 204 a. However, the outsole material 204a may be applied to the outer surface 206 of the midsole element 202a using other methods. For example, the outsole material 204a may be applied by dipping a portion of the midsole element 202a into the outsole material 204a, or by using a contact applicator such as a brush or roller. In some examples, the outer surface 206 of the midsole element 202a may be masked prior to depositing the outsole material 204a to form a desired contour of the outsole 204. One example of masking is described in more detail below with respect to the spray application process shown in fig. 4. However, masking may also be used in conjunction with dipping and/or contact applicator processes.

Once the outsole material 204a is applied to the outer surface 206 of the midsole element 202a, the sole structure 200 is provided to a mold 302 to impart a contour to the finished outsole 204. However, prior to molding, the outsole material 204a may be allowed to partially cure on the outer surface 206 of the midsole element 202A, thereby increasing the viscosity of the outsole material 204a to assist in handling the sole structure 200 between the depositing step (fig. 2A) and the molding step (fig. 2B). In particular, the outsole material 204a may be partially cured until the outsole material 204a remains wet to the touch, but cannot flow under gravity along the outer surface 206 of the midsole element 202 a.

After outsole material 204a is sufficiently cured, sole structure 200 is placed within mold cavity 304 of mold 302 and subjected to a molding process to impart the contours of outsole 204. In methods as shown herein in which outsole material 204a is applied to midsole element 202a in a substantially final form, the molding process may be accomplished as a cold press method in which sole structure 200 is molded and cured at ambient temperatures. As illustrated by fig. 2B and 2C, mold cavity 304 may include a variety of mold features for imparting tread pattern 214 to outsole material 204 a.

With outsole material 204a cured and outsole 204 fully formed on outer surface 206 of molded midsole 202, sole structure 200 may be removed from mold 302 and attached to upper 100 to form article of footwear 10. Because the outsole material 204a is cured using a cold pressing process, and the structure of the midsole 202 is substantially unchanged from that of the midsole element 202A, the cold pressing process illustrated in fig. 2A-2C may provide an outsole 204 having a pronounced profile relative to the outer surface 206 of the midsole 202. For example, outsole 204 will appear as a raised layer on outer surface 206 of midsole 202, resulting in a distinct parting line between outsole 204 and midsole 202.

Referring now to fig. 3A-3C, another method for forming sole structure 200 according to the present disclosure is shown. Unlike the method described with respect to fig. 2A-2C in which the midsole element 202A is generally formed prior to application of the outsole material 204a, the method shown in fig. 3A involves applying uncured outsole material 204a to the midsole preform 202b, and then simultaneously forming the midsole 202 and outsole 204 in a heated compression molding process. An example of using the preform 202b in conjunction with a compression molding process is described in more detail above.

In this example, the midsole element 202b is a midsole preform 202b having a larger size (i.e., volume) than the final midsole 202. The use of the midsole preform 202b is particularly suitable for a midsole 202 formed from a foamed polymer material that does not undergo significant expansion after molding (e.g., a compression molded foam), because the midsole 202 and outsole 204 may be molded simultaneously, without concern for post-mold expansion of the midsole 202, as discussed above with respect to the method of fig. 2A-2C.

The midsole preform 202b includes an outer surface 206a, the outer surface 206a including a top surface 208a and a bottom surface 210a, the bottom surface 210a being formed on a side of the midsole preform 202b opposite the top surface 208 a. Peripheral side surface 212a extends from top surface 208a to bottom surface 210a and forms an outer peripheral outline of midsole preform 202 b. The surfaces 208a, 210a, 212a of the midsole preform 202b correspond to the molded surfaces 208, 210, 212 of the midsole 202.

Fig. 3A illustrates an initial step of the method, in which uncured outsole material 204a is applied to outer surface 206a of midsole preform 202b in an uncured and fluid state. An applied thickness T of outsole material 204a on an outer surface 206 of midsole 202_204aAre selected to accommodate manufacturing processes (e.g., molding) and performance characteristics (e.g., traction, wear resistance, cushioning, durability). For example, outsole material 204a may be of greater thickness T in areas where molded outsole 204 is to have a greater thickness, or in areas where lugs or traction elements of outsole 204 may be formed_204aIs applied.

In the illustrated example, outsole material 204a is applied to midsole preform 202b using a deposition process, wherein outsole material 204a is deposited on outer surface 206a of midsole preform 202b by applicator 300. Thus, the thickness T of outsole material 204a_204aMay be controlled by adjusting operating parameters of applicator 300 such as, for example, deposition rate, number of passes, droplet size, and/or application temperature.

Although the illustrated example shows a single outsole material 204a deposited only on the bottom surface 210a of the midsole preform 202b, in some examples, the outsole material 204a may be deposited on the peripheral side surface 212 a. Additionally or alternatively, more than one outsole material 204a may be deposited in different areas of outer surface 206 to provide sole structure 200 with desired properties. For example, outsole material 204a having greater wear resistance may be deposited in areas of sole structure 200 associated with increased ground contact frequency or force, while outsole material 204a having greater flexibility may be applied in midfoot region 14 of sole structure 200.

Once the outsole material 204a is applied to the outer surface 206a of the midsole preform 202b, the sole structure 200 is provided to a mold 302a to impart contours to the finished outsole 204. However, prior to molding, the outsole material 204a may be allowed to partially cure on the outer surface 206a of the midsole preform 202B, thereby increasing the viscosity of the outsole material 204a to aid in handling the sole structure 200 between the depositing step (fig. 3A) and the molding step (fig. 3B). In particular, the outsole material 204a may be partially cured until the outsole material 204a remains wet to the touch, but cannot flow under gravity along the outer surface 206 of the midsole 202.

After the outsole material is sufficiently cured, sole structure 200 is placed within mold cavity 304 of mold 302a and subjected to a molding process to impart the contours of outsole 204. In the method in which outsole material 204a is applied to midsole preform 202b, the molding process may be completed as a heated compression molding process in which sole structure 200 is subjected to heat and pressure by mold 302a to impart contours to each of midsole 202 and outsole 204 simultaneously. Thus, as shown in fig. 3B, mold 302a may include heating element 306.

With outsole material 204a cured, sole structure 200 may be removed from mold 302 and attached to upper 100 to form article of footwear 10. In contrast to the method of molding sole structure 200 (fig. 2A-2C) using a cold press process, in which outsole 204 is formed as a distinct layer on outer surface 206 of midsole 202, forming sole structure 200 (fig. 3A-3C) using a compression molding process may cause outsole 204 to be partially impregnated within outer surface 206 of midsole 202 to provide substantially unitary midsole 202 and outsole 204 structures for sole structure 200. This effect is provided by allowing the foam material of the midsole 202 to soften under the influence of heat and pressure, thereby allowing the outsole material 204a to be absorbed by the material of the midsole 202.

As discussed above, in any of the methods for forming sole structure 200, the material of outsole 204 may be applied using a variety of processes, such as, for example, a spray deposition process, a dipping process, or a direct application process. To provide a unique outsole profile, or to prevent the outsole 204 from being applied in specific areas of the sole structure 200, one or more masks 400 may be used during the application of the outsole material 204 a. As shown in fig. 4, in some examples in which jet deposition is used, the mask 400 may be provided as a floating mask 400, the floating mask 400 having a mask plate 402 and more than one spacer 404 configured to separate the mask plate 402 from an outer surface of the midsole 202 or midsole preform 208 by a desired distance. Mask plate 402 includes more than one aperture 406 that corresponds to a desired contour of outsole 204.

The use of the floating mask 400 provides several advantages over conventional surface masks. From a manufacturing perspective, floating mask 400 advantageously allows the midsole to be masked while providing only minimal contact points with midsole 202. This is particularly helpful where the midsole 202 or midsole preform 202b is provided to the outsole material application step in a partially cured or glued state, where the outer surface 206 of the midsole 202 or midsole preform 202b may be adhered to the mask 400.

In addition, the use of floating mask 400 allows outsole material 204a to be applied in a faded or gradient structure. For example, as outsole material 204a passes through apertures 406 of mask plate 402, droplets of outsole material 204a may be dispersed from the edges of apertures 406 to provide a dusting effect along the edges of outsole 204. In particular, the drop application density may decrease in a direction outward from the perimeter of each aperture 406.

Referring now to fig. 5, in some examples of the present disclosure, outsole material 204a may include particulate additives 210 to provide a granular texture to outsole 204. In some examples, the particulate additive 210 may include reground and recycled polymeric material. Here, the particulate additive 210 may be mixed with the outsole material 204a prior to application to the midsole elements 202a, 202 b. However, in other examples, the outsole material 204a may be applied to the outer surface 206 of the midsole elements 202a, 202b, and the particulate additive 210 may be deposited onto the uncured outsole material to provide a textured surface. Examples of particulate additive 210 may include reground polymer materials that are recovered during the production of sole structure 200. For example, the particulate additive 210 may include an excess of cured outsole material 204a, which cured outsole material 204a is reground and distributed onto uncured outsole material 204 a.

The following items provide example configurations for the article of footwear described above.

Item 1: a method of forming a sole structure for an article of footwear, the method comprising providing a midsole element formed from a first polymer material; depositing an outsole material comprising an uncured second polymer material on an outer surface of the midsole element; molding the midsole element and the outsole material to impart an outsole profile to the outsole material; and curing the outsole material on the outer surface of the midsole element.

Item 2: the method of item 1, wherein the first polymeric material is a foamed material.

Item 3: the method of clause 1, wherein the second polymeric material is a polyurethane.

Item 4: the method of clause 3, wherein the second polymeric material is polyurea.

Item 5: the method of item 1, wherein the midsole element is a finished midsole.

Item 6: the method of clause 5, wherein the molding step comprises a cold pressing process.

Item 7: the method of item 1, wherein the midsole element is a midsole preform.

Item 8: the method of item 7, wherein the molding step comprises a compression molding process.

Item 9: the method of item 1, further comprising partially curing the second polymeric material prior to molding the midsole element and the outsole material.

Item 10: the method of item 1, wherein the outsole material comprises a particulate additive.

Item 11: the method of item 1, further comprising masking an outer surface of the midsole element.

Item 12: a method of forming a sole structure for an article of footwear, the method comprising providing a midsole element formed from a foamed polymeric material; depositing an outsole material comprising an uncured polyurethane material on an outer surface of the midsole element; molding the midsole element and the outsole material to impart an outsole profile to the outsole material; and curing the outsole material on the outer surface of the midsole element.

Item 13: the method of clause 12, wherein the uncured polyurethane material is polyurea.

Item 14: the method of item 12, wherein the midsole element is a finished midsole.

Item 15: the method of item 14, wherein the molding step comprises a cold pressing process.

Item 16: the method of item 12, wherein the midsole element is a midsole preform.

Item 17: the method of item 16, wherein the molding step comprises a compression molding process.

Item 18: the method of item 12, further comprising partially curing the polyurethane material prior to molding the midsole element and the outsole material.

Item 19: the method of item 12, wherein the outsole material comprises a particulate additive.

Item 20: the method of item 12, further comprising masking an outer surface of the midsole element.

The foregoing description has been presented for purposes of illustration and description. The foregoing description is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular configuration are generally not limited to that particular configuration, but are interchangeable where applicable and can be used in a selected configuration, even if not explicitly shown or described. The particular configuration of individual elements or features may also be varied in a number of ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.