(12) United States Patent
`Knoche et al.
`
`USOO6782642B2
`(10) Patent No.:
`US 6,782,642 B2
`(45) Date of Patent:
`Aug. 31, 2004
`
`(54) LIGHT RUNNING SHOE
`(75) Inventors: Bernhard Knoche, Nuremberg (DE);
`Klaus Knoerr, Langensendelbach (DE);
`Gerald Kuhtz, Nuremberg (DE)
`(73) Assignee: adidas International, Amsterdam (NL)
`-
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 0 days.
`
`(*) Notice:
`
`(21) Appl. No.: 09/920,439
`1-1.
`(22) Filed:
`Aug. 1, 2001
`(65)
`Prior Publication Data
`
`US 2002/0035796 A1 Mar. 28, 2002
`O
`O
`Foreign Application Priority Data
`(30)
`Aug. 2, 2000 (DE) ......................................... 100 37 728
`(51) Int. Cl. .................................................. A43B 5/00
`(52) U.S. Cl. ...............
`36/129: 36/59 C
`(58) Field of Search ............................... 36/59 R, 59 C,
`36/129
`
`(56)
`
`References Cited
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`1/1855 Foster ......................... 228/50
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`1/1915 Robinson .................... 36/71.5
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`7/1921 Eckel ......................... 442/250
`2,333,303 A 11/1943 Enos .......................... 36/25 R
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`... 42894
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`... 36/32 R
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`... 36/129
`4,245.406 A 1/1981 Landay et al.................. 36/14
`27. A 8. E. R, et al. .................... 3.
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`5,193,240 A 3/1993 Salpietro ..................... 12/146
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`alphs . . . . . . . . . . .
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`5,396,675 A 3/1995 Vincent et al. ............... 12/142
`5,477.577. A 12/1995 Hadley..............
`... 12/142
`3. A 3.E. Nils - - - - -
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`6,032,388 A 3/2000 Fram .........
`... 36/129
`2001/0045028 A1 11/2001 Crane et al. ................... 36/44
`FOREIGN PATENT DOCUMENTS
`
`OZOC
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`- - -
`
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`DE
`EP
`EP
`EP
`EP
`EP
`EP
`EP
`EP
`WO
`WO
`WO
`WO
`
`............ A43B/S/00
`2/1981
`3021129 C2
`6/1984 ............ A43B/S/00
`O111084
`3/1987
`.......... B29C/45/14
`O161136
`5/1989
`A43B/7/14
`O387268
`2/1990
`A43B/5/08
`O353430
`10/1990
`A43B/5/02
`O389752
`11/1990
`... A43B/21/26
`O320993
`6/1991
`A43B/3/18
`O395.538
`O458174 A1 11/1991
`... A43B/13/12
`WO 89/04125
`5/1989
`A43B/7/14
`WO 89/O5593
`6/1989
`... A43B/21/26
`WO 94/13164
`6/1994 ........... A43B/13/00
`WO 98/39984
`9/1998 ........... A43B/13/18
`OTHER PUBLICATIONS
`Photograph of ASIC(R) show with a thermoplastic urethane
`grid affixed with glue to a conventional outsole in a rear foot
`portion of the Shoe.
`* cited by examiner
`Primary Examiner M. D. Patterson
`(74) Attorney, Agent, or Firm- Testa, Hurwitz & Thibeault,
`LLP
`ABSTRACT
`(57)
`The present invention relates to a Sole for an article of
`footwear and the method of manufacture. The Sole includes
`a mesh layer at least partially embedded in a Sole layer. The
`method for manufacturing the Sole includes the Steps of
`providing a mold, inserting a mesh into the mold, and
`forming a Sole layer in the mold, the Sole layer having a
`mesh layer at least partially embedded in the sole layer. The
`invention also relates to an article of footwear that includes
`this sole, and the method of manufacture thereof.
`28 Claims, 7 Drawing Sheets
`
`
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`450
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`MacNeil Exhibit 2167
`Yita v. MacNeil IP, IPR2020-01139, Page 1
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`Aug. 31, 2004
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`Aug. 31, 2004
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`U.S. Patent
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`Aug.31, 2004
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`Aug. 31, 2004
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`U.S. Patent
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`Aug. 31, 2004
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`ØZZZZZZZZZZZZZ
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`Aug. 31, 2004
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`

`

`1
`LIGHT RUNNING SHOE
`
`US 6,782,642 B2
`
`RELATED APPLICATION
`This application claims the benefit of and priority to
`copending German Patent Application No. 10037728.9, filed
`at the German Patent Office on Aug. 2, 2000, entitled “Light
`Running Shoe,” the entire disclosure of which is hereby
`incorporated herein by reference.
`
`TECHNICAL FIELD
`The invention generally relates to a light weight Sole,
`article of footwear, and method of manufacture. More
`Specifically, the invention relates to a Sole and article of
`footwear having a mesh layer at least partially embedded in
`a Sole layer, and methods of manufacture.
`
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`2
`contoured Surface including a knit Structure formed from
`one or more threads. The one or more threads can include
`Spun fibers. The threads can be constructed from one or more
`metals, polyesters, polyamides, aramids, and combinations
`of these materials.
`In various embodiments, the mesh layer can extend
`beyond a bottom pound engaging Surface of the Sole layer or
`can be substantially coterminous with the bottom surface of
`the Sole layer. The Sole layer can include one or more profile
`grooves defined by the bottom surface of the sole layer. The
`Sole layer can include a damping material including ethylene
`Vinyl acetate, polyurethane, rubber, and combinations of
`these materials.
`In yet another aspect, the invention relates to a method for
`manufacturing a Sole for an article of footwear. The method
`includes the Steps of providing a mold, inserting a mesh into
`the mold, and forming a Sole layer in the mold, the Sole layer
`having the mesh layer at least partially embedded in the Sole
`layer. The method can include the Step of mounting the mesh
`to an inner Surface of the mold. The mold can have an inner
`Surface Structure complementary to that of the mesh. Alter
`natively or additionally, the inner Surface Structure can form
`one or more profile grooves in the bottom Surface of the Sole
`layer formed therein. The sole layer can be formed so that
`the mesh extends beyond a bottom surface of the sole layer
`or is substantially conterminous with the bottom surface of
`the sole layer. The sole layer can be formed by injection
`molding, compression molding, or other Suitable method.
`In Still yet another aspect, the invention relates to a
`method for manufacturing an article of footwear. The
`method includes the steps of providing a mold, inserting a
`mesh into the mold, and forming a Sole layer in the mold, the
`Sole layer having the mesh layer at least partially embedded
`in the Sole layer. The method also includes attaching an
`upper to the Sole layer. The method can include the Step of
`applying the mesh to an inner Surface of the mold. The mold
`can have an inner Surface Structure complementary to that of
`the mesh. Alternatively or additionally, the inner Surface
`Structure cam form one or more profile grooves in the
`bottom surface of the sole layer formed therein. The sale
`layer can be formed So that the mesh extends beyond a
`bottom Surface of the Sole layer or is Substantially cotermi
`nous with the bottom surface of the sole layer. The sole layer
`can be formed by injection molding, compression molding,
`or other Suitable method.
`These and other objects, along with advantages and
`features of the present invention herein disclosed, will
`become apparent through reference to the following
`description, the accompanying drawings, and the claims.
`Furthermore, it is to be understood that the features of the
`various embodiments described herein are exemplary only,
`are not mutually exclusive, and can exist in various combi
`nations and permutations.
`BRIEF DESCRIPTION OF THE DRAWINGS
`The drawings are not necessarily to Scale, emphasis
`instead generally being placed upon illustrating the prin
`ciples of the invention. In the following description, various
`embodiments of the present invention are described with
`reference to the following drawings, in which:
`FIG. 1A is a schematic perspective view of a bottom and
`Side of a Sole in accordance with the present invention;
`FIG. 1B is a schematic enlarged view of a portion of the
`Sole of FIG. 1A taken at B;
`FIG. 1C is a schematic cross-sectional view of the Sole of
`FIG. 1A taken at line C-C,
`
`BACKGROUND
`Soles of conventional athletic shoes. Such as running
`shoes, are characterized by layered Structures which typi
`cally consist of an outer Sole, a mid Sole, and an inner Sole.
`The outer Sole conventionally consists of a non-abrasive,
`low-elastic material or rubber which is characterized by a
`relatively high density and therefore also by a relatively high
`weight. The outer Sole Significantly contributes to the weight
`of the shoe, which causes the wearer to tire quickly, espe
`cially in competition Situations. The conventionally used
`mid Sole also contributes significantly to the weight of the
`Sole and the resulting shoe.
`SUMMARY OF THE INVENTION
`The sole and article of footwear of the present invention
`overcome the problem of high weight in known Soles and
`articles of footwear. The invention generally relates to a light
`weight Sole that avoids the use of a conventional, heavy
`outsole, without Sacrificing traction and damping. Since
`conventional outsoles have a relatively high weight, the total
`weight of the Sole is significantly reduced. According to the
`invention, the Sole is constructed from a light weight rigid or
`Semi-rigid polymeric layer having a mesh or fibers at least
`partially embedded in the layer. The mesh can be substan
`tially embedded or coterminous with the polymeric sole
`layer. The mesh provides traction for the wearer and abra
`Sion resistance for the Sole. Profile depressions can be
`formed in the sole layer to further provide traction for the
`WCC.
`In one aspect, the invention relates to a Sole for an article
`of footwear. The Sole includes a Sole layer and a mesh layer
`at least partially embedded in the sole layer. The mesh layer
`can have a contoured Surface including a knit Structure
`formed from one or more threads. The one or more threads
`Van include Spun fibers. The threads can be constructed from
`one or more metals, polyesters, polyamides, aramids, and
`combinations of these materials. The mesh layer can extend
`beyond a bottom ground engaging Surface of the Sole layer
`or can be Substantially coterminous with the bottom Surface
`of the Sole layer. The Sole layer can include one or more
`profile grooves defined by the bottom surface of the sole
`layer. The Sole layer can include a damping material includ
`ing ethylene Vinyl acetate, polyurethane, rubber, and com
`binations of these materials.
`In another aspect, the invention relates to an article of
`footwear. The article of footwear includes an upper, a Sole
`layer attached to the upper, and a mesh layer at least partially
`embedded in the Sole layer. The mesh layer can have a
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`3
`FIG. 2A is a schematic perspective view of the bottom and
`Side of another Sole in accordance with the present inven
`tion;
`FIG.2B is a schematic cross-sectional view of the Sole of
`FIG. 2A taken along line B-B;
`FIG. 3A is a schematic side view of an article of footwear
`in accordance with the present invention;
`FIG. 3B is a schematic cross-sectional view of the article
`of footwear of FIG. 3A taken along line B-B,
`FIGS. 4A-4B are a schematic perspective view and a
`partial enlarged view of another article of footwear in
`accordance with the present invention;
`FIG. 5 is a schematic perspective view of yet another
`article of footwear in accordance with the present invention;
`FIGS. 6A-6I are schematic views of various mesh struc
`tures in accordance with the present invention;
`FIG. 7 is a schematic side view of a compression mold
`and mesh in accordance with the present invention; and
`FIG. 8 is a schematic side view of a mesh and an injection
`mold in accordance with the present invention.
`DESCRIPTION
`When Shoes are designed and constructed, in particular
`athletic ShoeS Such as running shoes, importance is attached
`to the weight of the shoe. The weight is determined by the
`type and the quantity of the materials used. Especially in the
`case of running ShoeS which are used for competitions, there
`is the objective to provide a shoe which is as light as possible
`but which, at the same time, maintains its essential proper
`ties. Examples of Such properties are good traction and
`damping from the Sole, as well as precise fit and Support of
`the foot by the upper.
`The invention avoids the use of a conventional, heavy
`outsole, without Sacrificing traction and damping. Since
`conventional outsoles have a relatively high weight, the total
`weight of the Sole is significantly reduced. According to the
`invention, the Sole is constructed from a light weight cush
`ioning layer having a light weight mesh at least partially
`embedded in the layer that provides traction for the wearer
`and abrasion resistance for the Sole.
`FIGS. 1A-1C depict one embodiment of a sole 120
`constructed in accordance with the present invention. The
`sole 120 generally includes a mesh 130 embedded in a
`bottom, ground engaging sole layer 140. The mesh 130
`extends along and is Substantially coterminous with a bot
`tom surface 142 and, optionally, a front surface 144 of the
`sole layer 140. Also shown are a plurality of profile grooves
`150 defined by the bottom surface 142 of the sole layer 140
`to further improve traction.
`Referring to FIGS. 1B-1C, the mesh 130 has a contoured
`surface in that it is formed by individual threads 135 that are
`woven together as opposed to, for example, a flat grid-like
`structure. The threads 135 are spun from fibers of one or
`more different materials and then are woven into a contoured
`knit structure, yarn, or fabric to form the mesh 130. The
`mesh 130 also can be formed by various methods other than
`knitting or weaving, for example, by Shaping or molding
`polymeric and/or other materials, to form a contoured or
`non-planar Surface. The threads 135 also can be formed from
`fibers other than by Spinning or weaving, for example, by
`heat-welding, adhesion, or coextrusion. The mesh 130 also
`can be constructed directly from fibers, for example, by
`knitting, weaving, adhering, coextruding, or heat-welding.
`The mesh 130 extends substantially across the bottom
`surface 142 and the front surface 144 of the sole layer 140.
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`Optionally, however, the mesh can extend over only portions
`of the bottom surface 142, for example, the area about the
`heel and/or over the side of the sole layer 140.
`The mesh 130 is constructed from light weight materials
`having relatively good abrasion and grip properties. The
`mesh 130 and the threads 135 can be constructed from
`polymers, rubber, metals, or combinations of these or other
`like materials. Suitable polymers include polyesters, polya
`mides and aramids, for example, poly-paraphenylene
`terephthalamide. Suitable aramids include KEVLAR(R) poly
`paraphenylene terephthalamide fiber sold by DuPont
`(France), and TWARONGR) aramid fibers sold by Akzo Nobel
`GmbH (Germany). Other suitable polymeric materials
`include: polyurethanes, Such as a thermoplastic polyure
`thane (TPU); ethylene vinyl acetate (EVA); thermoplastic
`polyether block amides, such as the PEBAX(R) brand sold by
`Elf Atochem; thermoplastic polyester elastomers, Such as
`the HYTREL(R) brand sold by DuPont; nylons, such as nylon
`12 that may include 10 to 30 percent or more glass fiber
`reinforcement; Silicones, polyethylenes, and equivalent
`materials. The above polymeric materials can be used in
`combination with other materials, Such as rubber or metal.
`Other suitable materials will be apparent to those skilled in
`the art.
`The sole layer 140 is constructed from conventional
`mid-Sole materials that are relatively light weight, have
`relatively good damping properties, and are compliant, yet
`resilient. Shocks induced by the natural running motion are
`dampened preferably by the sole layer 140 so that the joints
`and the muscles of the wearer of the Shoe are protected,
`particularly while running. Suitable damping materials
`include aerated materials or foams, Such as ethylene Vinyl
`acetate (EVA) foam, polyurethane (PU) foam, foam rubber,
`and combinations of these materials. The sole layer 140 can
`also be formed using the energy management System
`described in German Patent No. 19914 472 and U.S. Pat.
`No. 4,297,796, incorporated here in by reference.
`Furthermore, different damping elements known from the
`prior art can be combined with the sole layer 140 or used in
`addition to the Sole layer 140, Such as gel air cushions,
`padded inserts or an insole.
`One or more profile or flex grooves 150 can be included
`in the sole layer 140 to further improve traction and impart
`flexibility to the sole 120. The sole layer 140 also can
`include profile ridges or other known protruding features to
`improve traction. Traction also can be improved by com
`bining a mesh 130 that is substantially coterminous with the
`sole layer 140, as described above in connection with FIGS.
`1A-1C, with a mesh that extends beyond the bottom ground
`engaging Surface 142 of the Sole layer 140, as described
`below in connection with FIGS. 2A-2B.
`FIGS. 2A-2B depict another exemplary embodiment of a
`sole 220 that generally includes a mesh 230 and a sole layer
`240. Also shown are profile grooves 250 defined by a bottom
`surface 242 of the sole layer 240. As shown in FIG. 2B, the
`mesh 230 is partially embedded in the sole layer 240 and
`extends beyond the bottom surface 242 of the sole layer 240.
`The mesh 230 is formed from individual threads 235 that are
`twisted and Spun about each other and shaped into a pattern
`that varies across the bottom Surface 242 of the Sole 240.
`The mesh 230 and the Sole 240 can be constructed from
`any of the materials and using any of the methods described
`above in connection with FIGS. 1A-1C. The mesh 230 may
`be constructed from materials characterized by abrasion
`resistance, good grip and traction, and low weight, So that
`projecting portions 234 form a profile on the bottom Surface
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`S
`242 of the sole 220 to provide traction with the ground when
`in use by a wearer. This also can increase the useful lifetime
`of the Sole 220 because the mesh 230 can be constructed
`from materials that are abrasion resistant. The mesh 230
`contributes to the low weight of the sole 220, which lessens
`fatigue caused by the weight of a shoe incorporating the Sole
`220 when used, for example, while running.
`The mesh 230 can cover all or portions of the bottom
`Surface 242, front Surface 244 or side Surface of the Sole 220
`and be combined with a mesh that is coterminous with the
`bottom surface 242 of the sole layer 240. The sole 220 can
`optionally contain either no profile elements or a variety of
`profile elements that can be raised or grooved. The Soles of
`the present invention can also include an additional Sole
`layer, and the mesh can be embedded in this additional layer
`instead of the cushioning Sole layer.
`FIGS. 3A-3B depict an embodiment of an article of
`footwear or shoe 301 that generally includes an upper 310
`attached to a sole 320 that includes a mesh 330 partially
`embedded in a sole layer 340. As shown in FIG. 3B, the
`mesh 330 includes embedded portions 332 that are embed
`ded in the sole layer 340, and projecting portions 334 that
`project from the sole layer 340. The mesh 330 is attached to
`the sole layer 340 by the embedded portions 332. The
`projecting portions 334 provide traction during use and
`resist abrasion of the sole layer 340. The shoe 301 optionally
`can include an insole 345 and/or a mid sole (not shown).
`The mesh 330 and the sole layer 340 can be constructed
`from any of the mesh and Sole layer materials described
`above. The mesh 330 may be constructed from materials
`characterized by abrasion resistance, good grip, and low
`weight, So that the projecting portions 334 of the mesh 330
`form a profile on the bottom surface 342 of the sole 320 to
`provide traction with the ground when in use by a wearer.
`This also can increase the useful lifetime of the Sole 320,
`because the mesh 330 is abrasion resistant. The mesh 330
`contributes to the low weight of shoe 301, which lessens
`fatigue caused by the weight of the shoe 301 when used, for
`example, while running.
`The profile or configuration of the ground engaging
`bottom surface 342 of the sole 320 can be varied by the size
`and the shape of the mesh 330. Different profiles also can be
`realized by varying the kind of Spinning used to form the
`mesh 330, for example, by varying the number and arrange
`ment of burls in the knit and by varying the strength of the
`knit fabrics. The profile also can be varied by including
`profile elements Such as ridges or grooves.
`The mesh 330 has a non-planar or contoured protruding
`surface, and is formed by individual fibers 336 that are
`woven, spun, heat-melded, glued or otherwise attached
`together, as opposed to, for example, a flat grid-like Struc
`ture. The mesh 330 can be constructed from knit or woven
`threads spun from fibers of one or more different materials
`or constructed from fibers directly. The mesh also can be
`formed without threads or fibers, for example, by Shaping,
`extruding, gluing, heat-welding or molding polymers,
`rubber, and/or metals to form the contoured, non-planar
`Surface.
`The upper 310 serves for the accommodation and support
`of the foot. Conventional materials, construction, and fabrics
`can be used for the upper 310 to ensure a precise fit. The
`upper 310 can consist of light natural or synthetic fibers that
`are perforated or comprise a loose weave or net for
`breathability. The upper also can include Supporting
`elements, Such as heel Supporting elements. The upper 310
`can be attached to the sole 320 by conventional methods, for
`example, by Stitching, Stapling, tacking, and/or adhesive.
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`FIGS. 4A-4B depict another embodiment of an article of
`footwear or shoe 401 in accordance with the present inven
`tion. The shoe 401 generally includes an upper 410 attached
`to a sole 420 that includes a mesh 430 embedded in a sole
`layer 440. The mesh 430 extends along and is substantially
`coterminous with a bottom surface 442 of the sole layer 440.
`Also shown are profile grooves 450 defined by the bottom
`surface 442 of the sole layer 440. The mesh 430 is woven
`from spun threads 435.
`The materials and construction and alternative embodi
`ments of the shoe 401, including the mesh 430, the sole layer
`440, and the upper 410, are as described above, for example,
`in connection with FIGS. 1A-1C. For example, the mesh
`430 can be combined with a mesh that extends from the
`bottom surface of the sole layer like that described in
`connection with FIGS 2A-2B and FIGS 3A-3B.
`FIG. 5 depicts yet another embodiment of an article of
`footwear or shoe 501. The shoe 501 generally includes an
`upper 510 attached, to a sole 520 that includes a mesh 530
`embedded in a sole layer 540. The mesh 530 extends along
`and is substantially coterminous with a bottom surface 542
`of the sole layer 540. Also shown are profile grooves 550
`defined by the bottom surface 542 of the sole layer 540. The
`mesh 530 is woven from spun threads 135, as described with
`respect to FIGS. 1A-1C. Shoe 501 avoids the use of a
`conventional, heavy outsole, without Sacrificing good
`damping, abrasion resistance, and traction properties.
`The materials and construction and alternative embodi
`ments of the shoe 501 including the mesh 530, the sole layer
`540, and the upper 510, are as described above, for example,
`in connection with FIGS. 1A-1C. For example, the mesh
`530 can be combined with a mesh that extends from the
`bottom surface of the sole layer like that described in
`connection with FIGS 2A-2B and FIGS 3A-3B.
`FIGS. 6A-6I depict varying mesh configurations in accor
`dance with the present invention. FIG. 6A depicts a close
`knit weave. FIG. 6B depicts a loose knit weave. FIG. 6C
`depicts a mesh pattern having a Series of Substantially
`parallel threads. FIG. 6D depicts a generally spiral mesh.
`FIG. 6E depicts a loose knit weave. FIG. 6F depicts a spiral
`weave constructed from threads of spun fiber. FIG. 6G
`depicts a two layer cross-hatch. FIG. 6H depicts a wave
`pattern melded on its sides to two threads. FIG. 6I depicts a
`parallel mesh constructed from threads of spun fiber. The
`elements of the mesh configurations shown in FIGS. 6A-6I
`can be woven, glued, heat-welded or otherwise constructed.
`The elements also can be formed in a mold, for example, a
`compression or injection mold having an inner Surface
`configured to the desired contours of the mesh. For example,
`the spiral configuration of FIG. 6D can be formed in this
`manner. The mesh can be constructed from any of the
`materials and using any of the methods described above.
`More than one mesh design can be combined to adapt
`different portions of the sole profile to different requirements
`as shown in FIGS. 2A-2B. For example, one mesh configu
`ration or design can be used in the heel portion of the Sole
`and another in the forefoot portion of the sole.
`Another aspect of the present invention concerns methods
`of manufacturing a Sole for an article of footwear. The
`method includes the Steps of providing a mold, inserting a
`mesh into the mold, and forming a Sole layer in the mold, the
`Sole layer having Smash layer at least partially embedded in
`the Sole layer. The mold can be any type of mold, including
`a compression mold or an injection mold, as described
`below in FIG. 7 and FIG.8. The sole, including the mesh and
`the Sole layer, can be constructed from any of the materials
`
`MacNeil Exhibit 2167
`Yita v. MacNeil IP, IPR2020-01139, Page 11
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`7
`and have any of the configurations described above. The
`mesh can be Substantially coterminous and/or project from
`the bottom surface of the sole layer, as described above.
`FIG. 7 depicts an embodiment of a compression mold 770
`and a mesh 730. The mold 770 generally includes an inner
`surface 772 that determines the shape of the sole layer to be
`formed, and structural features 774 such as depressions that
`are complementary to the geometry of the mesh 730. During
`the molding process, the mesh 730, that has been inserted
`into the complementary structural features 774, is partially
`embedded in the sole layer as the sole layer is formed in the
`mold, such that portions of the mesh 730 extend from the
`bottom surface of the sole layer as described above. The
`mesh 730 can be positioned and retained in the mold 770 to
`maintain its desired position during the molding Step, for
`example, by aligning the mesh 730 within the complemen
`tary Structures 774 or a registration device, Such as regis
`tration pins.
`The mold also can have additional Structural features on
`the inner surface 772 to form profile ridges and/or grooves
`as described above. When forming a sole with both cote
`rminous mesh and mesh that extends beyond the Sole layer,
`the mold 770 might have complementary structures in some
`portions of the inner Surface and not in others.
`The method also can include the Step of coating the
`portions of the mesh that are to extend from the Sole layer
`with a removable film or release agent, So that these portions
`are Selectively prevented from being embedded in the Sole
`layer during the embedding Step. This obviates the need for
`complementary Structural features in the mold and allows
`the mold to be used in forming a variety of soles with
`different mesh configurations that are partially embedded in
`the Sole layer. This Step can also be used to coat only
`portions of the mesh So that the uncoated portion of the mesh
`is embedded in the Sole layer, and the coated portion is only
`partially embedded in the sole layer. The method also can
`include the Step of coating portions of the mesh that are to
`be embedded and/or partially embedded in the sole layer
`with a bonding agent Such as an adhesive or crosslinking
`agent to improve bonding between the mesh and the Sole
`layer. Use of a release agent would prevent bonding, as
`known by those skilled in the art.
`After inserting the mesh 730 in the mold 770, a sole slug
`made of a preferred material of the Sole layer is placed in the
`mold 770. Standard Vulcanization methods then can be used
`to apply heat and force to the sole slug in mold 770 so that
`the Sole material flows in the contours of the inner Surface
`772 of the mold 770 and bloats. The material of the Sole
`layer also penetrates into the mesh 730 and Subsequently
`cures. After conventional cooling and eventual post
`Vulcanizing corrections, a form stable, light Sole according
`to the present invention is obtained.
`FIG. 8 depicts an exemplary embodiment of an injection
`mold 860 and a mesh 830. The injection mold 860 generally
`includes an inner surface 872 that determines the shape of
`the Sole layer to be formed, and optional Structural features
`874 that are complementary to the geometry of the mesh
`830. During the molding process, the mesh 830 that has been
`inserted into the complementary structural features 874 is
`partially embedded in the Sole layer as the Sole layer is
`formed in the mold, such that portions of the mesh 830
`extend from the bottom Surface of the Sole layer, as
`described above. The mesh 830 can be mounted in the
`injection mold 860 to retain its desired position during the
`molding Step, for example, by aligning it within the comple
`mentary structures 874 or with another type of registration
`device Such as registration pins.
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`US 6,782,642 B2
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`8
`The mold 860 also can have structural features to form
`profile ridges and/or grooves as described above. When
`farming a Sole with both coterminous mesh and mesh that
`extends beyond the sole layer, the mold 860 might have
`complementary Structures in Some portions of the inner
`Surface and not in others.
`The method also can include the Step of coating the
`portions of the mesh that are to extend from the Sole layer
`with a removable film or release agent, So that these portions
`are Selectively prevented from being embedded in the Sole
`layer during the embedding Step. This obviates the need for
`complementary Structural features and allows the injection
`mold to be used in forming a variety of soles with different
`mesh configurations that are partially embedded in the Sole
`layer and/or Substantially coterminous with the Sole layer.
`The method also can include the Step of coating portions of
`the mesh that are to be embedded in the sole layer with a
`bonding agent Such as adhesive or crosslinker to improve
`bonding between the mesh and the Sole layer. Use of a
`release agent would prevent bonding, as known by those
`skilled in the art.
`After inserting the mesh 830 into the injection mold 872,
`the material of the sole layer is injected into the mold 872
`and is Vulcanized using conventional injection molding
`methods and techniques So that the Sole material flows in the
`contours of the inner Surface 872 of the mold 860 and bloats.
`The material of the Sole layer also penetrates into the mesh
`830 and subsequently cures. After conventional cooling and
`eventual post-Vulcanizing corrections, a form stable, light
`Sole according to the present invention is obtained.
`Yet another aspect of the present invention is directed to
`a method for manufacturing an article of footwear. The
`method generally includes the Steps of providing a mold;
`inserting a mesh into the mold; forming a Sole layer in the
`mold, the Sole layer having a m