Customization of Inner Sole Board

Patent metadata

Field	Value
Publication number	US-2016278482-A1
Application number	US-201514629957-A
Country	US
Kind code	A1
Filing date	Feb 24, 2015
Priority date	Aug 6, 2008
Publication date	Sep 29, 2016
Grant date	—

Abstract

An inner sole board having varying regions of flexibility is provided for use in an article of footwear. The inner sole board may include different materials along its length at different locations that vary its flexibility. An inner sole board is manufactured in an injection molding process requiring only one mold. The process includes a first step of providing a mold, a second step of providing an injection molding assembly, a third step of preparing an injection molding assembly and mold, a fourth step of injecting material into the mold, and a fifth step of establishing the dimensions of a first portion. During the injection molding process, the flow rate of at least one material may be controlled by a nozzle gate to control the shape and size of the flex zone it creates. In this manner, the inner sole board may be customized for a specific sport or individual.

First claim

1 - 6 . (canceled)

7 . A kit for customizing an article of footwear including a sock liner, the kit comprising:
a group of solid inner sole boards; wherein each inner sole board of the group of inner sole boards is configured to be removably inserted into the article of footwear under the sock liner; wherein each inner sole board has a unique flexibility characteristic relative to each other inner sole board of the group of solid inner sole boards; and wherein each inner sole board comprises:
a first portion of the inner sole board that is more rigid than the sock liner, the first portion of the inner sole board comprising a first rigid, substantially incompressible copolymer material;
a second portion of the inner sole board that is more rigid than the sockliner, the second portion of the inner sole board comprising a second rigid, substantially incompressible material; and
the first copolymer material having greater flexibility than the second material;
wherein the first portion and the second portion of the inner sole board are bonded to one another at a bonding zone;
wherein the bonding zone of the inner sole board comprises a mechanical bond between the first material and the second material that is initiated when the first material and the second material are in a molten state, the bonding zone having a bond width, wherein a first portion of the bond width extends into the first portion of the inner sole board, and wherein a second portion of the bond width extends into the second portion of the inner sole board; and
wherein the second portion of at least a first inner sole board of the group of inner sole boards surrounds a periphery of the first portion of the first inner sole board in a forefoot region of the first inner sole board.

8 . The kit of claim 7 , wherein the group of inner sole boards comprises one or more left-foot inner sole boards.

9 . The kit of claim 7 , wherein the group of inner sole boards comprises one or more right-foot inner sole boards.

10 . The kit of claim 7 , wherein the kit comprises one or more left-foot inner sole boards and one or more right-foot inner sole boards.

11 - 20 . (canceled)

21 . The kit of claim 7 , wherein a thickness of the first material is substantially equal to a thickness of the second material in proximity of the bonding zone.

22 . The kit of claim 21 , wherein a top surface and a bottom surface of the first portion and a top surface and a bottom surface of the second portion are exposed and form, collectively, an outer surface of the inner sole board.

23 . The kit of claim 7 , wherein the group of inner sole boards includes at least one pair of inner sole boards having a right-foot inner sole board and a left-foot inner sole board, wherein the right-foot inner sole board has a different arrangement of the first material and the second material than the left-foot inner sole board.

24 . The kit of claim 7 , wherein the first portion of the first inner sole board has a first thickness and the second portion of the first inner sole board has a second thickness, wherein the first thickness is substantially equal to the second thickness in proximity of the bonding zone.

25 . The kit of claim 24 , wherein a top surface and a bottom surface of the first portion of the first inner sole board and a top surface and a bottom surface of the second portion of the first inner sole board are exposed and form outer surfaces of the inner sole board.

26 . An article of footwear comprising:
a ground-engaging sole plate; a sock liner; and a solid inner sole board disposed between the ground-engaging sole plate and the sock liner, the solid inner sole board including:
a first portion of the inner sole board that is more rigid than the sockliner, comprising a first rigid, substantially incompressible material; and
a second portion of the inner sole board that is more rigid than the sockliner, comprising a second rigid, substantially incompressible material;
the first rigid, substantially incompressible material having a greater flexibility than the second rigid, substantially incompressible material;
wherein a size and a location of the first portion with respect to the second portion is configured to conform to a set of flexibility characteristics associated with an athletic activity;
wherein the first portion and the second portion of the inner sole board are bonded to one another at a bonding zone; and
wherein the bonding zone of the inner sole board comprises a mechanical bond between the first rigid, substantially incompressible material and the second rigid, substantially incompressible material that is initiated when the first rigid, substantially incompressible material and second rigid, substantially incompressible material are in a molten state, the bonding zone having a bond width, wherein the first portion of the inner sole board includes a first portion of the bond width, and wherein the second portion of the inner sole board includes a second portion of the bond width.

27 . The article of footwear of claim 26 , wherein the first portion is disposed in a forefoot region of the article of footwear.

28 . The article of footwear of claim 27 , comprising:
the first portion having a first thickness; the second portion having a second thickness; and wherein the first thickness and the second thickness are substantially equal proximate the bonding zone.

29 . The article of footwear of claim 28 , wherein the first portion is substantially coextensive with the forefoot region.

30 . The article of footwear of claim 26 , wherein a top surface and a bottom surface of the first portion of the first inner sole board and a top surface and a bottom surface of the second portion of the first inner sole board are exposed and form outer surfaces of the inner sole board.

31 . The article of footwear of claim 26 , wherein the first portion has a substantially circular shape.

32 . The article of footwear of claim 26 , wherein the first portion is disposed in a heel region of the article of footwear.

33 . An article of footwear comprising:
a ground-engaging sole plate; a sock liner; and a solid inner sole board disposed between the ground-engaging sole plate and the sock liner, the solid inner sole board including:
a first portion of the inner sole board that is more rigid than the sockliner, comprising a first rigid, substantially incompressible material; and
a second portion of the inner sole board that is more rigid than the sockliner, comprising a second rigid, substantially incompressible material;
the first rigid, substantially incompressible material having a greater flexibility than the second rigid, substantially incompressible material;
wherein a bonding zone between the first portion and the second portion of the inner sole board comprises a mechanical bond between the first rigid, substantially incompressible material and the second rigid, substantially incompressible material, the bonding zone having a bond width, wherein the first portion of the inner sole board includes a first portion of the bond width, and wherein the second portion of the inner sole board includes a second portion of the bond width.

34 . The article of footwear of claim 33 , wherein the first portion is disposed in a forefoot region of the article of footwear.

35 . The article of footwear of claim 34 , comprising:
the first portion having a first thickness; the second portion having a second thickness; and wherein the firs

Assignees

• Nike Inc

Inventors

• Baucom Jim
• Gerber Clifford B

Classifications

• B29D35/142

  Soles · CPC title

• B29D35/0009

  by injection moulding; Apparatus therefor · CPC title

• A43B17/02 Primary

  wedge-like or resilient · CPC title

• A43B17/003

  characterised by the material (made of wood A43B17/12, made of sponge, rubber or plastic materials A43B17/14) · CPC title

• A43B13/12

  Soles with several layers of different materials · CPC title